Training module engine (4)

Learning and Development Centre, India

Model name 5204PTO bhp (At rated speed) 42.6Latest Emission Compliance TREM III (~Tier 1)Rated ERPM 2300Cooling system Liquid cooled with overflow reservoirWater to Coolant concentration. (Ethylen Glaycol) 50/ 50Nom Engine torque @ rpm 167 / 180.4 @ 1500No of cylinders 3Bore (mm) 106.5Stroke (mm) 110Displacement (lt) 2.9Compression ratio 17.8 : 1Firing order 1 - 2 - 3

Operating range,rpm850-2460 ERPM

working 1200 -2300 ERPMService Injection Timing (Plunger Travel,mm) 4.93 - 5.03Aspiration NaturalCombustion DIFIP Mico Bosch InlineFuel Filter Stanadyne filterMuffler underhoodFuel Shut-off Manual / Need to LockAir Intake heater NAAir Cleaner 6" DryRadiator Core - 48 mm, Al

Basic Specifications - Engine

3Learning and Development Centre, India

EngineFuel input energy Mech. Power

Driving automobile

Running pump/ machines

Running generators

What is engine ?

Engine is a machine which converts fuel energy into mechanical power

Applications

Engine and its application


IHP (Indicated horse power )

* Power developed inside the cylinder. P L A NIHP depends upon : IHP = ---------- n

4500Speed whereStroke length P = Mean effective Pressure.Bore L = length of strokeMean effective pressure A = Cylinder bore

N = RPMn = No. of Cylinder

BHP (Brake horse power)

* Measured at crankshaft

BASICS OF ENGINE


TorqueIt is the twisting force which rotates the shaft.Product of force & distance of force from centre of shaft

T = F x Rwhere, T = Torque, N.m

F = Force, NR = Distance between force and centre

Power * Rate of doing work.* Product of torque & rotational speed.* Expressed in watt or hp.

Power (watt) = T x wwhere, T = torque, N.m

w = rotational speed, rad /sec2 N T

Power (hp) = ------------ where, T = Torque, kg.m4500 N = speed , rpm.


Relationship Between H.P, Speed & Torque

Engine can run faster than its speed atwhich it reaches the max power

BHP increases with increase in speedup to certain speed and then drops

Diesel engine produces max. torque atintermediate speed than at max

Rated engine speed is higher than peaktorque speed. It is possible to takethe advantage of torque reserve.


FOUR STROKE

Suction

Compression

Power

Exhaust

Functioning of 4-stroke diesel Engine


Suction

• Inlet valve opens

• Piston moves down

• Air is sucked into combustion chamber

Compression

• Inlet & exhaust valve closes.

• Piston moves up

• Air is compressed• Certain degree before the end of stroke,

fuel is injected.

Working of 4 stroke diesel engine (suction/comp)


Power• Inlet valve closed

• Exhaust valve closed.

• Fuel is ignited

• Piston moves down

Exhaust

• Exhaust valve opens.

• Inlet valve remain closed

• Piston moves up.

• Exhaust gases are expelled out.

Working of 4-stroke diesel engine (Power / Exhaust)


Inlet / Exhaust systemDeals with inflow of fresh Air & outflow of exhaust gasesIn John Deere Tractors we used Dry air cleaner :

* Main parts are pre cleaner, main housing & cleaning element

* Cleaning element is made up of paper / nylon hair

* Air passes from atmosphere through cleaning element to inlet manifold

Primary Element

Secondary Element

Suction side

Main Housing



ENGINE COOLING SYSTEM

Why cooling system is needed ?

Necessity of cooling system* Temperatures in the Combustion Chamber of Engine can reach 4,500 F ( 2,500 C) socooling of this area around the cylinder is critical. Area around exhaust valves are especiallycrucial. If engine goes without cooling for long, it can seize.

* High temperature oxidizes the lubricating oil thus producing carbon deposit on the surface

* Large overheating may lead to engine components due to thermal stresses

* High temperature also lowers the volumetric efficiency & overall performance of the engine

Requirement of efficient cooling system* Remove only 30 % of total heat in combustion chamber

* Remove the heat at fast rate when engine is hot


P

Radiator

COOLING SYSTEM

Basic:Inside engine, fuel is constantly burning. A lot of the heatfrom this combustion goes right out the exhaust system, butsome of it soaks into the engine, heating it up. The engineruns best when its coolant is about (93 degrees Celsius).

At this temperature:The combustion chamber is hot enough to completely vaporize the fuel, providing bettercombustion and reducing emissions.

The oil used to lubricate the engine has a lower viscosity (it is thinner), so the engine partsmove more freely and the engine wastes less power moving its own components around.Metal parts wear less.


Forced circulationIt uses pump to circulate water through different parts

Main parts arePump

Fan

Radiator and pressure cap

Water jacket

Thermostat valve

Hose pipes

ENGINE COOLING SYSTEM


PumpThe water pump is a simple centrifugal pump driven by a belt connected to the crankshaft of theengine. The pump circulates fluid whenever the engine is running.Driven by beltBottom of the radiator is connected to the suction of the pump

FanMounted on pump pulley

It draws atmospheric air through theradiator & thus increases the cooling efficiency

It throws fresh air over the engine surfaces

Cooling system : components


Cooling : Thermostat valve / Radiator

Any liquid-cooled Automobile engine has a small device called the Thermostat that sitsbetween the Engine and the radiator. The thermostat in most Automobile is about 2 inches(5 cm) in diameter. Its job is to block the flow of coolant to the radiator until l the enginehas warmed up. When the engine is cold, no coolant flows through the engine. Once theengine reaches its operating temperatures ( 95 degrees C), the thermostat opens. By lettingthe engine warm up as quickly as possible, the thermostat reduces engine wear, depositsand emissions.

Radiator is a type of heat exchanger. It is designed to transferheat from the hot coolant that flows through it to the air blownthrough it by the fan. Most modern cars use aluminum radiators.These radiators are made by brazing thin aluminum fins to flattenedaluminum tubes. The coolant flows from the inlet to the outletthrough many tubes mounted in a parallel arrangement. The finsconduct the heat from the tubes and transfer it to the air flowingthrough the radiator.Main Parts of Radiator are: Upper Tank, Lower Tank & Tubes


Major Specification Cooling system

47 N.M ( 35 lbs*ft)Thermostat Cover to Cylinder Head30 N.M ( 24 lbs*ft)Sheet metal pulley and for fan to pulley or Hub

Back plate to Water pump Housing33 N.m ( 24 lbs*ft)Water Pump Nut47 N.M ( 35 lbs* Ft)Water pump to Cylinder Block Cap screw

TorqueITEM

137 mmDistance from Pulley or Hub to pumphousing Sealing Surface

19mm (0.75 in) Deflection with 89N.m (20lb.ft)Force applied half way between the two pulleys

Fan belt Tension82 Degree Centigrade (180 Degree F)Thermostat Opening0.25 mm ( 0.01 in.)Impeller Recess

DIMENSIONS OF NEW PARTITEM



Pressure feed system

Pump is provided to circulate lubricating oil to moving parts

Oil goes to main gallery from where it passes throughdrilled holes to main bearing, camshaft bearing, connecting rod

Combination of splash & pressure

Some parts are lubricated by splashSome parts are lubricated by pressure(Camshaft bearing ,Main bearing etc.)

Lubrication : Splash / Force feed


The engine lubrication system is designed to deliver clean oil at the correct temperature andpressure to every part of the engine. The oil is sucked out the sump into the pump, than forcedthrough an oil filter and pressure feeded to the main bearings and to the oil pressure gauge. Fromthe main bearings, the oil passes through feed-holes into drilled passages in the crankshaft andon to the big-end bearings of the connecting rod. The cylinder walls and piston-pin bearings arelubricated by oil fling dispersed by the rotating crankshaft. The excess being scraped off by thelower ring in the piston. A bleed or tributary from the main supply passage Feeds each camshaftbearing. Another bleed supplies the timing gears on the camshaft drive. The excess oil thendrains back to the sump

Lubrication system


Functions of lubricantMinimizes the friction & wearRemoves the heat from engine parts thus acting as cooling agentIt absorbs shocks between bearing & moving parts thus reducing the noiseForms good seal between piston & cylinder wallCleaning agent to carry away dirt, carbon particles to sump

LUBRICATION SYSTEM

Photograph attached here talks aboutgeneral concept of lubrication systemand not current JD Engine


The engine has a pressure lubrication system. In themain it consists of the gear pump (F), filter strainer inthe suction pipe, full flow oil filter, oil cooler, oilpressure regulating valve (O), oil by-pass valve (E)and an electrical pressure warning switch(connected to main oil gallery) The pump drawslubrication oil from the crankcasethrough a strainer and a suction line. The oil isthen pumped through an oil line to the oil coolerOil filter and through the main oil gallery (H) ofthe cylinder block. From the oil gallery , oil isforwarded under pressure to the main bearingsand spray jets to cool the pistons. Drilled crosspassages in the crankshaft distribute oil fromthe main bearings to connecting rod

Lubrication system : operation


Parts of pressure lubrication system

Oil pump

Oil sump / oil pan

Oil pressure relief valve

Oil filter

Oil pump

Pump supplies oil to moving parts

Normally gear type pump is used

Oil sump

It is the lowest part of engine

It is used to store the oil

Components involved in Lubrication System

Oil Pump40 Litre per min at 2000rpm with standard oil,pressure 3 bars


The pressure relief valve maintains oil pressurewithin desired operating range

Incase of Increase of pressure it relieves oil to Oilsump

The bypass valve is in composite materialIt allows cold oil to bypass filter and cooler to reduce lagtime in getting oil to bearings during cold weather start-up.

Lubrication : valve

Bypass Valve

Pressure Relief Valve


The oil cooler is mounted between support and oil filter.

Depending on cooling requirements of the application, differentcapacity oil coolers are used. 6, 8 or 10 plates model.

The filter has a built in bypass valve to allow oil flowshould the filter becomes plugged.

The filter must be replaced at each oil drain service.

Lubrication : oil cooler


Oil spray jet is located in block webbing, between bearing supports.

It sprays oil to cool piston and lube wrist pin.

The orifice size is predetermined (1.02mm).

If it is not reinstalled at rebuild, an oversized orifice will result inoil pressure drop.

Lubrication : piston cooling


Rocker Arm Lubrication

Lubrication thru Camshaft groove

Oil Spray Jet

Lubrication : camshaft



FUEL SYSTEM

Functions

Supply correctamount of fuel

Inject fuel at correcttime in cylinder

Atomize the fuel

Parts of fuel systems

Fuel tank

Fuel filter

Fuel injector pump

Injector

Fuel lines


A water separator is included in the filter element.It can be drained loosening the bottom screw

The fuel filter has also a hand primer to bleed fuelcircuit through the knob provided at top of the Assy

Fuel filter {Fitted with Rotary FIP}


Water Separator keeps water & Contamination separate from diesel, whichcan be removed with the help of knob provided under Separator

Water Separator / Sediment BowlWater is the enemy of Fuel injection components


Feed pump

Function :

Sucks the fuel from tank Supply the fuel to fuel filter

Consist of :

Inlet port

Outlet ports

Suction valve

Delivery valve

Cam


A

B

C

D

E

FG H

IJ

Function of Fuel injection pumpSupplies fuel to injector according to firing order

Normally plunger or rotary pump

Plunger pump consists of plunger & barrel

Quantity of fuel is controlled by turning the plunger

Works at high pressure

FUEL SYSTEM


A

B

C

DF

G H

I

J

Fuel Injection Pump

A - Fuel inlet on Feed pump

B - Fuel outlet on primary Fuel FilterC - Fuel supply to FIP from Secondary

FilterD - Fuel Return Line

F - Fuel Injection lines

G - Oil fill plug

H - Fast idling screw

I - Slow idle screw

J - Slow idle screw fine adjustment


Governor

Maintain the constant speed (desiredspeed) in response to load

Speed controlling device

Does not allow to exceed the max. speed

Does not stop engine during idling

Maintain desired speed

Governor does all these by regulating the fuelsupply. It decides how much fuel to supply toengine.


No governor conditions

If load increases ,the tractor travel speedwill decrease

If load decreases, the tractor travel speedwill increase

Load -add fuel

Load - reducefuel

Governor function

Engine overrun when load suddenly drops


Nozzle shall spray accurately with correct spray pattern and openingpressure

Spring : controls opening and closing of needle

Needle : opens when fuel pressure is more than needle pressure

Needle opens at 190 bar pressure

For high speed engine, needle shall open and close quickly

Needle get jammed, then there is dribbling of fuel

Less tension in spring :

More fuel

Engine advance and smoke

Nozzle



Cylinder Head Bolt Torque procedure

Tighten Cap screw in Sequence to the Torque Specified, Beginning with No. 1With the help of Torque wrench:

Step – 1 Tighten all cap screw to 100 N.m (75 lb-ft)Step – 2 Tighten all cap screw to 150 N.m (110 lb-ft)Step – 3 Wait 5 Minutes & recheck to insure 150 N.m (110 lb-ft)Step – 4 Tighten each cap screw an additional 60 degree + 10 degree

Front side


Valve Clearance adjustmentValve Clearance must be adjusted when Engine is Cold:1. Use Fly wheel turning tool (G) to rotate Fly wheel in running Direction

View from water pump side (Front)2. Rotate till First Piston (front) has reached Top Dead Center on Compression

Stroke3. Insert Timing Pin (H) into fly wheel bore

In this position, we can adjust “FOUR VALVES” 1,2,4 & 5 {First Cylinder Inlet &Exhaust and Second Cylinder Exhaust & Third Cylinder Inlet}

4. Turn Crank Shaft 360 degree & reinsert timing pin5. Adjust Valve Clearance of 3rd & 6th valve {Second Cylinder inlet &

Third Cylinder Exhaust}

Front of Engine

6 5 4 3 2 1

Inlet - 0.35 mm / 0.014”, EX - 0.45mm / 0.018”


Fuel Injection Timing adjustment

Purpose:To perform the timing setting on fuel pump in field tractors.

Scope :If the fuel pump removed from the tractor for any reasons, is mounted again onsame tractor without disturbing the fuel pump calibration / setting, then one has toonly align the marking on fuel pump with marking on spacer. There is no need tofollow this timing setting procedure. It means, this condition is not under scope ofsubject procedure.

If the removed fuel pump from tractor is re-calibrated & / or settings are changed, then itfollows under this scope of this procedure.

If a new fuel pump is fitted on field tractor, then it follows under scope of this procedure.


Removal of FIP from Engine


FIP FITMENTa) Align the keyway of the FIP gear & key on shaft, you can use one drop of Fevi kwick

on keyway so that key does not fall while assembly. Engage the gear & shaft completely.b) Torque the FIP gear tightening nut to the specified limit (85Nm). Flywheel should be locked

by the pin to ensure the proper tighteningc) Engage the FIP mounting nuts (4 nos.) in the stud & tighten them. (Do not torque fully)d) Assemble & torque the high-pressure lines to specified limit (30Nm).e) Now loosen nuts & rotate the FIP to the

extreme inside i.e. top towards manifold.This is very important to take care ofbacklash in the gear train. This operationshould be done by special tool. Thanagain tighten the nuts. Hand tight

Fitment of FIP after Recalibration


f) Note the plunger lift in the portion when the pin gets into the flywheel TDC hole. Now keep theflywheel pin in engaged position rotate the FIP outward to make plunger lift to 4.95 - 5.05mm for Trem III Engines).g) Repeat the point no b, c, d, e & f to confirm plunger lift is 4.95 - 5.05mm when the flywheel pin gets engaged. For getting overall view of Arrangement refer photograph


FIP TIMING SETTING

a) Remove inspection plate of the FIP with the help of Allen key. Mount the FIPsetting gauge on the FIP, the Gauge plunger point should touch the tappet top.

b) Now remove the timing pin & rotate the engine slowly clockwise with the helpof Engine rotating tool, the needle of the FIP gauge will also rotate. Continue torotate the engine till the FIP plunger no. 1 comes to BDC.

c) It should be ensured that there is no further movement of Needle in the FIP gaugeeven after rotating the engine for few degrees either side.

d) Set the' 0' in the dial gauge on this point correctly. Confirm that the zero settingis correct by checking again by rotating the engine few degrees either side.

e) Now rotate the engine slowly in clockwise direction, the gauge needle will alsostart rotating. Measure the number of rotation .Put the timing pin in side the flywheel

housing & engage the pin in flywheel. The action of engine rotation & engaging the pinshould be simultaneously carried out with measurement of needle rotation.

f) Note the plunger lift in the portion when the pin gets into the flywheel TDC hole.Now keep the flywheel pin in engaged position rotate the FIP outward to make plungerlift to 4.95 - 5.05 mm for Trem III engine only).

g) Repeat the point no b, c, d, e & f to confirm plunger lift is 4.95 - 5.05 mm whenthe flywheel pin gets engaged.


Measurement of Cylinder Liner Protrusion

Before checking liner protrusionInstall liner without o-rings. Clean all deposits fromunder the flange of the liner and mating bore in theblock. Clean the lower sealing & packing surfaces toensure proper seating. Check protrusion at severalplaces to be sure that the liner is seated evenly.If liner protrusion is above specificationMachine the block bore by applying lappingcompound to liner flange & turning it right or left inthe bore to rub off the material. (Liner can also beused for this purpose.If liner protrusion is below specificationAdd shims under the liner flange. They are availablein two sizes: 0.05, 0.10 mm.Note: Only one shim is allowed per cylinder. Ifmore than one shim is required, install either newliner or cylinder block.Specification

Liner protrusion 0.01 – 0.10 mm.Max permissible difference between linerprotrusion of adjacent cylinders 0.03mm.


How to Measure the Liner Protrusion

Note : Lines protrusion should be checked without placing of "0" Rings

A. Install liner without packing or O-rings. If linerdoes not rotate smoothly by hand, remove linerand polish lower pilot bore in block with emerycloth or brush.

B. Align liner and cylinder block marks, thenScore at four points with Cap Screw & Thickwasher & tight to 100 NM

C. Using gauge, Measure liner protrusion (A) atfour Points 0.01 – 0.10 mmand maximum permissible difference betweenadjacent Cylinders should not be more than0.03 mm

D. If liner protrusion or permissible differenceis above specifications, apply lappingcompound to liner flange shoulder in theblock & turn sleeve with Tool left & Rightto rub off required material


How to Measure Piston Protrusion

A – Piston at TDCB – Centre line of Cylinder Liner Bore

Measure Piston Protrusion:NOTE: Press down on top of piston to remove clearancesbefore measuring piston protrusion.

1. Set dial indicator at “zero”.2. While pressing gauge downward, turn crankshaft until

piston is at “TDC” position.3. Piston protrusion should be within 0.08 mm - 0.35 mm4. If protrusion is out of specifications, check all

concerned parts to determine the cause.


Piston Protrusion

A - Piston protrusion above block surface :

Specification: Piston protrusion above blocksurface 0.08-0.35 mm.

If piston protrusion is belowspecification then check:1. Piston pin and pin bushing2. Bend of connecting rod3. Connecting bearing clearance4. Connecting journal diameterEffects:1. Reduced compression pressure.2. Incomplete combustion leads to high

fuel consumption & smoke (white/black).3. Power developed will be less.4. Starting problem.


Crankshaft End play MeasurementNOTE: It is recommended to measure crankshaftend play prior to removing crankshaft to determinecondition of thrust bearings.Check crankshaft end play using a dial indicator andcompare with specifications.Crankshaft—Specification2-piece thrust bearing—End Play ....... 0.13—0.40mm (0.005—0.016 in.)Wear tolerance ......................... 0.50 mm (0.02 in)If end play is still not within specification with newstandard 2-piece or 6-piece thrust bearings, install a5-piece thrust bearing with oversized thrust washers.

SpecificationOversized Crankshaft Thrust Washer—Thickness......................... + 0.18 mm (0.007 in.)NOTE: Oversized thrust bearing set contains three0.18 mm (0.007 in.) oversized thrust washers to beinstalled as shown

A—Oversized Thrust WashersB—Front of EngineC—Rear Bearing Cap Side

(A)


Crankshaft main bearing Clearance using Plastic gauge

1. Place a strip of PLASTIGAGE in the center of the bearing.2. Install cap and tighten cap screws to 135 N.m (100 lb-ft).3. Remove cap and compare the width of PLASTIGAGE

with scale provided on side of package to determineclearance.

4. Maximum permissible clearance is 0.15 mm (0.006 in)

If journals are worn, tapered, out-of-round, scored ordamaged, the crankshaft journals can be regroundand correct undersize bearing inserts installed.

SpecificationUndersized Crankshaft Main Bearing—1st Size 0.25 mm (0.01 in.)2nd Size............................... . 0.50 mm (0.02 in.)3rd Size................................. 0.75 mm (0.03 in.)


A—Camshaft/Upper Idler GearB—Injection Pump/Upper Idler GearC—Upper Idler/Crankshaft GearD—Crankshaft/Lower Idler GearE—Oil Pump/Lower Idler GearMeasure backlash between gears using a dial indicator andcompare with specifications as given below:

Helical Timing Gear—SpecificationUpper Idler/Crankshaft GearBacklash 0.07— 0.30 mm (0.003—0.012 in.)Wear Tolerance -0.40 mm (0.016 in.)Upper Idler/Camshaft Gear—Backlash - 0.07—0.35 mm (0.003—0.014 in.)Wear Tolerance - 0.51 mm (0.020 in.)Upper Idler/Injection PumpGear—Backlash - 0.07—0.35 mm (0.003—0.014 in.)Wear Tolerance - 0.51 mm (0.020 in.)Lower Idler/Crankshaft Gear—Backlash - 0.07—0.35 mm (0.003—0.014 in.)Wear Tolerance - 0.51 mm (0.020 in.)Lower Idler/Oil Pump Gear—Backlash - 0.04—0.38 mm (0.0016—0.015 in.)Wear Tolerance - 0.40 mm (0.016 in.)

Measure Timing Gear Backlash

If backlash is not correct, install new gears.


Using a dial indicator, check camshaft end play.SpecificationCamshaft—End Play - 0.08—0.23 mm (0.003—0.009 in.)Maximum Wear - 0.38 mm (0.015 in.)Thrust Plate—Thickness 3.935—3.985 mm (0.155—0.157 in.)Maximum Wear - 3.8 mm (0.15 in.)NOTE: If end play exceeds specifications then checkthickness of thrust plate as this determines end play

Camshaft End Play Measure


Compression Pressure Test

Dummy Nozzle & adopter

Compression Test Kit

REASON:To determine the condition of the pistons, rings, cylinderwalls and valves.EQUIPMENT:Compression Gauge Assembly, Adapter, ClampCONNECTIONS:1. Run engine for 5 minutes to bring to operating temperature.Shut off engine.2. Remove injection nozzles.3. Compression Gauge Assembly, Adapter and Clamp.4. After test is completed, bleed the fuel system.PROCEDURE:1. Disconnect fuel shut-off solenoid wiring lead (A) or fuelshut-off knob (C).IMPORTANT: DO NOT overheat starting motor during test.2. Crank engine for five seconds with starter.3. Record pressure reading for each cylinder.Cylinder—SpecificationCylinder—Pressure 2400 kPa (24 bar) (350 psi)Minimum - Maximum Difference BetweenCylinders—Pressure 350 kPa (3.50 bar) (50 psi)


Cont:RESULTS: · If pressure reading is below specification, squirt approximately two teaspoons of cleanengine oil into cylinders through injector ports and repeat test.

If pressure increases significantly, check piston, rings, and cylinder walls for wear ordamage.If pressure does not increase significantly after retest, check for leaking valves, valveseats or cylinder head gasket.

Compression Pressure Test


Engine Oil Pressure Test

REASON:To determine if bearings or lubrication systemcomponents are worn.EQUIPMENT:Special SocketPressure Gauge AssemblyHose AssemblyCONNECTIONS:1. Remove oil pressure sender & use

hose and 0—700 kPa (0—6.9 bar) (0—100 psi)gauge.

2. Connect Pressure Gauge Assembly andHose Assembly.

IMPORTANT: If pressure reading is below 72 kPa (0.72 bar) (10.5 psi), STOP ENGINE.Specification

Engine Oil Temperature at 825 rpm Engine Speed—Temperature 93°C (200 °F)0il Pressures Should be 100 kPa (1 bar) (15 psi)Engine Oil Temperature at 2500 rpm Engine Speed—Temperature 105°C (220°F)Oil Pressure should be 277—483 kPa (2.77—4.83 bar) (40—70 psi)

Training module engine (4)

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