New Generation Volvo Diesel Engine Fundamentals Classroom Training En

Service training

Diesel Engine Fundamentals Classroom training Trainer booklet

Service training

Diesel Engine Fundamentals Classroom training Participant booklet

Diesel Engine Fundamentals Classroom training

Contents

Introduction Course content........................................................................................................................... 1 Course objectives....................................................................................................................... 2 Engine history The diesel engine, yesterday and today .................................................................................... 3 First diesel engine ...................................................................................................................... 4 Diesel engines in vehicles.......................................................................................................... 5 Engines for heavier vehicles ...................................................................................................... 6 Diesel engines in Volvo vehicles................................................................................................ 7 Engine range Engine range.............................................................................................................................. 8 General and basic priciples General and basic principles Diesel engine ........................................................................................................................ 9 Internal combustion engine ............................................................................................... 10 Fuel-air mixture .................................................................................................................. 11 Rotating movement............................................................................................................. 12 Power from crankshaft........................................................................................................ 13 Diesel engine - petrol engine ............................................................................................. 14 Diesel engine - another approach ...................................................................................... 15 Sturdy engine components in the diesel engine................................................................. 16 Four strokes for a complete cycle....................................................................................... 17 Four stroke - six cylinder .................................................................................................... 18 Firing order ......................................................................................................................... 19 The diesel engine is miserly with its fuel ............................................................................ 20 Three diesel engine types .................................................................................................. 21 Precombustion indirect-injection engines........................................................................... 22 Swirl-chamber engine ......................................................................................................... 23 Different characteristics Direct injection ............................................................................. 24 Different characteristics Indirect-injection and swirl-chamber ............................................ 25 Diesel engine fundamentals. Test 1 ................................................................................... 26 Engine design ..................................................................................................................... 28


V-engine ............................................................................................................................. 29 Volvo - V8 engines.............................................................................................................. 30 The main engine components ............................................................................................ 31 Cylinder block ..................................................................................................................... 32 Cylinder block - inside ........................................................................................................ 33 Camshaft in cylinder block.................................................................................................. 34 Cylinder liner design ........................................................................................................... 35 Cylinder bore ...................................................................................................................... 36 Cylinder head...................................................................................................................... 37 Diesel engine fundamentals. Test 2 ................................................................................... 38 Cylinder head - Inlet and exhaust ducts ............................................................................. 40 Cylinder head - Copper sleeve ........................................................................................... 41 Cylinder head - Details ....................................................................................................... 42 Cylinder head and cylinder liner seals................................................................................ 43 Cylinder head and cylinder liner seals................................................................................ 44 Cranking mechanism.......................................................................................................... 45 A few facts about loads ...................................................................................................... 46 Crankshaft .......................................................................................................................... 47 Power impulse .................................................................................................................... 48 Crankshaft - Oscillation ...................................................................................................... 49 Damper ............................................................................................................................... 50 The crankshaft is perfectly balanced .................................................................................. 51 Seven main bearings.......................................................................................................... 52 Seven main bearings - connecting rod ............................................................................... 53 V-engine, two connecting rods ........................................................................................... 54 Lubrication ducts ................................................................................................................ 55 What happens in an in-line six cylinder engine .................................................................. 56 Main bearing caps .............................................................................................................. 57 Main bearings screw........................................................................................................... 58 Support bearing .................................................................................................................. 59 Flywheel.............................................................................................................................. 60 Flywheel - other tasks......................................................................................................... 61 Connecting rod ................................................................................................................... 62 Connecting rod - details...................................................................................................... 63 Gudgeon pin ....................................................................................................................... 64 Gudgeon pin hole ............................................................................................................... 65 Gudgeon pin - journal led ................................................................................................... 66 Connecting rod bearing ...................................................................................................... 67


Diesel engine fundamentals. Test 3 ................................................................................... 68 Piston.................................................................................................................................. 70 Piston - Thermal stress and mechanical stress.................................................................. 71 Piston - Materials ................................................................................................................ 72 Articulated piston ............................................................................................................... 73 Piston - Tolerance............................................................................................................... 74 Piston cooling ..................................................................................................................... 75 Piston rings ......................................................................................................................... 76 Piston rings material first ring ............................................................................................. 77 Piston rings material second ring ....................................................................................... 78 Piston rings material oil ring ............................................................................................... 79 Piston rings - Oil ring .......................................................................................................... 80 Diesel engine fundamentals. Test 4 ................................................................................... 81 Valve mechanism ............................................................................................................... 83 Pushrod engine .................................................................................................................. 84 Overhead camshaft ............................................................................................................ 85 Camshaft ............................................................................................................................ 86 Camshaft - Design .............................................................................................................. 87 Engine timing mechanism .................................................................................................. 88 Engine timing mechanism - Sound insulation .................................................................... 89 Crankshaft seal................................................................................................................... 90 Valves, valve guides and valve seats................................................................................. 91 Valves ................................................................................................................................. 92 Valve stem .......................................................................................................................... 93 Valve springs ...................................................................................................................... 94 Valve seals ......................................................................................................................... 95 Pushrod and rocker arm ..................................................................................................... 96 Diesel engine fundamentals. Test 5 ................................................................................... 97 Lubrication system Lubrication system Lubrication system.............................................................................................................. 99 Engine oil quality .............................................................................................................. 100 Splash lubrication - Pressure lubrication .......................................................................... 101 Pressure lubrication .......................................................................................................... 102 Lubrication system - Function........................................................................................... 103 Lubrication system - schematic ........................................................................................ 104 Oil pump - function............................................................................................................ 105


Oil pump - parts ................................................................................................................ 106 Oil filter housing ................................................................................................................ 107 Oil flows through the filter ................................................................................................. 108 Oil cooler........................................................................................................................... 109 Oil sump............................................................................................................................ 110 Diesel engine fundamentals. Test 6 ................................................................................. 111 Fuel system Fuel system Fuel injection system ........................................................................................................ 114 Injection pump .................................................................................................................. 115 Mechanical regulator or governor..................................................................................... 116 Supply pump..................................................................................................................... 117 Smoke limiter .................................................................................................................... 118 Fuel filter ........................................................................................................................... 119 Pressure pipes.................................................................................................................. 120 Injector - copper sleeve .................................................................................................... 121 Nozzle sleeve - needle ..................................................................................................... 122 Injector - function .............................................................................................................. 123 Diesel engine fundamentals. Test 7B............................................................................... 124 Fuel systems with unit injectors........................................................................................ 126 Unit injector - system function .......................................................................................... 127 Diesel engine fundamentals. Test 7C............................................................................... 128 Common rail ..................................................................................................................... 130 Injector .............................................................................................................................. 131 Diesel engine fundamentals. Test 7D............................................................................... 132 Engine management system Engine management system EMS - Engine Management System ................................................................................ 133 Engine control unit ............................................................................................................ 134 Sensors on the engine...................................................................................................... 135 Other sensors ................................................................................................................... 136 Example of communication .............................................................................................. 137 Diesel engine fundamentals. Test 7A............................................................................... 138 Intake and exhaust system Intake and exhaust system Intake and exhaust system............................................................................................... 140


Air filter ............................................................................................................................. 141 Cyclone filter .................................................................................................................... 142 Starter element ................................................................................................................. 143 Exhaust pressure governor .............................................................................................. 144 Compression brake VEB .................................................................................................. 145 Compression brake VEB+ ................................................................................................ 146 Compression brake JAK................................................................................................... 147 Engine brake function....................................................................................................... 148 Diesel engine fundamentals. Test 8 ................................................................................. 149 Turbocharger Turbocharger Turbocharger history......................................................................................................... 151 Turbocharging................................................................................................................... 152 Turbocharger bearing ....................................................................................................... 153 Wastegate......................................................................................................................... 154 Turbocharger system........................................................................................................ 155 Exhaust pressure governor .............................................................................................. 156 Turbocharger type VGT .................................................................................................... 157 Charge air cooling............................................................................................................. 158 Air to air cooling ................................................................................................................ 159 Diesel engine fundamentals. Test 9 ................................................................................. 160 Cooling system Cooling system Volvo coolant .................................................................................................................... 162 Cooling system ................................................................................................................ 163 External components of the cooling system..................................................................... 164 Thermostat ....................................................................................................................... 165 Schematic presentation of the cooling system ................................................................. 166 Radiator ............................................................................................................................ 167 Cooling fans in vehicles.................................................................................................... 168 Cooling fans in bus ........................................................................................................... 169 Cooling fans in VCE ......................................................................................................... 170 Diesel engine fundamentals. Test 10 ............................................................................... 171 Emissions Emissions Vehicle emissions and environmental impact .................................................................. 174


Engine emission ............................................................................................................... 175 Carbon dioxide and Hydrocarbons ................................................................................... 176 Nitrogen oxides (NOX) ..................................................................................................... 177 Particulate matter.............................................................................................................. 178 Diesel engine fundamentals. Test 11A............................................................................. 180 EGR EGR Emisson control, schematic description of the system..................................................... 181 EGR system...................................................................................................................... 182 I-EGR, Large engine platform........................................................................................... 183 I-EGR, Medium engine platform ....................................................................................... 184 I-EGR Function, Medium engine platform ........................................................................ 185 Diesel engine fundamentals. Test 11B............................................................................. 186 SCR SCR SCR - Selective Catalytic Reduction ................................................................................ 187 Main components in the Volvo SCR system .................................................................... 188 Solution principle for the Volvo SCR system.................................................................... 189 Overview of the exhaust gas processing system ............................................................. 190 Diesel engine fundamentals. Test 11C ............................................................................ 191 CCV CCV CCV - CrankCase Ventilation - Closed............................................................................. 193 Diesel engine fundamentals. Test 11D ............................................................................ 194

Introduction > Course content

Notes

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Introduction > Course content Key points  Course content  Practical exercises  Theoretical summary  Course schedule

Working procedure Go through Course content (overview). Explain briefly what the different subjects will include - give examples. Explain that each practical session will start with theory and after there it will be a practical session. Test questions are also included. Remind the participants that later there will be a written test to complete the course. Go through the schedule.

Additional information Course guide Start by welcoming the participants to the course. Introduce yourself and let all the participants introduce themselves, e.g. give their name, company, say where they come from, how long they have worked for Volvo and detail any previous experience of other truck workshops they may have. Present the course timetable and give a general idea of what is going to be covered over the days (Course contents and objectives). Also mention practical issues such as breaks, smoking, mobile phones, etc. If this is the first time the participants have been on a Volvo course, tell them a little about the Volvo Company. Hand out the student material and inform the participants of the post test that will be held on the last day. The use of the student material, including any personal notes the participants may have made, will be allowed during the written post test. Mention that some of the tasks from the practical training can be performed as individual tests. Morning and afternoon breaks should be adapted to suit local times.

Trainer notes

Page 1 (trainer)

Introduction > Course objectives

Course objectives After completing the course, you should be able to • Select and use appropriate tools and equipment. • Carry out jobs in a safe way, without causing damage to equipment, component, vehicle or person. • Check and adjust a range of engine components. e.g. valves, unit injectors, engine brake system, fuel systems, belts etc. • Verify proper operation after adjustment. • The purpose of this training is to give you a good knowledge of the Basic Diesel Technology in practical and theoretical.

Notes

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Introduction > Course objectives

Key points  Course objectives  Check and adjust  Appropriate tools and equipment.  Damage  Verify proper operation

Working procedure Go through Course objectives (overview).

Additional information Course guide

Trainer notes

Page 2 (trainer)

Engine history > The diesel engine, yesterday and today

The diesel engine, yesterday and today It all began in 1892 when Rudolf Diesel was granted a patent for a new type of engine. It was to be far more efficient than all previously known engine types and it would be powered by a fuel which was cheaper than petrol. Rudolf Diesel initially intended powering his new engine with coal dust, but soon switched his attention to liquid fuel. Today, all diesel engines are driven by diesel oil. Diesel's first engine was completed in 1893. It suffered a host of problems and did not produce enough power to keep itself running. Not before 1897 did Diesel manage to produce an engine which functioned anything like he had envisioned. Since then, considerable effort has been invested in research and development to bring the diesel engine to today's levels of superb efficiency and operational reliability. The picture on the left shows one of the very earliest engines. It has a bore of 220 mm and a stroke of 400 mm. And it's 3 metres tall. The engine on the right is a Volvo TAD 1630. Roughly 80 years of development separate Rudolf Diesel's first engine from this hyper-modern power unit. Diesel engines today weigh less than half as much as their first ancestors, and they pump out more than 30 times as much power.

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Engine history > The diesel engine, yesterday and today Key points  History  Rudolf Diesel  Frenchman  Born 1858  1876 Otto patent 4-stroke engine  1892 patent diesel  Coaldust  First working engine = 4.5 ton - 20hp - 26% efficiency  1913 suicide on the way to England  The first engines were made for heavier vehicles  First Volvo truck 1928  Volvo truck engine 1946  Turbocharger 1954

Working procedure Go through the text in the student material and also add your own experience/knowledge. Be sure that the participants have understood the main purpose of this information. Ask question to be sure that the participants have understand the main purpose of this chapter/slide/information/text.

Trainer notes

Page 3 (trainer)

Engine history > First diesel engine

First diesel engine The first diesel engines were large and clumsy and they were certainly not designed for installation in moving vehicles. Rather, they were intended as powerplants for industry or as prime movers powering generators or pumps.

The two-cylinder engine in the picture to the right is from 1898 and it produced 50 hp (37 kW). It was used to power industrial machines and was in regular operation until 1930. It was produced by a German manufacturer, MAN in Augsburg.

Notes

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Engine history > First diesel engine Key points  Large and clumsy  For industry  Powering generators or pumps  1898  50 hp (37 kW)  MAN in Augsburg


Trainer notes

Page 4 (trainer)

Engine history > Diesel engines in vehicles

Diesel engines in vehicles It took considerable research effort and innumerable trials before the diesel engine was ready for installation in moving vehicles. The very first vehicle engines came in the early 1920s. One of the first, a Benz from 1922, can be seen here on the right. It had two cylinders and produced just 22 kW or 30 horsepower.

Notes

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Engine history > Diesel engines in vehicles Key points  Installation in moving vehicles  Early 1920s  Benz from 1922  Two cylinders and produced just 22 kW or 30 horsepower


Trainer notes

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Engine history > Engines for heavier vehicles

Engines for heavier vehicles The first engines were made for heavier vehicles such as trucks and tractors. The truck pictured here is a Daimler-Benz made in 1923. Lightweight series-manufactured diesel engines for passenger cars first made an entry about ten years later. The first such engines bore the Daimler-Benz badge and they had a power output of about 33 kW or 45 horsepower. Rudolf Diesel, the inventor of the diesel engine, died in 1913, long before engines bearing his name became a common sight in moving vehicles. Volvo Penta launch diesel engine in 1958. The engine type was called MD1. Volvo Construction Equipment launch diesel engine in 1954. Volvos busses got a new diesel engine 1945 and one year later it was also introduce in the trucks. The engine type was called VDA.

Notes

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Engine history > Engines for heavier vehicles Key points  Truck Daimler-Benz made in 1923  Lightweight series-manufactured diesel engines  33 kW or 45 horsepower  Rudolf Diesel, the inventor of the diesel engine, died in 1913  Volvo Penta launch diesel engine in 1958. The engine type was called MD1  Volvo Construction Equipment launch diesel engine in 1954  Volvos busses got a new diesel engine 1945  Volvo trucks got a new diesel engine 1946  The engine type was called VDA


Trainer notes

Page 6 (trainer)

Engine history > Diesel engines in Volvo vehicles

Diesel engines in Volvo vehicles Diesel engines were first fitted to Volvo trucks in 1946. The first engine was a six-cylinder unit producing 71 kilowatts (96 horsepower). It carried the VDA designation (Volvo Diesel engine type A). More than a decade previously, however, in 1933, Volvo's trucks were powered by an engine similar in concept to the diesel engine. It was known as the Hesselman engine and it ran on the same fuel as the diesel engine, but featured an electrical ignition system. The Hesselman unit is often referred to as a "semi-diesel" engine. The latest generation of engines with which you work are developments of these early units. Everyone concerned has invested enormous effort and expertise in making the diesel engine better and better. And the result can be seen if you compare the first VDA engine with a similarly-sized engine of today. Just look at the power outputs, for example. The VDA produced 71 kW and had a displacement of 6.12 litres. A corresponding engine of today, the D6A (slightly smaller but with a turbocharger and intercooler) produces more then 150 kW! And there's more. Fuel consumption is lower. Durability and service life are longer. Operating reliability is far higher. So a lot has happened since 1946! But what of the future? Well, this is what it looks like in general terms: there is no other type of engine currently in existence which can compete with the diesel engine in heavy-duty vehicles or as a power source for large generators and pumps.

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Engine history > Diesel engines in Volvo vehicles Key points  71 kilowatts (96 horsepower)  VDA (Volvo Diesel engine type A)  Hesselman unit is often referred to as a "semi-diesel" engine  VDA produced 71 kW and had a displacement of 6.12 litres  D7E (slightly smaller but with a turbocharger and intercooler) produces more then 150 kW!  Fuel consumption is lower  Durability and service life are longer  Operating reliability is far higher  Future


Trainer notes

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Engine range > Engine range

Engine range We shall look at the diesel engine range on the engine that we have today. Volvo have engines in a range from approx. 240 horsepower and up to 700 horsepower. The cylinder volume is between 7 litres and up to 16 litres. The smallest engine is the D7E and it was launched in 2006... _ ...the next engine in range is the D9 engine and it was launched in 2001... _ ...and the D11 engine, launched in 2008... _ ... we have also the D13 engine. This engine was launched in 2005 and the biggest of them all is... _ ...the D16 and this is also the most powerful of them all.

Notes

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Engine range > Engine range Key points  Range  D7E  D9  D11  D13  D16

Working procedure Talk with the participants about the Volvo engine range. Explain why we have overlap for different engines power and torque. There is overlapping of different engine powers and torques. That has to do with different taxation in different markets. Some markets have tax depending on power other markets set the tax depending on volume.

Additional information Go through the information shown in the additional information. Her it is possible to run the movie “AN INTRO TO DIESEL ENGINE”. This is like a teaser for the participants. The movie going through the fundamentals estimated time 15 min. An another way is to show each chapter where it belongs. This decision is up to the teacher to decide. In the tranier notes under headline "Additional information" the trainer find information when it is time to run each chapter.

Trainer notes

Page 8 (trainer)

General and basic priciples > General and basic principles > Diesel engine

Diesel engine High demands are placed on modern engines. They must meet demands for low fuel consumption combined with high performance, while at the same time having low levels of noise and exhaust emissions. There are few power sources on which so much research and development work is expended as on the diesel engine, which is basically quite an old invention. Development work has essentially been concentrated on refining existing technology, but a great number of completely new solutions have been developed in recent years. Electronic Management Systems (EMS) have been used for a number of years, and electronics are steadily taking on a more central role in each new generation of engines. The earlier fuel injection system EDC (Electronic Diesel Control), and Unit Injector have now been developed into a more advanced EMS system that is integrated into the TEA (Truck Electronic Architecture) vehicle electronic system.

Notes

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General and basic priciples > General and basic principles > Diesel engine

Key points  Low fuel consumption combined  High performance  Low levels of noise  Exhaust emissions  Electronic Management Systems (EMS)  Electronic Diesel Control (EDC)  Unit Injector  TEA vehicle electronic system

Working procedure Go through the text in the student material and also add your own experience/knowledge. Be sure that the participants have understood the main purpose of this information. Ask question to be sure that the participants have understand the main purpose of this information/text. Walk around different engines if it is possible and let the participants point out engine main part on the outside. Show the participants the engine parts and explain how they are connected to each other, do not forget to tell them what is happen if they do not understand the basic when they shall e.g. fault tracing.

Additional information

Her it is time to run the movie “AN INTRO TO DIESEL ENGINE” chapter "Introduction" and "Basic design". This is like a teaser for the participants.

Trainer notes

Page 9 (trainer)

General and basic priciples > General and basic principles > Internal combustion engine

The diesel engine is an internal combustion engine  Combustion chamber  Piston  Cylinder ·

Notes

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General and basic priciples > General and basic principles > Internal combustion engine

Key points  Internal combustion engine  Combustion chamber  Piston  Cylinder

Working procedure Go through the text in the student material and also add your own experience/knowledge. Be sure that the participants have understood the main purpose of this information. Ask question to be sure that the participants have understand the main purpose of this information/text. Show the participants the engine parts and explain how they are connected to each other, do not forget to tell them what is happen if they do not understand the basic when they shall e.g. fault tracing.

Trainer notes

Page 10 (trainer)

General and basic priciples > General and basic principles > Fuel-air mixture

Fuel-air mixture  Ignited  Pressure  Considerable force  Rotate in a circle

Notes

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General and basic priciples > General and basic principles > Fuel-air mixture

Key points  Fuel-air mixture  High pressure  Pushes the piston  Force  Rotate in a circle


Trainer notes

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General and basic priciples > General and basic principles > Rotating movement

Rotating movement  Connecting rod  Crankshaft

Notes

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General and basic priciples > General and basic principles > Rotating movement

Key points  Movement of the piston  Rotating movement  Connecting rod  Crankshaft.  The force -piston-connecting rod-crankshaft  Propel the vehicle


Trainer notes

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General and basic priciples > General and basic principles > Power from crankshaft

Power from crankshaft  Vehicle  Transmission components  Driven wheels  Driveline

Notes

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General and basic priciples > General and basic principles > Power from crankshaft

Key points  Crankshaft-gearbox-rear axle-wheel  Driveline


Trainer notes

Page 13 (trainer)

General and basic priciples > General and basic principles > Diesel engine - petrol engine

Diesel engine - petrol engine  Petrol engine  Ready-mixed blend of petrol and air  Compressed  Ignited  Spark

Notes

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General and basic priciples > General and basic principles > Diesel engine - petrol engine

Key points  Diesel engine  Petrol engine  Differences  Petrol engine.  Electrically generated spark


Trainer notes

Page 14 (trainer)

General and basic priciples > General and basic principles > Diesel engine - another approach

Diesel engine - another approach  Unblended air  Hot air  Compressed  Ignite the diesel fuel  Compression ignition  Peak pressure  Diesel engine 7 and 20 MPa  Petrol engine 3 to 5 MPa

Notes

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General and basic priciples > General and basic principles > Diesel engine - another approach

Key points  Unblended air  Compressed  Hot - ignite the diesel fuel  Fuel  Hot air  Ignited  Compression ignition.  Combustion pressure  Diesel engine 7 to 20 MPa  Petrol engine 3 to 5 MPa  Peak pressure


Trainer notes

Page 15 (trainer)

General and basic priciples > General and basic principles > Sturdy engine components in the diesel engine

Sturdy engine components in the diesel engine  High working pressure  Mechanical stress  More expensive to produce

Notes

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General and basic priciples > General and basic principles > Sturdy engine components in the diesel engine Key points  Sturdy components  High working pressure  Mechanical stress  More expensive


Trainer notes

Page 16 (trainer)

General and basic priciples > General and basic principles > Four strokes for a complete cycle

Four strokes for a complete cycle  Inlet stroke  Compression stroke  Operating stroke  Exhaust stroke

Notes

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General and basic priciples > General and basic principles > Four strokes for a complete cycle

Key points  Four strokes for a complete cycle  Inlet stroke  Compression stroke  The piston compresses the air  2-3 MPa (20-30 bar)  700-900°C  Fuel injection occurs at the end of the compression stroke  2000-2500°C  Operating stroke  Exhaust stroke



Her it is time to run the movie “AN INTRO TO DIESEL ENGINE” chapter "4stroke principle". This is like a teaser for the participants.

Trainer notes

Page 17 (trainer)

General and basic priciples > General and basic principles > Four stroke - six cylinder

Four stroke - six cylinder Firing order is 1 - 5 - 3 - 6 - 2 - 4 Cylinder 1 The compression stroke has just begun. Cylinder 2 Operating stroke; the pressure is very high right now. Cylinder 3 Exhaust stroke is completed, the inlet stroke begins. Cylinder 4 End of compression stroke, fuel is sprayed in and ignited. Cylinder 5 Inlet stroke has just begun and clean air is fed in. Cylinder 6 The exhaust stroke has just begun.

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General and basic priciples > General and basic principles > Four stroke - six cylinder

Key points  Four-stroke principle  Firing order, 1 - 5 - 3 - 6 - 2 - 4  Cylinder 1 the compression stroke has just begun  Cylinder 2 operating stroke; the pressure is very high right now  Cylinder 3 exhaust stroke is completed, the inlet stroke begins  Cylinder 4 end of compression stroke, fuel is sprayed in and ignited  Cylinder 5 inlet stroke has just begun and clean air is fed in  Cylinder 6 the exhaust stroke has just begun



Her it is time to run the movie “AN INTRO TO DIESEL ENGINE” chapter "Induction stroke", "Compression stroke", "Working stroke" and "Exhaust stroke". This is like a teaser for the participants. After that you have run the four stroke you can also run "Sum up 4-stroke principle" so the participants can see as a sequence.

Trainer notes

Page 18 (trainer)

General and basic priciples > General and basic principles > Firing order

Firing order  Direction the piston is moving  Position of the valves  A six-cylinder engine has a very close firing order  Three operating strokes  Once the crankshaft has rotated twice, combustion has taken place in all the cylinders  Absolute precision is essential for the engine to run perfectly

Notes

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General and basic priciples > General and basic principles > Firing order

Key points  Piston moving  Position of the valves  Each turn of the crankshaft-three operating strokes  Once the crankshaft has rotated twice, combustion has taken place in all the cylinders  One combustion stroke does not have time to be completed before the next starts


Additional information Operating strokes are coloured red. With the engine operating at 2000 rpm. per minute, there are 6000 combustion strokes per minute or 100 per second. If the engine is run at that speed, it takes just three minutes to reach a million combustion strokes. Her it is time to run the movie “AN INTRO TO DIESEL ENGINE” chapter "Firing order". This is like a teaser for the participants.

Trainer notes

Page 19 (trainer)

General and basic priciples > General and basic principles > The diesel engine is miserly with its fuel

The diesel engine is miserly with its fuel  Cooling losses  Exhaust losses  Friction losses

Notes

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General and basic priciples > General and basic principles > The diesel engine is miserly with its fuel Key points  Fuel-chemical energy  Converts into mechanical effort.  Sankey diagram  Energy 100%.  Cooling losses ca. 25% (diesel engine)  Exhaust losses ca. 25% (diesel engine)  Friction losses ca. 10% (diesel engine)  Efficiency rating ca. 40% (diesel engine)


Additional information Diesel engines have the highest efficiency rating of all, up to 43-44% in a truck engine (D13 up to 47%). Passenger-car diesels are somewhat less efficient, at about 38%, roughly the same level as twostroke diesel engines for vehicles. Petrol engines have an efficiency rating of about 30%. The first engines from the end of the previous century had an efficiency rating of a mere 2-5%.

Trainer notes

Page 20 (trainer)

General and basic priciples > General and basic principles > Three diesel engine types

Three diesel engine types  Direct-injection engines  Precombustion indirect-injection engines  Swirl-chamber engines

Notes

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General and basic priciples > General and basic principles > Three diesel engine types

Key points  Three diesel engine types  Direct-injection engines  Precombustion indirect-injection engines  Swirl-chamber engines  All Volvo diesel engines are direct-injection units


Trainer notes

Page 21 (trainer)

General and basic priciples > General and basic principles > Precombustion indirect-injection engines

Precombustion indirect-injection engines  Fuel  Pre-chamber  Combustion  Glowplug

Notes

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General and basic priciples > General and basic principles > Precombustion indirect-injection engines Key points  Precombustion indirect-injection engines  Roughly 25%, is separated into a pre-chamber  Fuel into the pre-chamber  Not sufficient air in the pre-chamber  Mixture is pressed out into the combustion chamber  Heated electrically  VDA diesel engine-indirect-injection engine


Trainer notes

Page 22 (trainer)

General and basic priciples > General and basic principles > Swirl-chamber engine

Swirl-chamber engine  Combustion chamber  Swirl-chamber

Notes

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General and basic priciples > General and basic principles > Swirl-chamber engine

Key points  Swirl-chamber engine  Lrger volume than the indirect-injection engine  Roughly 50% in the swirl-chamber  Same process as in the indirect-injection diesel  Swirl-chamber engines-passenger-car diesels


Trainer notes

Page 23 (trainer)

General and basic priciples > General and basic principles > Different characteristics Direct injection

Different characteristics Direct injection  Small losses  Higher efficiency  Lower fuel consumption  Engine speeds, up to about 4000 rpm

Notes

Page 24

GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > Different characteristics Direct injection Key points  Various engine types have different characteristics  Direct injection-Small losses compared with the others  Direct injection-Higher efficiency rating and lower fuel consumption  Direct injection-Up to about 4000 rpm


Trainer notes

Page 24 (trainer)

General and basic priciples > General and basic principles > Different characteristics Indirectinjection and swirl-chamber

Different characteristics Indirect-injection and swirl-chamber  Combustion is quick  Operate at high speeds, up to about 6000 rpm.  Greater losses  Lower efficiency  High fuel consumption

Notes

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Page 25

General and basic priciples > General and basic principles > Different characteristics Indirectinjection and swirl-chamber Key points  Indirect-injection and swirl-chamber  Combustion is quick  Operate at high speeds, up to about 6000 rpm  Greater losses than for direct-injection engines  Lower efficiency rating  Higher fuel consumption


Trainer notes

Page 25 (trainer)

General and basic priciples > General and basic principles > Diesel engine fundamentals. Test 1

Diesel engine fundamentals. Test 1 Decide which is correct. A petrol engine takes in a ready-mixed blend of fuel and air. The diesel engine works under higher pressure than a petrol engine. The diesel engine is sometimes equipped with an electrical ignition system. The highest pressure resulting from combustion is known as peak pressure. In a diesel engine, finely atomised fuel is sprayed into the combustion chamber. These parts are subjected to greater mechanical stresses in a diesel engine than in a petrol engine. True False State the correct sequence for the following processes (put the figures in the appropriate boxes 1 -6 ). The air is compressed The fuel is ignited by the hot air Clean air enters into the cylinders Finely atomised fuel is sprayed in Combustion produces high pressure The exhaust gases leave the cylinder State the correct sequence, putting the figures in the appropriate boxes ( 1 - 4 ).

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Key points • Question • Answer

Working procedure It is now time to hand out the question to the participants. Let each participants work with the question for about 5-10 minutes. After that shall the trainer go through the correct answer. Discuss the answers with the participants if there have been any misunderstandings or linguistic problems. Questions that could help to improve the format of the questionnaire in the future may arise.


Introduction to diesel engines. Test 1 Key Decide which is correct. *A petrol engine takes in a ready-mixed blend of fuel and air. *The diesel engine works under higher pressure than a petrol engine. The diesel engine is sometimes equipped with an electrical ignition system. *The highest pressure resulting from combustion is known as peak pressure. *In a diesel engine, finely atomised fuel is sprayed into the combustion chamber. These parts are subjected to greater mechanical stresses in a diesel engine than in a petrol engine. *True False State the correct sequence for the following processes (put the figures in the appropriate boxes 1 -6 ). The air is compressed 2 The fuel is ignited by the hot air 4 Clean air enters into the cylinders 1 Finely atomised fuel is sprayed in 3 Combustion produces high pressure 5 The exhaust gases leave the cylinder 6 State the correct sequence, putting the figures in the appropriate boxes ( 1 - 4 ). Inlet stroke 1 Exhaust stroke 4 Operating stroke 3 Compression stroke 2 During one of the strokes in a diesel engine, the piston is on its way down and both valves are shut. Which stroke is this? Inlet stroke Exhaust stroke Compression stroke *Opearating stroke

Page 26 (trainer)


nlet stroke Exhaust stroke Operating stroke Compression stroke During one of the strokes in a diesel engine, the piston is on its way down and both valves are shut. Which stroke is this? Inlet stroke Exhaust stroke Compression stroke Opearating stroke Peak pressure in a diesel engine can approach 20 MPa (200 bar). No, not so high. Yes, this is true. No, much higher. How many ignitions are there in a six-cylinder diesel engine for each turn of the crankshaft? Two Three Six How many times does the crankshaft turn for all six cylinders to fire once? One Two Six You have to know both the direction in which the piston is moving and the positions of the valves in order to determine exactly what is happening in a cylinder at any given moment in time. True False The firing order in a Volvo diesel engine is always: 1-5-4-2-3-6 1-2-3-4-5-6 1-5-3-6-2-4 Which of these engine types has the highest efficiency rating? Petrol engine Direct-injection diesel engine Diesel engine with pre-chamber All Volvo truck diesels as of 1986 are: Pre-combustion chamber engines Direct-injection engines Swirl-chamber engines

GT120017A v.1.0.01_en

Page 27


Peak pressure in a diesel engine can approach 20 MPa (200 bar). No, not so high. *Yes, this is true. No, much higher. How many ignitions are there in a six-cylinder diesel engine for each turn of the crankshaft? Two *Three Six How many times does the crankshaft turn for all six cylinders to fire once? One *Two Six You have to know both the direction in which the piston is moving and the positions of the valves in order to determine exactly what is happening in a cylinder at any given moment in time. *True False The firing order in a Volvo diesel engine is always: 1-5-4-2-3-6 1-2-3-4-5-6 *1 - 5 - 3 - 6 - 2 - 4 Which of these engine types has the highest efficiency rating? Petrol engine *Direct-injection diesel engine Diesel engine with pre-chamber All Volvo truck diesels as of 1986 are: Pre-combustion chamber engines *Direct-injection engines Swirl-chamber engines

Trainer notes

Page 27 (trainer)

General and basic priciples > General and basic principles > Engine design

Engine design  In-line engine or straight engine  Turbocharged engines  Reliable design  Moving parts  Low engine speeds  Well-balanced  Long service life  Quiet  Simple service  Large crankshaft bearing surface  Seven main bearings  Ideal for turbocharging

Notes

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General and basic priciples > General and basic principles > Engine design

Key points  Designed in different ways  Cylinders are positioned  Straight line-In-line engine or straight engine  Turbocharged engines  Volvo's diesel engines are 6-cylinder in-line engines or "straight-sixes"  Volvo produced 6-cylinder in-line truck engines way back in the 1920s  Semi-diesel  Suitable for large-displacement engines  Simple and it contains a relatively small number of moving parts  Low engine speeds  Well-balanced  Long service life and quiet, smooth operation  Service on this engine is simple  Large crankshaft bearing surface  Crankshaft is journalled in seven main bearings


Trainer notes

Page 28 (trainer)

General and basic priciples > General and basic principles > V-engine

V-engine  Volvo 8-cylinder engine

Notes

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Page 29

General and basic priciples > General and basic principles > V-engine Key points  V-engine  Forties  400 bhp  Military vehicles  Truck  120 bhp


Trainer notes

Page 29 (trainer)

General and basic priciples > General and basic principles > Volvo - V8 engines

Volvo - V8 engines Here are a few reasons why Volvo no longer builds V-engines:  Five main bearings  Two connecting rods - one crankshaft journal  Service is much more difficult

Notes

Page 30

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General and basic priciples > General and basic principles > Volvo - V8 engines

Key points  Reasons why Volvo no longer builds V-engines  The crankshaft only has five main bearings  The in-line six has seven main bearings  Two connecting rods  On the same crankshaft journal  The crankshaft bearing surfaces are not very large  Service is much more difficult


Trainer notes

Page 30 (trainer)

General and basic priciples > General and basic principles > The main engine components

The main engine components  Valve cover  Cylinder head  Cylinder head gasket  Cylinder liner  Timing gear casing  Flywheel housing  Cylinder block  Vibration damper  Crankshaft, Connecting rod, Piston, Flywheel  Stiffening frame (on some engines)  Oil sump

Notes

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Page 31

General and basic priciples > General and basic principles > The main engine components

Key points  Main engine components  Essential for the engine  Work in order for the engine to function safely and reliably.  Cylinder block with cylinder liners, pistons, piston rings and gudgeon pins  Crankshaft mechanism with all its relevant parts  Timing mechanism  Valve cover  Cylinder head  Cylinder head gasket  Cylinder liner  Timing gear casing  Flywheel housing  Cylinder block-Engine block  Vibration damper  Crankshaft, Connecting rod, Piston, Flywheel  Stiffening frame (on some engines)  Oil sump Other components  Inlet manifold  Exhaust manifold  Oil cooler  Oil filter  Coolant pump  Injection equipment.


Trainer notes

Page 31 (trainer)

General and basic priciples > General and basic principles > Cylinder block

Cylinder block  Cast in one piece  Cast-iron  Reinforcement ribs

Notes

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General and basic priciples > General and basic principles > Cylinder block

Key points  Cast in one piece  Cast-iron with a special alloy  Reinforcement ribs on the inside  Vibration in the block  Quiet engine


Trainer notes

Page 32 (trainer)

General and basic priciples > General and basic principles > Cylinder block - inside

Cylinder block - inside  Coolant jacket  Cylinder liners  O-rings  Main bearings  Bearings for the camshaft  Lubricating oil ducts  Piston cooling duct

Notes

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Page 33

General and basic priciples > General and basic principles > Cylinder block - inside

Key points  Coolant in the cylinder block  Coolant jacket  Cylinder liner recesses  Grooves for sealing rings  Main bearings  Robust reinforcement ribs leading down to the main bearings  Additional reinforcement around the holes for the cylinder head bolts  Bearings for the camshaft  Machined guides for the valve tappets  Lubricating oil ducts  Main duct (gallery duct)  Piston cooling duct  Piston cooling nozzles-one for each cylinder


Trainer notes

Page 33 (trainer)

General and basic priciples > General and basic principles > Camshaft in cylinder block

Camshaft in cylinder block  Location  Lifters  Pushrods  Rocker arms  Transmission gears

Notes

Page 34

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General and basic priciples > General and basic principles > Camshaft in cylinder block

Key points  Location  Lifters  Pushrods  Rocker arms  Transmission gears


Trainer notes

Page 34 (trainer)

General and basic priciples > General and basic principles > Cylinder liner design

Cylinder liner design  Directly in the block  Pressed into recesses in the block  Direct contact with the coolant

Notes

GT120017A v.1.0.01_en

Page 35

General and basic priciples > General and basic principles > Cylinder liner design

Key points  Cylinder bores directly in the lock  Dry cylinder liners  Wet cylinder liners


Trainer notes

Page 35 (trainer)

General and basic priciples > General and basic principles > Cylinder bore

Cylinder bore  High degree of precision  Cylinder bore  Milled  Honed  Plateau honing  Checked pattern  Oil pockets  Tapered profile

Notes

Page 36

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General and basic priciples > General and basic principles > Cylinder bore

Key points  High degree of precision  Cylindrical throughout  Smooth surface.  Milled and honed  Plateau honing  Oil pockets  Constant film of oil  Shorter running-in period  Tapered profile  Prevents carbon on the piston


Trainer notes

Page 36 (trainer)

General and basic priciples > General and basic principles > Cylinder head

Cylinder head  Cast-iron alloy  Huge stresses  Combustion process

Notes

GT120017A v.1.0.01_en

Page 37

General and basic priciples > General and basic principles > Cylinder head

Key points  Cylinder head  Cast-iron alloy  Huge stress  High temperature  High pressure


Trainer notes

Page 37 (trainer)


Diesel engine fundamentals. Test 2 Place the right figure beside the appropriate name. Flywheel casing Vibration damper Cylinder head Timing cover Flywheel Cylinder liner Cylinder block Connecting rod Valve cover Crankshaft Oil sump Piston This component in a Volvo diesel engine. is cast in one piece is known as the cylinder block is made of silumin features robust reinforcement ridges on the inside is made of a special cast-iron alloy

Page 38

GT120017A v.1.0.01_en


Key points  Question  Answer

Working procedure Discuss the answers with the participants if there have been any misunderstandings or linguistic problems. Questions that could help to improve the format of the questionnaire in the future may arise. Let each participants work with the question for about 5-10 minutes. After that shall the trainer go through the correct answer.


Introduction to diesel engines. Test 2 Key Place the right figure beside the appropriate name. Flywheel casing 6 Vibration damper 7 Cylinder head 3 Timing cover 5 Flywheel 11 Cylinder liner 1 Cylinder block 4 Connecting rod 9 Valve cover 2 Crankshaft 8 Oil sump 12 Piston 10 This component in a Volvo diesel engine. *is cast in one piece *is known as the cylinder block is made of silumin *features robust reinforcement ridges on the inside *is made of a special cast-iron alloy *has space for coolant fluid has cylinders drilled directly in it

Which of these figures shows a wet cylinder liner? A B *C Plateau honing helps ensure a permanent oil film on the cylinder wall and shortens the running-in period. *True False The diesel engine's cylinder head gasket is made of a heat-resistant copper alloy

Page 38 (trainer)


as space for coolant fluid has cylinders drilled directly in it Which of these figures shows a wet cylinder liner? A B C Plateau honing helps ensure a permanent oil film on the cylinder wall and shortens the running-in period. True False The diesel engine's cylinder head gasket is made of a heat-resistant copper alloy an aluminium alloy steel plate a new ceramic material The lower O-rings in the liner seal are made of rubber which hardens and thus provides effective sealing. True False Decide which is/are correct. The upper liner seal is a thin O-ring. The cylinder head gasket can withstand high peak pressures. The lower cylinder liner gasket consists of two or three O-rings.

Notes

GT120017A v.1.0.01_en

Page 39


an aluminium alloy *steel plate a new ceramic material The lower O-rings in the liner seal are made of rubber which hardens and thus provides effective sealing. True *False Decide which is/are correct. *The upper liner seal is a thin O-ring. *The cylinder head gasket can withstand high peak pressures. *The lower cylinder liner gasket consists of two or three O-rings.

Trainer notes

Page 39 (trainer)

General and basic priciples > General and basic principles > Cylinder head - Inlet and exhaust ducts

Cylinder head - Inlet and exhaust ducts  Cooling jacket  Exhaust outlet  Injector sleeve  Inlet and exhaust ducts  Valve seat  Valve guide

Notes

Page 40

GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > Cylinder head - Inlet and exhaust ducts Key points  Direct contact  Large cooling jacket  The hottest areas  Inlet duct  Exhaust duct  Valve seat  Valve guide


Trainer notes

Page 40 (trainer)

General and basic priciples > General and basic principles > Cylinder head - Copper sleeve

Cylinder head - Copper sleeve  Injector  Copper sleeve  Cooling jacket

Notes

GT120017A v.1.0.01_en

Page 41

General and basic priciples > General and basic principles > Cylinder head - Copper sleeve

Key points  Injector  Copper sleeve  Cooling jacket


Trainer notes

Page 41 (trainer)

General and basic priciples > General and basic principles > Cylinder head - Details

Cylinder head - Details  Cylinder head  Hole for injector  Valve guide  Injector sleeve  Valve seat, exhaust  Valve seat, inlet

Notes

Page 42

GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > Cylinder head - Details

Key points  Cylinder head  Hole for injector  Valve guide  Injector sleeve  Valve seat, exhaust  Valve seat, inlet


Trainer notes

Page 42 (trainer)

General and basic priciples > General and basic principles > Cylinder head and cylinder liner seals

Cylinder head and cylinder liner seals  High pressure in the cylinder  Coolant, which also contains chemical additives  Engine oil, which contains chemical additives

Notes

GT120017A v.1.0.01_en

Page 43

General and basic priciples > General and basic principles > Cylinder head and cylinder liner seals Key points  Seals  Cylinder head gasket-highest forces  High pressure  Coolant  Engine oil  Steel plate  O-rings  Ridges or grooves


Trainer notes

Page 43 (trainer)

General and basic priciples > General and basic principles > Cylinder head and cylinder liner seals

Cylinder head and cylinder liner seals  Wet cylinder liner  O-rings  Upper end  Liner collar  Lower seal  Different colours for securing correct mounting

Notes

Page 44

GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > Cylinder head and cylinder liner seals Key points  Rubber O-rings  Upper end-thin O-ring  The silicon sealant-prevent friction  Lower seal-two or three O-rings  Different material  Different colours


Trainer notes

Page 44 (trainer)

General and basic priciples > General and basic principles > Cranking mechanism

Cranking mechanism  Vibration damper  Gudgeon pin  Piston  Piston rings  Connecting rods  Main bearing  Flywheel  Connecting rod bearing  Thrust washers (axial bearings)  Crankshaft

Notes

GT120017A v.1.0.01_en

Page 45

General and basic priciples > General and basic principles > Cranking mechanism

Key points  Cranking mechanism  Vibration damper  Gudgeon pin  Piston  Piston rings  Connecting rods  Main bearing  Flywheel  Connecting rod bearing  Thrust washers (axial bearings)  Crankshaft


Trainer notes

Page 45 (trainer)

General and basic priciples > General and basic principles > A few facts about loads

A few facts about loads  High pressure  Immense forces  Peak pressure 11 MPa  Piston surface - 130 cm2  140 kN (kilo Newton), in other words about 14 tonnes

Notes

Page 46

GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > A few facts about loads

Key points  Peak pressure 11 MPa  Piston surface 130 cm2  Force 140 kN (kilo Newton)(14 tonnes)  D13, the peak pressure is 20 MPa


Trainer notes

Page 46 (trainer)

General and basic priciples > General and basic principles > Crankshaft

Crankshaft  Immense stress  Stringent quality standards as regards both material and design  Forged of special steel and undergo a special heat treatment  Fatigue resistance and hard bearing surfaces  Centrifugal forces  Counterbalances

Notes

GT120017A v.1.0.01_en

Page 47

General and basic priciples > General and basic principles > Crankshaft

Key points  Crankshaft  Immense stress  Material  Design  Forged of special steel  Special heat treatment  Additional fatigue resistance  Hard bearing surfaces  Centrifugal forces  Connecting rod's lower section  Counterbalances


Trainer notes

Page 47 (trainer)

General and basic priciples > General and basic principles > Power impulse

Power impulse  Power impulse  Torsional tendencies

Notes

Page 48

GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > Power impulse

Key points  Power impulse  Torsional tendencies


Trainer notes

Page 48 (trainer)

General and basic priciples > General and basic principles > Crankshaft - Oscillation

Crankshaft - Oscillation  Rapid oscillation  Vibration damper  Flywheel

Notes

GT120017A v.1.0.01_en

Page 49

General and basic priciples > General and basic principles > Crankshaft - Oscillation

Key points  Rapid oscillation  Snap the crankshaft  Vibration damper  Flywheel  Pulsationes and vibrations


Trainer notes

Page 49 (trainer)

General and basic priciples > General and basic principles > Damper

Damper  Fluid-type damper  The flywheel mass (damper ring)  Bushing  Sealed housing  Viscous silicon oil  Steady speed

Notes

Page 50

GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > Damper Key points  Fluid-type damper  Very efficient  Damper ring  Bushing  Sealed housing  Viscous silicon oil  Surrounds the flywheel mass


Trainer notes

Page 50 (trainer)

General and basic priciples > General and basic principles > The crankshaft is perfectly balanced

The crankshaft is perfectly balanced  Imbalance  Considerable stress  Vibration in the engine  Precisely balanced

Notes

GT120017A v.1.0.01_en

Page 51

General and basic priciples > General and basic principles > The crankshaft is perfectly balanced

Key points  Imbalance  Considerable stress  Provokes vibration  Precisely balanced  Balanced in a special machine


Trainer notes

Page 51 (trainer)

General and basic priciples > General and basic principles > Seven main bearings

Seven main bearings  Seven main bearings  Renowned long service life

Notes

Page 52

GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > Seven main bearings

Key points  Seven main bearings  Long service life


Trainer notes

Page 52 (trainer)

General and basic priciples > General and basic principles > Seven main bearings - connecting rod

Seven main bearings - connecting rod  Sturdy crankshaft bearing  Large bearing surfaces  Long service life  High engine reliability  One crankshaft bearing journal and connecting rod between the main bearings

Notes

GT120017A v.1.0.01_en

Page 53

General and basic priciples > General and basic principles > Seven main bearings - connecting rod Key points  Sturdy crankshaft bearing  Large bearing surfaces  Long service life  High engine reliability  One crankshaft bearing journal and connecting rod between the main bearings


Trainer notes

Page 53 (trainer)

General and basic priciples > General and basic principles > V-engine, two connecting rods

V-engine, two connecting rods  Bearing  Vital difference  V-engine - two connecting rods

Notes

Page 54

GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > V-engine, two connecting rods

Key points  In-line six-V-engine  Two connecting rods-same crankshaft bearing journal  Not be as generously dimensioned


Trainer notes

Page 54 (trainer)

General and basic priciples > General and basic principles > Lubrication ducts

Crankshaft - Lubrication ducts  Pressure-lubricated  Drilled oil ducts in the crankshaft

Notes

GT120017A v.1.0.01_en

Page 55

General and basic priciples > General and basic principles > Lubrication ducts

Key points  Lubrication ducts-drilled in the cylinder block  Oil under pressure-pressure lubricated  Main bearing journals  Crankshaft bearing journals


Trainer notes

Page 55 (trainer)

General and basic priciples > General and basic principles > What happens in an in-line six cylinder engine

What happens in an in-line six cylinder engine  Pistons 1 and 6 perform their upward and downward movements simultaneously.  Pistons 2 and 5 move together.  Pistons 3 and 4 move together.  120 crankshaft degrees  Ignition impulses

Notes

Page 56

GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > What happens in an in-line six cylinder engine Key points  Pistons 1 and 6  Pistons 2 and 5  Pistons 3 and 4.  120 crankshaft degrees


Trainer notes

Page 56 (trainer)

General and basic priciples > General and basic principles > Main bearing caps

Main bearing caps  Journal led  Main bearing caps  Replaceable  Ready for installation  Bearing shells  Steel core  Bearing-quality metal

Notes

GT120017A v.1.0.01_en

Page 57

General and basic priciples > General and basic principles > Main bearing caps

Key points  Main bearing caps  Replaceable slider bearings  Immense precision  Manufacturer  Bearing shells  Steel core  Bearing-quality metal


Trainer notes

Page 57 (trainer)

General and basic priciples > General and basic principles > Main bearings screw

Main bearings screw  Upper bearing shell  Lower shell  Main bearing cap

Notes

Page 58

GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > Main bearings screw

Key points  Main bearing screws  Extremely robust  Absorb considerable force during combustion  The upper bearing shell  The lower shell - main bearing cap  Screwed to the cylinder block


Trainer notes

Page 58 (trainer)

General and basic priciples > General and basic principles > Support bearing

Support bearing  Axial position  Acceleration  Retardation  Axial movement  Thrust washers

Notes

GT120017A v.1.0.01_en

Page 59

General and basic priciples > General and basic principles > Support bearing

Key points  Support bearing  One main bearing  Specific axial position  Move back when the vehicle is under acceleration  Move forth when the vehicle brakes are applied  Controls the crankshaft's axial movement  Loose thrust washers  Coated with bearing alloy  Precision-machined bearing surfaces


Trainer notes

Page 59 (trainer)

General and basic priciples > General and basic principles > Flywheel

Flywheel  Power impulses

Notes

Page 60

GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > Flywheel Key points  Flywheel  Fairly uneven  Power impulses  Crankshaft's speed increases and slows down every impulse  Even out variations in speed  Balancing


Trainer notes

Page 60 (trainer)

General and basic priciples > General and basic principles > Flywheel - other tasks

Flywheel - other tasks  Starter ring  Indication grooves

Notes

GT120017A v.1.0.01_en

Page 61

General and basic priciples > General and basic principles > Flywheel - other tasks

Key points  Starter ring  Starter motor gear  Electronic fuel injection control  Indication grooves


Trainer notes

Page 61 (trainer)

General and basic priciples > General and basic principles > Connecting rod

Connecting rod  Forged  High-alloy steel  Chrome-molybdenum steel  Chrome manganese silicon steel  Extremely durable  Strong and lightweight  I-shaped profile  Flexing  Big end  Small end  Bronze bushing

Notes

Page 62

GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > Connecting rod

Key points  Connecting rod  Forged from high-alloy steel  Chrome-molybdenum steel  Chrome manganese silicon steel  Extremely durable  Strong and lightweight  I-shaped profile  Tendency to flexing  Big end  Small end  Gudgeon pin


Trainer notes

Page 62 (trainer)

General and basic priciples > General and basic principles > Connecting rod - details

Connecting rod - details  Classified  Marked  Front marking  Trapezoidal  Lubricated via ducts  Splash lubrication  Diagonally split

Notes

GT120017A v.1.0.01_en

Page 63

General and basic priciples > General and basic principles > Connecting rod - details

Key points  Classified by weight  Marked with number or letters  Marking facing to the front  Trapezoidal  Piston more ridgit  Lubricated via ducts  Splash lubrication  Gudgeon pin  Diagonally split  Serrations  Split


Trainer notes

Page 63 (trainer)

General and basic priciples > General and basic principles > Gudgeon pin

Gudgeon pin  Crankshaft mechanism  High-quality material  Chrome-manganese steel  Chrome-molybdenum steel alloys  Minimise weight  Surface-hardened  Finely-ground

Notes

Page 64

GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > Gudgeon pin

Key points  Gudgeon pin  Crankshaft mechanism  Considerable stress and load  High-quality material  Chrome-manganese steel  Chrome-molybdenum steel alloys  Tubular  Surface-hardened  Finely-ground  Fine tolerances


Trainer notes

Page 64 (trainer)

General and basic priciples > General and basic principles > Gudgeon pin hole

Gudgeon pin hole  Larger diameter  Changes shape  High load

Notes

GT120017A v.1.0.01_en

Page 65

General and basic priciples > General and basic principles > Gudgeon pin hole

Key points  Larger diameter at the recess  Changes shape under high load



Gudgeon pin hole The gudgeon pin hole has a larger diameter at the recess, providing space for the gudgeon pin when it changes shape under high load.

Trainer notes

Page 65 (trainer)

General and basic priciples > General and basic principles > Gudgeon pin - journal led

Gudgeon pin - journal led  Journal led  Floating fit  Locking rings

Notes

Page 66

GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > Gudgeon pin - journal led

Key points  Journal led  Floating fit  Locking rings


Trainer notes

Page 66 (trainer)

General and basic priciples > General and basic principles > Connecting rod bearing

Connecting rod bearing  Two bearing shells  Machined big end  Guide lugs  Pressure-lubricated

Notes

GT120017A v.1.0.01_en

Page 67

General and basic priciples > General and basic principles > Connecting rod bearing

Key points  Connecting rod bearing  Machined big end  Guide lugs  Fit properly  Pressure-lubricated


Trainer notes

Page 67 (trainer)


Diesel engine fundamentals. Test 3 Place the right number beside the appropriate name. Crank bearing Vibration damper Crankshaft Thrust washers Piston Connecting rods Flywheel Main bearing Piston rings Gudgeon pin Decide which is correct. Volvo diesel engines have fluid-type vibration dampers. The crankshaft is balanced in a special machine. Imbalance in the crankshaft affects the main bearings but does not cause vibration in the engine or particularly heavy load on the crankshaft. The ducts in the crankshaft's counterbalances are part of the lubrication system. The crankshafts in Volvo diesel engines are forged from special steel. True False

Page 68

GT120017A v.1.0.01_en





Introduction to diesel engines. Test 3 Key Place the right number beside the appropriate name. Crank bearing 8 Vibration damper 4 Crankshaft 5 Thrust washers 6 Piston 2 Connecting rods 10 Flywheel 9 Main bearing 7 Piston rings 1 Gudgeon pin 3 Decide which is correct. *Volvo diesel engines have fluid-type vibration dampers. *The crankshaft is balanced in a special machine. Imbalance in the crankshaft affects the main bearings but does not cause vibration in the engine or particularly heavy load on the crankshaft. The ducts in the crankshaft's counterbalances are part of the lubrication system. The crankshafts in Volvo diesel engines are forged from special steel. *True False Nitro-carburisation is a heat-treatment method for crankshafts. *True False A bearing shell is made of a steel shell lined with bearing metal. *True False The term "seven-bearing crankshaft" means that the crankshaft has as many main bearing pins as crankshaft pins. True *False This illustration shows the crank weight positions in relation to each other.

Page 68 (trainer)


itro-carburisation is a heat-treatment method for crankshafts. True False A bearing shell is made of a steel shell lined with bearing metal. True False The term "seven-bearing crankshaft" means that the crankshaft has as many main bearing pins as crankshaft pins. True False This illustration shows the crank weight positions in relation to each other. Pistons 1 and 3 make their vertical movements at the same time. Pistons 2 and 5 make their vertical movements at the same time. Pistons 3 and 6 make their vertical movements at the same time. Pistons 1 and 6 make their vertical movements at the same time. Pistons 3 and 4 make their vertical movements at the same time. There are 120:2 crankshaft degrees between ignition points. There are 120 crankshaft degrees between ignition points. The main bearings and crankshaft bearings are slider bearings. True False The support bearing, the fourth main bearing, keeps the crankshaft in a pre-determined axial position. True False Decide what is correct. The flywheel evens out variations in rpm. The starter ring gear is on the flywheel. The clutch acts on the flywheel's surface-ground face. The connecting rod's big-end is split diagonally. True False

Notes

GT120017A v.1.0.01_en

Page 69


Pistons 1 and 3 make their vertical movements at the same time. *Pistons 2 and 5 make their vertical movements at the same time. Pistons 3 and 6 make their vertical movements at the same time. *Pistons 1 and 6 make their vertical movements at the same time. *Pistons 3 and 4 make their vertical movements at the same time. There are 120:2 crankshaft degrees between ignition points. *There are 120 crankshaft degrees between ignition points. The main bearings and crankshaft bearings are slider bearings. *True False The support bearing, the fourth main bearing, keeps the crankshaft in a pre-determined axial position. *True False Decide what is correct. *The flywheel evens out variations in rpm. *The starter ring gear is on the flywheel. *The clutch acts on the flywheel's surface-ground face. The connecting rod's big-end is split diagonally. *True False

Trainer notes

Page 69 (trainer)

General and basic priciples > General and basic principles > Piston

Piston  Absorb combustion pressure  Transfer considerable force  Gudgeon pin  Connecting rod  Crankshaft  Piston roof  Perfect fit  Combustion pressure  Loss of engine power  Piston ring  Piston ring groove

Notes

Page 70

GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > Piston Key points  Piston  Immense load  Crankshaft mechanism  Transfer considerable force  Gudgeon pin - connecting rod - crankshaft  Piston roof  Guide surface  Combustion pressure leakage  Piston and cylinder wall  Piston rings  Piston ring groove


Trainer notes

Page 70 (trainer)

General and basic priciples > General and basic principles > Piston - Thermal stress and mechanical stress

Piston - Thermal stress and mechanical stress  Thermal stress  Mechanical stress  Combustion pressure load  Wear against the cylinder wall  Wear of the ring groove owing to piston ring movement  Wear of the gudgeon pin bearing

Notes

GT120017A v.1.0.01_en

Page 71

General and basic priciples > General and basic principles > Piston - Thermal stress and mechanical stress Key points  Thermal stress  Mechanical stress  Combustion pressure load  Wear against the cylinder wall  Wear of the ring groove  Wear of the gudgeon pin bearing


Trainer notes

Page 71 (trainer)

General and basic priciples > General and basic principles > Piston - Materials

Piston - Materials  Aluminium alloy  Silicon  Iron  Nickel  Manganese  Copper  Magnesium  Extremely durable  Thermal expansion

Notes

Page 72

GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > Piston - Materials

Key points  Aluminium alloy  Steel  Diameter


Trainer notes

Page 72 (trainer)

General and basic priciples > General and basic principles > Articulated piston

Articulated piston  Articulated pistons - split pistons  Separately journal led  Gudgeon pin  Top section - steel  Bottom section - aluminium

Notes

GT120017A v.1.0.01_en

Page 73

General and basic priciples > General and basic principles > Articulated piston

Key points  Articulated pistons (split pistons)  Separately journal led  Top section - steel  Bottom section - aluminium  Small gap prevent heat transference  Higher temperature  Higher co-efficient of efficiency


Trainer notes

Page 73 (trainer)

General and basic priciples > General and basic principles > Piston - Tolerance

Piston - Tolerance  Dimensional tolerances  Cylinder liner kits  Piston heat  Piston ring  Piston ring carrier

Notes

Page 74

GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > Piston - Tolerance

Key points  Tight dimensional tolerances  Differences 0.07-0.08 mm  Pistons and liners - complete kits  Heat is transferred  Vulnerable to wear  Piston ring carrier made of cast-iron


Trainer notes

Page 74 (trainer)

General and basic priciples > General and basic principles > Piston cooling

Piston cooling  Internal piston cooling  Channel  Oil sprayed into channel  Efficient cooling  Extremely hot  High load  Oil-borne piston cooling  Piston cooling duct  Piston cooling nozzles  Inside of the piston

Notes

GT120017A v.1.0.01_en

Page 75

General and basic priciples > General and basic principles > Piston cooling

Key points  Internal piston cooling  Piston crown- channel  Very efficient cooling


Trainer notes

Page 75 (trainer)

General and basic priciples > General and basic principles > Piston rings

Piston rings  Two types  Compression ring  Compression pressure  Combustion pressure  High pressure  High temperature  Oil scraper ring

Notes

Page 76

GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > Piston rings

Key points  Piston ring  Ring grooves  Compression rings  Compression pressure  Combustion pressure  High pressure  High temperature  Wear  Forces stemming  Oil scraper rings  Oil on the cylinder walls  Oil - back to the sump


Trainer notes

Page 76 (trainer)

General and basic priciples > General and basic principles > Piston rings material first ring

Piston rings material first ring  Cast-iron  Surface-treated  Two compression rings  One oil scraper ring  Keystone ring  Chrome-plated  Molybdenum

Notes

GT120017A v.1.0.01_en

Page 77

General and basic priciples > General and basic principles > Piston rings material first ring

Key points  Cast-iron  Surface-treated  Two compression rings  One oil scraper ring  Different versions  Trapezoidal cross-section - Keystone ring  Ability to keep clean  Chrome-plated  Molybdenum


Trainer notes

Page 77 (trainer)

General and basic priciples > General and basic principles > Piston rings material second ring

Piston rings material second ring  Chrome-plated  Internal ridge  Twistrings

Notes

Page 78

GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > Piston rings material second ring

Key points  Chrome-plated  Internal ridge  Twist  "Twistrings"


Trainer notes

Page 78 (trainer)

General and basic priciples > General and basic principles > Piston rings material oil ring

Piston rings material oil ring  Chrome-plated  Expanding spring

Notes

GT120017A v.1.0.01_en

Page 79

General and basic priciples > General and basic principles > Piston rings material oil ring

Key points  Chrome-plated  Two scraper edges  Spring


Trainer notes

Page 79 (trainer)

General and basic priciples > General and basic principles > Piston rings - Oil ring

Piston rings - Oil ring  Oil  Return holes

Notes

Page 80

GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > Piston rings - Oil ring

Key points  Oil  Led back  Crankcase  Oil sump  Return holes


Trainer notes

Page 80 (trainer)


Diesel engine fundamentals. Test 4 The gudgeon pin is prevented from moving towards the cylinder wall by. a screw which locks the pin to the connecting rod. a decive which locks it to the small-end. lock-rings in the piston. Put the numbers in the appropriate boxes. Piston rings Piston crown Piston ring groove Piston shirt Combustion chamber Lock ring Decide what is correct. Pistons and cylinder liners are classified according to diameter. Piston and liner are matched together as per the classification letter.

GT120017A v.1.0.01_en

Page 81





Introduction to diesel engines. Test 4 Key The gudgeon pin is prevented from moving towards the cylinder wall by. a screw which locks the pin to the connecting rod. a decive which locks it to the small-end. *lock-rings in the piston. Put the numbers in the appropriate boxes. Piston rings 3 Piston crown 2 Piston ring groove 5 Piston shirt 6 Combustion chamber 1 Lock ring 4 Decide what is correct. *Pistons and cylinder liners are classified according to diameter. *Piston and liner are matched together as per the classification letter. Pistons are marked with classification figures 1, 2, 3 etc. A twist-ring twists in the ring groove, thus scraping the oil as the piston moves downwards. *True False The Keystone ring has a trapezoidal cross-section. *True False A Keystone ring has the ability to keep clean because the chamfered surfaces work against the ring carrier's surfaces. *True False The oil scraper ring has two chrome-plated scraper edges which are pressed against the cylinder wall. *True

Page 81 (trainer)


istons are marked with classification figures 1, 2, 3 etc. A twist-ring twists in the ring groove, thus scraping the oil as the piston moves downwards. True False The Keystone ring has a trapezoidal cross-section. True False A Keystone ring has the ability to keep clean because the chamfered surfaces work against the ring carrier's surfaces. True False The oil scraper ring has two chrome-plated scraper edges which are pressed against the cylinder wall. True False

Notes

Page 82

GT120017A v.1.0.01_en


False

Trainer notes

Page 82 (trainer)

General and basic priciples > General and basic principles > Valve mechanism

Valve mechanism  Overhead valve  Valve  Rocker arm  Pushrod  Camshaft

Valve tappet  Valve lifter (even called valve lifters)  Robustly dimensioned  Considerable loads  Spherical  Surface-hardened  The jacket  Rotates

Notes

GT120017A v.1.0.01_en

Page 83

General and basic priciples > General and basic principles > Valve mechanism

Key points  Valve mechanism  Overhead valve engines  Valve  Rocker arm  Pushrod  Camshaft  Open and shut the valves  Valve tappet  Convert the camshaft's rotating  Tappets (even called valve lifters)  Bottom of the tappet  The contact surface - cam  Spherical  Surface-hardened



Her it is time to run the movie “AN INTRO TO DIESEL ENGINE” chapter "Valve mechanism". This is like a teaser for the participants.

Trainer notes

Page 83 (trainer)

General and basic priciples > General and basic principles > Pushrod engine

Pushrod engine  Pushrod act  Rocker arm  Valve yoke

Notes

Page 84

GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > Pushrod engine

Key points  Pushrod engine  Pushrod  Rocker arm  Valves  Valve yoke


Trainer notes

Page 84 (trainer)

General and basic priciples > General and basic principles > Overhead camshaft

Overhead camshaft  Rocker arm  Directly  Cam

Notes

GT120017A v.1.0.01_en

Page 85

General and basic priciples > General and basic principles > Overhead camshaft

Key points  Overhead camshaft  Acted directly by the cam  NO pushrods  Few parts  Valve mechanism


Trainer notes

Page 85 (trainer)

General and basic priciples > General and basic principles > Camshaft

Camshaft  Forging  Casting  Steel alloy  Special cast-iron alloy  One cam for each valve  Camshaft bearings  Surface-hardened  Pressure-lubricated  Axial bearing - Thrust washer

Notes

Page 86

GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > Camshaft

Key points  Camshaft  Forging or casting  Steel alloy  Special cast-iron alloy  One cam for each valve  Seven bearing  Surface-hardened  Pressure-lubricated  Two cams between  Robust design  Immense forces  Axial bearing  Axial bearing - thrust washer


Trainer notes

Page 86 (trainer)

General and basic priciples > General and basic principles > Camshaft - Design

Camshaft - Design  Valves open and shut at exactly the right time  Driven by the crankshaft  Engine timing mechanism - Timing gears  A = the total camheight  B = called the basic circle  C = the camlift

Notes

GT120017A v.1.0.01_en

Page 87

General and basic priciples > General and basic principles > Camshaft - Design

Key points  Precisely designed  Valves open and shut  Exactly the right time  Engine's torque  Exhaust gas values  Opening and closing timing  Driven by the crankshaft  "Engine timing mechanism" - "Timing gears" A - B = C  A = the total camheight  B = called the basic circle  C = the camlift


Trainer notes

Page 87 (trainer)

General and basic priciples > General and basic principles > Engine timing mechanism

Engine timing mechanism  Timing gear plate  Crankshaft gear  Idler gear, double  Gear for power take off (extra equipment)  Idler wheel, adjustable  Camshaft gear  Drive gear, air compressor  Drive gear, power steering and fuel feed pump  Intermediary gear, power steering and feed pump  Drive gear, lubrication oil pump  Flywheel damper with teeth for the inductive camshaft sensor

Notes

Page 88

GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > Engine timing mechanism

Key points  Engine timing mechanism  Drives the camshaft  Fuel pump  Other ancillaries  1. Timing gear plate  2. Crankshaft gear  3. Idler gear, double  4. Gear for power take off (extra equipment)  5. Idler wheel, adjustable  6. Camshaft gear  7. Drive gear, air compressor  8. Drive gear, power steering and fuel feed pump  9. Intermediary gear, power steering and feed pump  10. Drive gear, lubrication oil pump  11. Flywheel damper with teeth for the inductive camshaft sensor  Camshaft gear - positioned - crankshaft gear  The gears are marked  Helical teeth  Quietly  Less wear



Her it is time to run the movie “AN INTRO TO DIESEL ENGINE” chapter "Engine timing gear". This is like a teaser for the participants.

Trainer notes

Page 88 (trainer)

General and basic priciples > General and basic principles > Engine timing mechanism - Sound insulation

Engine timing mechanism - Sound insulation  Timing gear plate  Timing gear casings  Sound insulation  Laminated steel

Notes

GT120017A v.1.0.01_en

Page 89

General and basic priciples > General and basic principles > Engine timing mechanism - Sound insulation Key points  Timing gear plate  timing gear casings  Sound insulation  Laminated steel layers with an intermediate plastic layer in between


Trainer notes

Page 89 (trainer)

General and basic priciples > General and basic principles > Crankshaft seal

Crankshaft seal  Two different types of crankshaft seal  The first one is a rubber overlap seal  The second type is a Teflon overlap seal with two lips

Notes

Page 90

GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > Crankshaft seal

Key points  Two different types  Rubber overlap seal - radial sealing ring  Two rubber lips  Outer lip prevents dust  Inner rubber lip is spring-loaded  The second type is a Teflon overlap  Two lips  The outer lip prevents dust from  The inner rubber lip is a Teflon seal  This seal is not spring-loaded


Trainer notes

Page 90 (trainer)

General and basic priciples > General and basic principles > Valves, valve guides and valve seats

Valves, valve guides and valve seats  The job of the valve  One or two valve springs  Journal led  Valve guide  Valve's sealing  Valve seat

Notes

GT120017A v.1.0.01_en

Page 91

General and basic priciples > General and basic principles > Valves, valve guides and valve seats Key points  Valves  Valve guides  Valve seats  Open for precisely calculated periods  Shut during the remaining time  One or two valve springs  Valve's sealing surface  Valve leaks  Different angle for inlet and exhaust


Trainer notes

Page 91 (trainer)

General and basic priciples > General and basic principles > Valves

Valves  Considerable stress  High temperatures  800°C  Cooled by the air which flow  Force of the valve spring  Nickel chromium steel  Stellite  Friction-welded  Nimonic 80  Chrome-plated

Notes

Page 92

GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > Valves Key points  Considerable stress  Direct contact with the combustion process  High temperature  The exhaust valve  800°C  The inlet valve cooled by the air  Valve spring  Valve disc  30 kilo Newton  Nickel chromium steel  Stellite  Nimonic 80  Chrome-plated valve stems


Trainer notes

Page 92 (trainer)

General and basic priciples > General and basic principles > Valve stem

Valve stem  Journal led  Cast-iron  Replaceable  Seals  Valve seat rings

Notes

GT120017A v.1.0.01_en

Page 93

General and basic priciples > General and basic principles > Valve stem

Key points  Valve guide  Cast-iron  Replaceable  The valve disc  The valve seats  Valve seat rings  Heat-resist  Durable material


Trainer notes

Page 93 (trainer)

General and basic priciples > General and basic principles > Valve springs

Valve springs  Valve spring washer  Valve locks  Two halves  Valve springs  Guide washer

Notes

Page 94

GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > Valve springs

Key points  Valve spring  Valve spring washer  Two valve locks  Valve stem grooves  Single valve springs  Double valve springs  Oscillation of the springs


Trainer notes

Page 94 (trainer)

General and basic priciples > General and basic principles > Valve seals

Valve seals  Lubrication  High oil consumption  Rubber seals

Notes

GT120017A v.1.0.01_en

Page 95

General and basic priciples > General and basic principles > Valve seals

Key points  Seals  Lubrication  High oil consumption  Inlet duct  Combustion chamber  Rubber seals  Valve guide


Trainer notes

Page 95 (trainer)

General and basic priciples > General and basic principles > Pushrod and rocker arm

Pushrod and rocker arm  Strong  Lightweight  Tubular  Pressed-in end-pieces  Oil channel  Adjustment screw  Valve clearance  Thermal expansion  Journal led  Bronze bushings  Pressure-lubricated  Valve covers

Notes

Page 96

GT120017A v.1.0.01_en

General and basic priciples > General and basic principles > Pushrod and rocker arm

Key points  Pushrod  Rocker arm  Strong  Lightweight  Tubular  Pressed-in end-pieces  The adjustment screw  Valve clearance  Increases in length  The rocker arm shaft  Bronze bushings  Pressure-lubricated  Valve covers

Working procedure Go through the text in the student material and also add your own experience/knowledge. Be sure that the participants have understood the main purpose of this information. Ask question to be sure that the participants have understand the main purpose of this information/text. Show the participants the engine parts and explain how they are connected to each other, do not forget to tell them what is happen if they do not understand the basic when they shall e.g. fault tracing. Using the correct information from Impact for removing the cylinder head, Oil sump, piston and connecting rod.

Trainer notes

Page 96 (trainer)


Diesel engine fundamentals. Test 5 Place the right number beside the appropriate name. Camshaft Valve lifter Cam Pushrod Rocker arm shaft Rocker arm Lock-nut Valve Adjuster screw Valve spring Rocker arm bushing The engine timing mechanism consists of a gear which drives the camshaft and injection pump. It can also drive the... oil pump turbocharger coolant pump compressed air compressor power steering servo pump

GT120017A v.1.0.01_en

Page 97





Introduction to diesel engines. Test 5 Key Place the right number beside the appropriate name.

Camshaft 7 Valve lifter 6 Cam 8 Pushrod 5 Rocker arm shaft 11 Rocker arm 1 Lock-nut 3 Valve 9 Adjuster screw 4 Valve spring 10 Rocker arm bushing 2

The engine timing mechanism consists of a gear which drives the camshaft and injection pump. It can also drive the... *oil pump turbocharger *coolant pump *compressed air compressor *power steering servo pump

The valve lifter is found to one side of the cam's centre line so that the lifter can be made lighter the production process is simpler *lifter wear is more evenly distributed

Decide which is/are correct. *The exhaust valve is much hotter than the inlet valve *The valve's sealing surface can be coated with stellite *Some valves are made in two pieces The valve stem is made of Nimonic *The valve stems in Volvo engines are chrome-plated

Page 97 (trainer)


The valve lifter is found to one side of the cam's centre line so that the lifter can be made lighter the production process is simpler lifter wear is more evenly distributed Decide which is/are correct. The exhaust valve is much hotter than the inlet valve The valve's sealing surface can be coated with stellite Some valves are made in two pieces The valve stem is made of Nimonic The valve stems in Volvo engines are chrome-plated The valve seats are replaceable valve seat rings which are shrunk into place. True False A certain degree of valve clearance is essential since the valve increases in length when it heats up during operation. True False Place the figures in the appropriate boxes. Duct Valve Sealing surface Valve guide Valve lock Valve spring Valve spring washer Valve seat Guide washer If the camshaft gear incorrectly set by a single tooth, the valves will strike the piston. True False

Notes

Page 98

GT120017A v.1.0.01_en


The valve seats are replaceable valve seat rings which are shrunk into place.

*True False

A certain degree of valve clearance is essential since the valve increases in length when it heats up during operation.

*True False

Place the figures in the appropriate boxes.

Duct 3 Valve 4 Sealing surface 1 Valve guide 5 Valve lock 9 Valve spring 6 Valve spring washer 8 Valve seat 2 Guide washer 7

If the camshaft gear incorrectly set by a single tooth, the valves will strike the piston.

*True False

Trainer notes

Page 98 (trainer)

Lubrication system > Lubrication system > Lubrication system

Lubrication system If you were to ask anyone why there must be oil in an engine, the answer would almost certainly be something like "Surely you must understand that the engine has to be lubricated!". And of course it is true that engine components which rub against each other must be separated by a thin film of oil. In other words, these components must be lubricated, and lubricated with clean oil and the right sort of oil!

Notes

GT120017A v.1.0.01_en

Page 99

Lubrication system > Lubrication system > Lubrication system Key points  Lubrication system  Thin film of oil  Clean oil  Right sort of oil  Lubricate all moving engine parts  Wear and friction should be as little as possible  Conduct heat away  Sealing agent  Plateau honing  Clean  Sludge  Corrosion  Oils require a very complex compound  Base oil (refined mineral oil)  Additives  Synthetic oil



Her it is time to run the movie “AN INTRO TO DIESEL ENGINE” chapter "Lubrication system". This is like a teaser for the participants.

Trainer notes

Page 99 (trainer)

Lubrication system > Lubrication system > Engine oil quality

Engine oil quality  Oil change  Engine oil quality  The contents of sulphur in the fuel

Notes

Page 100

GT120017A v.1.0.01_en

Lubrication system > Lubrication system > Engine oil quality Key points  Specify oil  Viscosity  Different temperatures  Impact  Service schedule  Oil grade  Oil filter  Oil change  Engine oil quality  VDS  Sulphur


Trainer notes

Page 100 (trainer)

Lubrication system > Lubrication system > Splash lubrication - Pressure lubrication

Splash lubrication - Pressure lubrication  Splash-lubrication  Crankshaft's rotating motion  Pressure lubrication  Oil pump  Lubrication points  Cylinder walls  Timing gears

Notes

GT120017A v.1.0.01_en

Page 101

Lubrication system > Lubrication system > Splash lubrication - Pressure lubrication

Key points  Required points  Splash-lubrication  Crankshaft's rotating motion  Not sufficient for modern high-powered engines  Pressure lubrication  Oil pump  Lubrication points  Cylinder walls and timing gears are splash-lubricated


Trainer notes

Page 101 (trainer)

Lubrication system > Lubrication system > Pressure lubrication

Pressure lubrication  Oil sump  Oil pump  Oil cooler  Oil filter  Oil ducts  Lubricates  Cools  Cleans  Seals  Oil gallery

Notes

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Lubrication system > Lubrication system > Pressure lubrication Key points  Pressure-lubrication system  Circulating in a sealed system  Block diagram  Oil grade  Oil sump  Oil pump  Oil cooler  Oil filter  Oil ducts  Lubrication points  Back to the oil sump  100 litres a minute  Gear pump  Driven by the engine crankshaft  Two longitudinal oil channels  Main lubrication channel (oil gallery)  Piston cooling oil gallery  Timing gears  VCB  Valve  Rocker arm shaft  Camshaft bearings  Rocker arm bearings  Oil filter housing  Full flow filter  Bypass filter


Trainer notes

Page 102 (trainer)

Lubrication system > Lubrication system > Lubrication system - Function

Lubrication system - Function The lubrication system shown on these two pages comes from a 13-litre engine. The oil flow through the engine is regulated by six valves located inside the engine block, pump and oil filter housing.  Reduction valve  Safety valve  Thermostat valve for oil cooler  By-pass valve for full flow filter  Opening valve for piston cooling  Control valve for piston cooling

Notes

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Lubrication system > Lubrication system > Lubrication system - Function

Key points  A: Reduction valve  B: Safety valve  C: Thermostat valve for oil cooler  D: By-pass valve for full flow filter  E: Opening valve for piston cooling  F: Control valve for piston cooling


Trainer notes

Page 103 (trainer)

Lubrication system > Lubrication system > Lubrication system - schematic

Lubrication system - schematic  Strainer  Plastic tube  Oil pump  Pressure pipe  Oil cooler  Filter housing  Full flow filters  Main lubrication gallery  Separator turbine  VCB valve  Air compressor  Turbocharger  Bypass filter  Nozzles

Notes

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Lubrication system > Lubrication system > Lubrication system - schematic

Key points  Strainer (1)  Plastic tube (2)  Oil pump (3)  Pressure pipe (4)  Oil cooler (5)  Filter housing (6)  Full flow filters (7)  Main lubrication gallery (8)  Separator turbine (9)  VCB valve (10)  Air compressor (11)  Turbocharger (12)  Bypass filter (13)  Nozzles (14)


Trainer notes

Page 104 (trainer)

Lubrication system > Lubrication system > Oil pump - function

Oil pump - function  Gear-driven pump  Pump housing  Negative pressure  Gaps between the gear teeth  Lubrication ducts  Rotor pump

Notes

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Page 105

Lubrication system > Lubrication system > Oil pump - function Key points  Oil pump  Gear-driven pump  Two gear wheels  Pump housing  Negative pressure  Gaps between the gear teeth  Lubrication ducts  Rotor pump  100-200 kPa (1-2 bar)  300-500 kPa


Trainer notes

Page 105 (trainer)

Lubrication system > Lubrication system > Oil pump - parts

Oil pump - parts  Idler gear  Bearing sleeve  Attachment bracket and pumping housing  Bushing  Driveshaft  Drive gear  Driven shaft  Driving pump gear  Driven pump gear

Notes

Page 106

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Lubrication system > Lubrication system > Oil pump - parts Key points  Dimensioned  Driven by the engine timing mechanism  Idler gear  Bearing sleeve  Attachment bracket and pumping housing  Bushing  Driveshaft  Drive gear  Driven shaft  Driving pump gear  Driven pump gear


Trainer notes

Page 106 (trainer)

Lubrication system > Lubrication system > Oil filter housing

Oil filter housing  Number of valves - regulate oil flow  Spin-on type  10 bar without leaking  Burst test  Pressure up to 16 bar  75,000 times from 0 to 8 bar

Notes

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Lubrication system > Lubrication system > Oil filter housing Key points  Oil filter housing  Valves  Spin-on type  Rubber rings  10 bar without leaking.  75,000 times from 0 to 8 bar


Trainer notes

Page 107 (trainer)

Lubrication system > Lubrication system > Oil flows through the filter

Oil flows through the filter  Filter insert  Filter paper  Particles down to approx. 40 thousandths of a millimetre (40 µm)  Bypass filter - 10 µm  Oil flow rate is approx. 7 litres/minute  Oil filter replacement  Clogged oil filters

Notes

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Lubrication system > Lubrication system > Oil flows through the filter Key points  The oil flow  Filter paper  Particles down to approx. 40 thousandths of a millimetre (40 µm).  Particles down to approx. 10 µm  7 litres/minute


Trainer notes

Page 108 (trainer)

Lubrication system > Lubrication system > Oil cooler

Oil cooler  10-15% heat  130°C  100°C  Common type

Notes

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Page 109

Lubrication system > Lubrication system > Oil cooler Key points  Oil cooler  10-15%  130°C  100°C  Flat oil cooler


Trainer notes

Page 109 (trainer)

Lubrication system > Lubrication system > Oil sump

Oil sump  Moulded plastic (composite)  Reducing engine noise levels  Pressed steel variant  Aluminum  Sealing strip  Dry sump

Notes

Page 110

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Lubrication system > Lubrication system > Oil sump Key points  Oil sump  Moulded plastic (composite)  Noise level  Steel  Aluminum  Sealing strip  Dry sump  Lubricating oil tank

Working procedure Go through the text in the student material and also add your own experience/knowledge. Be sure that the participants have understood the main purpose of this information. Ask question to be sure that the participants have understand the main purpose of this information/text. Show the participants the engine parts and explain how they are connected to each other, do not forget to tell them what is happen if they do not understand the basic when they shall e.g. fault tracing. Point out main parts/valves and system layout in vehicle. Open an old oil pump.

Additional information If their is time you can also using VTT to read out oil pressure.

Trainer notes

Page 110 (trainer)

Lubrication system > Lubrication system > Diesel engine fundamentals. Test 6

Diesel engine fundamentals. Test 6 Oil has several vital functions, namely to: lubricate by forming a thin film of oil between the moving parts cool by leading away the heat act as a seal between the pistons and cylinders reduce coolant temperature by cooling the fluid keep the engine clean by leding away soot particles and dirt act as a noise-dampening material at the shaft seals Volvo's VDS oil grade can withstand more operational hours than a simpler oil quality. True False A high sulphur content in the fuel has no effect on the engine oil change frequency. True False Oil flow through the engine can be 100 litres/minute in a large engine. No, not so much Yes, that is true No, much more In Volvo engines, piston cooling features its own oil duct in the cylinder block.

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Page 111





Introduction to diesel engines. Test 6 Key Oil has several vital functions, namely to: *lubricate by forming a thin film of oil between the moving parts *cool by leading away the heat *act as a seal between the pistons and cylinders reduce coolant temperature by cooling the fluid *keep the engine clean by leding away soot particles and dirt act as a noise-dampening material at the shaft seals Volvo's VDS oil grade can withstand more operational hours than a simpler oil quality. *True False A high sulphur content in the fuel has no effect on the engine oil change frequency. True *False Oil flow through the engine can be 100 litres/minute in a large engine. No, not so much *Yes, that is true No, much more In Volvo engines, piston cooling features its own oil duct in the cylinder block. *True False The reduction valve prevents oil pressure from rising too high. *True False The piston cooling valve opens when oil pressure reaches a preset value. *True False The oil cooler is a type of heat exchanger.

Page 111 (trainer)


True False The reduction valve prevents oil pressure from rising too high. True False The piston cooling valve opens when oil pressure reaches a preset value. True False The oil cooler is a type of heat exchanger. True False Which is the pump's inlet and which is the outlet? Inlet Outlet The pump in question 9 is a Disc-type pump Rotor pump Crecent pump Internal gear wheel pump Gear wheel pump Eccentric pump What is this? Piston lubrication Piston cooling Oil reduction Return pipe for turbocharger oil Is the following statement correct? If the driver does not replace the oil filters, the filters become clogged. As a result, no oil will get to the lubrication points inside the engine. True False All Volvo diesel engines have full-flow filters. True False Oil filters must be replaced after a certain number of operational kilometers. How do you find out the replacement interval? I replacement them now and again. I check in the maintenance instructions. I ask a friend.

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*True False Which is the pump's inlet and which is the outlet? Inlet~2 Outlet~1 The pump in question 9 is a Disc-type pump Rotor pump Crecent pump Internal gear wheel pump *Gear wheel pump Eccentric pump What is this? Piston lubrication *Piston cooling Oil reduction Return pipe for turbocharger oil Is the following statement correct? If the driver does not replace the oil filters, the filters become clogged. As a result, no oil will get to the lubrication points inside the engine. True *False All Volvo diesel engines have full-flow filters. *True False Oil filters must be replaced after a certain number of operational kilometers. How do you find out the replacement interval? I replacement them now and again. *I check in the maintenance instructions. I ask a friend. Considerable amounts of heat must be directed away from the engine's interior. What proportion does the oil manage to lead away? Less than 5% *10-15% More than 25% In one of the tests on a Volvo oil filter, the pressure in the filter rises 75,000 times from 0 to 8 bar. *True False What is the name of the oil cooler type which Volvo uses in almost all its diesel engines? Central radiator Cyclone radiator

Page 112 (trainer)


onsiderable amounts of heat must be directed away from the engine's interior. What proportion does the oil manage to lead away? Less than 5% 10-15% More than 25% In one of the tests on a Volvo oil filter, the pressure in the filter rises 75,000 times from 0 to 8 bar. True False What is the name of the oil cooler type which Volvo uses in almost all its diesel engines? Central radiator Cyclone radiator Flat radiator With the engine under high operating load, the oil temperature can reach 130°C. True False

Notes

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*Flat radiator With the engine under high operating load, the oil temperature can reach 130°C. *True False

Trainer notes

Page 113 (trainer)

Fuel system > Fuel system > Fuel injection system

Fuel Injection system  Injection pump  Unit Injector system  Common Rail system  Injected at the right moment  Tank  Supply pump  Fuel filters  Pipe  Overflow valve  Return pipe  High pressure pipe  Injectors

Notes

Page 114

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Fuel system > Fuel system > Fuel injection system Key points  Fuel Injection system  Different systems  Injection pump  Radial type  In line type  Unit Injector system  Common Rail system  Fuel quantity  Milligrams of fuel  Engine speeds  Engine loads  Incorrect fuel quantities  Interference  Impairing  The right moment  Top dead centre  Injection sequence  Extremely precise tolerances  Tank  Supply pump  150 kPa (1.5 bar)  Fuel filters  Injection pump  Overflow valve  Return pipe  High pressure  Pressure pipe  Injectors  Atomised and sprayed into the combustion chamber



Her it is time to run the movie “AN INTRO TO DIESEL ENGINE” chapter "Fuel system". This is like a teaser for the participants.

Page 114 (trainer)

Fuel system > Fuel system > Injection pump

Injection pump  Older fuel system  One pump element for each cylinder  Pump-camshaft  Pressure-valve  Injector's pressure pipe  Control rod

Notes

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Page 115

Fuel system > Fuel system > Injection pump Key points  The injection pump  Older fuel system  Engine timing mechanism  Six pump elements  Piston  Cam on the pump-camshaft  Pressure-valve  Injector's pressure pipe


Trainer notes

Page 115 (trainer)

Fuel system > Fuel system > Mechanical regulator or governor

Mechanical regulator or governor  Mechanical regulator or governor  Electronic regulators  Linkage system  Accelerator pedal

Notes

Page 116

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Fuel system > Fuel system > Mechanical regulator or governor Key points  Mechanical regulator or governor  Electronic regulators  Control rod's position  Two spring-loaded weights  Linkage system  Accelerator pedal  Throttle arm


Trainer notes

Page 116 (trainer)

Fuel system > Fuel system > Supply pump

Supply pump  Piston pump  Pump camshaft  Hand-pump

Notes

GT120017A v.1.0.01_en

Page 117

Fuel system > Fuel system > Supply pump Key points  Supply pump  Specific pressure  Piston pump  Hand-pump


Trainer notes

Page 117 (trainer)

Fuel system > Fuel system > Smoke limiter

Smoke limiter  Black smoke  Legal limits  Inlet manifold  Turbocharger pressure

Notes

Page 118

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Fuel system > Fuel system > Smoke limiter Key points  Smoke limiter  Fuel  Black smoke  Legal limits  Inlet manifold  Turbo pressure  Less fuel means less smoke


Trainer notes

Page 118 (trainer)

Fuel system > Fuel system > Fuel filter

Fuel filter  Clearance - 0.001 to 0.002 mm  Hair - 20 times thicker  Filter insert  Filter housing  Spin-on filter  Box filter  Fuel filter - fine filter  Special paper

Notes

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Page 119

Fuel system > Fuel system > Fuel filter Key points  Fuel filter  Dirt particle  Damage  0.001 to 0.002 mm.  Hair is about 20 times thicker  Several different filters  Filter insert  Filter housing  Spin-on or box filter  Special type of paper  Creased and coiled


Trainer notes

Page 119 (trainer)

Fuel system > Fuel system > Pressure pipes

Pressure pipes  The pressure pipes - high-pressure leads  Steel  High pressures  Clamps·

Notes

Page 120

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Fuel system > Fuel system > Pressure pipes Key points  Pressure pipes (high-pressure leads)  Steel  High pressures  Thick, rigid walls  Inner diameter  Cylinder head's by clamps


Trainer notes

Page 120 (trainer)

Fuel system > Fuel system > Injector - copper sleeve

Injector - copper sleeve  Cylinder head  Copper sleeve  Considerable heat  Efficient heat dissipation

Notes

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Page 121

Fuel system > Fuel system > Injector - copper sleeve Key points  Injector  Inject  Atomised fuel  Combustion chamber  High pressure  Copper sleeve  Heat


Additional information The injector's job is to inject finely atomised fuel into the combustion chamber. The fuel is atomised by being sprayed in under high pressure

Trainer notes

Page 121 (trainer)

Fuel system > Fuel system > Nozzle sleeve - needle

Nozzle sleeve - needle  Shaped differently in different configurations  The type of engine  Shape of the combustion chamber  Nozzle sleeve  Ground needle  Tapered sealing  0.002-0.004 mm  Lubricates  Cools

Notes

Page 122

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Fuel system > Fuel system > Nozzle sleeve - needle Key points  Injector  Nozzle  Configurations  Type of engine and the shape of the combustion chamber  Nozzle sleeve  Needle  Tapered sealing surface  Seat in the sleeve  0.002-0.004 mm  Lubricates  Cools


Trainer notes

Page 122 (trainer)

Fuel system > Fuel system > Injector - function

Injector - function  Nozzle holder  Pressure pipe  Return fuel pipe  Spring  Pressure pin  Needle  Pressure chamber  Sleeve  Adjusted

Notes

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Page 123

Fuel system > Fuel system > Injector - function Key points  Nozzle holder  Coupling  Pressure pipe  Return fuel pipe  Force from the spring  Pressure pin  Needle  Opening pressure  Adjustment washers  Adjustment screw  Pressure chamber  Increases sufficiently  Four or five holes in the sleeve

Working procedure Go through the text in the student material and also add your own experience/knowledge. Be sure that the participants have understood the main purpose of this information. Ask question to be sure that the participants have understand the main purpose of this information/text. Show the participants the engine parts and explain how they are connected to each other, do not forget to tell them what is happen if they do not understand the basic when they shall e.g. fault tracing. Point out main parts/valves and system layout in vehicle. Read out feed pressure by using VTT.

Trainer notes

Page 123 (trainer)

Fuel system > Fuel system > Diesel engine fundamentals. Test 7B

Diesel engine fundamentals. Test 7B The injection pump ensures that the correct amount of fuel is injected into the engine ensures that the fuel is injected into the inlet manifold injects fuel at the correct point in time is made to extremely high tolerance levels

The injection pump in Volvo engines is lubricated from the engine's lubrication system has a pump element which supplies fuel to all the injectors has a regulator which meters the amount of fuel is driven by a belt from the timing mechanism varies the amount of fuel depending on the position of the control rod

The smoke limiter reduces the grey and white smoke regulates the amount of fuel so that black smoke stays within legal limits is affected by turbo pressure

The injector

Page 124

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Fuel system > Fuel system > Diesel engine fundamentals. Test 7B Key points  Question  Answer



Introduction to diesel engines. Test 7B Key The injection pump *ensures that the correct amount of fuel is injected into the engine ensures that the fuel is injected into the inlet manifold *injects fuel at the correct point in time *is made to extremely high tolerance levels

The injection pump in Volvo engines *is lubricated from the engine's lubrication system has a pump element which supplies fuel to all the injectors *has a regulator which meters the amount of fuel is driven by a belt from the timing mechanism *varies the amount of fuel depending on the position of the control rod

The smoke limiter. reduces the grey and white smoke *regulates the amount of fuel so that black smoke stays within legal limits *is affected by turbo pressure

The injector *has the job of injecting finely atomised fuel into the combustion chamber *gets very hot and this heat is led away via the copper sleeve has a lower section shaped like a pressure valve *is connected to the injection pump via the pressure pipes

The fuel filter must have an overflow valve *is made such that fuel flows through a paper filter insert *is of a type known as a spin-on or box filter

The diesel engine's exhaust gases

Page 124 (trainer)

Fuel system > Fuel system > Diesel engine fundamentals. Test 7B as the job of injecting finely atomised fuel into the combustion chamber gets very hot and this heat is led away via the copper sleeve has a lower section shaped like a pressure valve is connected to the injection pump via the pressure pipes

The fuel filter must have an overflow valve is made such that fuel flows through a paper filter insert is of a type known as a spin-on or box filter

The diesel engine's exhaust gases have a lower carbon monoxide content than in a petrol engine contains no lead compounds has a higher carbon monoxide content than in a petrol engine contains nitrogen oxides, just like petrol engine exhaust gases

Notes

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Page 125

Fuel system > Fuel system > Diesel engine fundamentals. Test 7B

*have a lower carbon monoxide content than in a petrol engine *contains no lead compounds has a higher carbon monoxide content than in a petrol engine *contains nitrogen oxides, just like petrol engine exhaust gases

Trainer notes

Page 125 (trainer)

Fuel system > Fuel system > Fuel systems with unit injectors

Fuel systems with unit injectors The unit injector system consists of:  A pump section corresponding to the pump element in an in-line injection pump.  A valve section with a fuel valve which is acted on by a solenoid valve.  An injector section corresponding to the injector jets in a normal injector.

Notes

Page 126

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Fuel system > Fuel system > Fuel systems with unit injectors

Key points  Unit injectors  Pump element and injector are combined  Electronic control  Injection timing and fuel volume can be controlled for each injection by the control unit  Control pulses  Solenoid valve  Mounted in the same place  Overhead camshaft or high level camshaft  A pump section corresponding to the pump element in an in-line injection pump  A valve section with a fuel valve which is acted on by a solenoid valve  An injector section corresponding to the injector jets in a normal injector


Trainer notes

Page 126 (trainer)

Fuel system > Fuel system > Unit injector - system function

Unit Injector - system function  High pressure  150-220 MPa (1500-2200bar)  Fewer harmful exhaust emissions  The feed section  Control unit  Cooled  Galleries in the cylinder head

Notes

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Fuel system > Fuel system > Unit injector - system function Key points  Injection pressure is very high  150-220 MPa (1500-2200bar)  Achieve atomisation of the fuel and better combustion  Fewer harmful exhaust emissions  The feed section (low pressure section)  Gear pump  Hand pump  Control unit  Cooled by the fuel  Galleries in the cylinder head  Overflow valve  Supply pressure  Vents small amounts of air from the system  Bleed screw for venting the fuel system  Starting characteristics  Reduce exhaust emissions  Raises the temperature in the cylinder and combustion chamber  Maximum is four revolutions at -20 ˚C


Trainer notes

Page 127 (trainer)

Fuel system > Fuel system > Diesel engine fundamentals. Test 7C

Diesel engine fundamentals. Test 7C The start of an injection is controlled by …. The fuel feed pressure By the spill valve closing point By the cam shaft lobe profile The injected fuel quantity is determined by …. The pumping element stroke The return spring closing force Electrical activation time, which is the length of time the spill valve remains closed The unit injector is supplied via External pressure pipes Integral ducts machined directly into the cylinder head. Channels in the camshaft bearing brackets Each unit injector has its own pumping element False True The EUI pumping element is activated by…. The camshaft lobe via a rocker

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Fuel system > Fuel system > Diesel engine fundamentals. Test 7C Key points  Question  Answer



Diesel engine fundamentals. Test 7C Key 1. The start of an injection is controlled by …. The fuel feed pressure *By the spill valve closing point By the cam shaft lobe profile

2. The injected fuel quantity is determined by …. The pumping element stroke The return spring closing force *Electrical activation time, which is the length of time the spill valve remains closed 3. The unit injector is supplied via External pressure pipes *Integral ducts machined directly into the cylinder head. Channels in the camshaft bearing brackets 4. False *True

Each unit injector has its own pumping element

5. The EUI pumping element is activated by…. *The camshaft lobe via a rocker Push rods Connecting rods

Trainer notes

Page 128 (trainer)


Push rods Connecting rods

Notes

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Trainer notes

Page 129 (trainer)

Fuel system > Fuel system > Common rail

Common rail  Common Rail system  Electronically controlled (EMS2)  Injectors  1600 bar  Two unit pumps  Sensors  Low pressure side  High pressure side  Feed pump  Fuel tank  Pre-filter  Fuel distributor  Fuel filter housing  Return line

Notes

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Fuel system > Fuel system > Common rail Key points  EMS2  Common rail  Injectors  High pressure  1600 bar  Engine control unit (EECU)  Sensors  Low pressure side (orange)  High pressure side (red)  Feed pump (1)  Fuel tank (2)  Pre-filter (3)  Fuel distributor (4)  Fuel filter housing (5)  Unit pumps (6)  Common rail (7)  Injectors (8)  Longitudinal channel (9) Return line


Trainer notes

Page 130 (trainer)

Fuel system > Fuel system > Injector

Injector  Injector body  Nozzle holder  Solenoid valve  Preinjection  Main injection  Post-injection ·

Notes

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Fuel system > Fuel system > Injector Key points

 Injector body  Nozzle holder  Solenoid valve  Preinjection  Main injection  Post-injection


Trainer notes

Page 131 (trainer)

Fuel system > Fuel system > Diesel engine fundamentals. Test 7D

Diesel engine fundamentals. Test 7D What is the part of the fuel system called the “common rail”? A thick walled metal tube that serves as an accumulator that stores fuel at high pressure The return line common for all injectors for returning leak-off fuel back to tank The part of the electrical cable harness used for activating all injector solenoids simultaneously

In a common rail system…. There are two high pressure pumps for each cylinder The injectors are mechanically activated by the engine timing gear The injector needle is always subject to high pressure

Notes

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Fuel system > Fuel system > Diesel engine fundamentals. Test 7D Key points  Question  Answer 



Diesel engine fundamentals. Test 7D Key 1.

What is the part of the fuel system called the “common rail”? *A thick walled metal tube that serves as an accumulator that stores fuel at high pressure The return line common for all injectors for returning leak-off fuel back to tank The part of the electrical cable harness used for activating all injector solenoids simultaneously

2.

In a common rail system…. There are two high pressure pumps for each cylinder The injectors are mechanically activated by the engine timing gear *The injector needle is always subject to high pressure

Trainer notes

Page 132 (trainer)

Engine management system > Engine management system > EMS - Engine Management System

EMS (Engine Management System)  Low fuel consumption  Noise  Exhaust emissions  EMS (Engine Management System)  EDC (Electronic Diesel Control)  Unit Injectors  TEA (Truck Electronic Architecture)  Electronic fuel injection  Diagnostics  Fault tracing  Engine control unit  Fault code  Information link  Display  Stored

Notes

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Engine management system > Engine management system > EMS - Engine Management System Key points  EMS (Engine Management System)  EDC (Electronic Diesel Control)  Unit Injectors  TEA (Truck Electronic Architecture)


Trainer notes

Page 133 (trainer)

Engine management system > Engine management system > Engine control unit

Engine control unit  Truck electronic architecture  Data links  Vehicle electronic control unit  Sensors  Cooled  Starter element  Unit injectors  Exhaust pressure governor (EPG)  Compression brake

Notes

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Engine management system > Engine management system > Engine control unit

Key points  1. Starter element  2. Unit injectors  3. Exhaust pressure governor (EPG)  4. Compression brake


Trainer notes

Page 134 (trainer)

Engine management system > Engine management system > Sensors on the engine

Sensors on the engine The engine control unit includes an atmospheric pressure sensor. Normally the engine is equipped with the following sensors:  Fuel pressure  Charge air temperature and charge pressure  Camshaft position  Engine coolant level  Air temperature and air pressure  Engine coolant temperature  Crankshaft position and engine speed  Oil temperature and oil pressure

Notes

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Engine management system > Engine management system > Sensors on the engine

Key points  1. Fuel pressure  2. Charge air temperature and charge pressure  3. Camshaft position  4. Engine coolant level  5. Air temperature and air pressure  6. Engine coolant temperature  7. Crankshaft position and engine speed  8. Oil temperature and oil pressure


Additional information The following is a list of engine sensors that provide input to the EMS: Ambient Air Temperature Sensor Ambient Pressure sensor Boost Air Pressure (BAP) Sensor Camshaft Position (Engine Position) Sensor Crankshaft Position (Engine Speed) Sensor Differential Pressure DPF Sensor EGR Differential Pressure Sensor EGR Temperature Sensor Engine Coolant Level (ECL) Sensor Engine Coolant Temperature (ECT) Sensor Engine Oil Pressure (EOP) Sensor Engine Oil Level (EOL) Sensor Engine Oil Temperature (EOT) Sensor Exhaust Temperature Sensor (DPF Sensors) Fuel Pressure Sensor Intake Air Temperature And Humidity (IATH) Sensor Intake Manifold (Boost) Temperature Sensor Throttle Position (TP) Sensor Turbo Speed Sensor Variable Geometry Turbocharger (VGT) Position Sensor

Trainer notes

Page 135 (trainer)

Engine management system > Engine management system > Other sensors

Other sensors  Vehicle speed (through sensors in the gearbox)  Cruise control  Retarder  ABS system  Brake, clutch and accelerator pedal  Parking brake  Engine brake

Notes

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Engine management system > Engine management system > Other sensors

Key points  3. Vehicle speed (through sensors in the gearbox)  4. Cruise control  5. Retarder  6. ABS system  7. Brake, clutch and accelerator pedal  8. Parking brake  9. Engine brake


Additional information The following is a list of engine sensors that provide input to the EMS: Ambient Air Temperature Sensor Ambient Pressure sensor Boost Air Pressure (BAP) Sensor Camshaft Position (Engine Position) Sensor Crankshaft Position (Engine Speed) Sensor Differential Pressure DPF Sensor EGR Differential Pressure Sensor EGR Temperature Sensor Engine Coolant Level (ECL) Sensor Engine Coolant Temperature (ECT) Sensor Engine Oil Pressure (EOP) Sensor Engine Oil Level (EOL) Sensor Engine Oil Temperature (EOT) Sensor Exhaust Temperature Sensor (DPF Sensors) Fuel Pressure Sensor Intake Air Temperature And Humidity (IATH) Sensor Intake Manifold (Boost) Temperature Sensor Throttle Position (TP) Sensor Turbo Speed Sensor Variable Geometry Turbocharger (VGT) Position Sensor

Trainer notes

Page 136 (trainer)

Engine management system > Engine management system > Example of communication

Example of communication When the driver, for example, wants to increase speed and depresses the accelerator pedal, a signal is transmitted from the accelerator pedal to the vehicle electronic control unit. This signal is transmitted over the data link to the engine control unit. The engine control unit checks the signals from its own sensors to ensure that it is possible to increase the throttle setting. If there is no impediment the engine control unit activates the speed increase. The engine control unit then handles the control of the engine independently for as long as conditions stay the same.

Notes

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Engine management system > Engine management system > Example of communication

Key points  Communication  Increase speed  Accelerator pedal  Signal  Vehicle electronic control unit  Data link  Engine control unit  Sensors  Throttle setting

Working procedure Go through the text in the student material and also add your own experience/knowledge. Be sure that the participants have understood the main purpose of this information. Ask question to be sure that the participants have understand the main purpose of this information/text. Show the participants the engine parts and explain how they are connected to each other, do not forget to tell them what is happen if they do not understand the basic when they shall e.g. fault tracing. Point out the engine sensors. Run sensor test in VCADS Pro.

Trainer notes

Page 137 (trainer)

Engine management system > Engine management system > Diesel engine fundamentals. Test 7A

Diesel engine fundamentals. Test 7A Which component is the EMS connected to Unit injector Sensors Fuel filter Oil pump Can you use the EMS system for diagnostic and fault tracing Yes No The engine control unit regulates different systems and components. Which one below is correct? Starter element Unit injectors Exhaust pressure governor (EPG) Compression brake Point out the following sensor on the engine/picture Fuel pressure

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Engine management system > Engine management system > Diesel engine fundamentals. Test 7A Key points  Question  Answer



Introduction to diesel engines. Test 7A Key Which component is the EMS connected to *Unit injector *Sensors Fuel filter Oil pump Can you use the EMS system for diagnostic and fault tracing *Yes No The engine control unit regulates different systems and components. Which one below is correct? *Starter element *Unit injectors *Exhaust pressure governor (EPG) *Compression brake Point out the following sensor on the engine/picture 1. Fuel pressure 2. Charge air temperature and charge pressure 3. Camshaft position 4. Engine coolant level 5. Air temperature and air pressure 6. Engine coolant temperature 7. Crankshaft position and engine speed 8. Oil temperature and oil pressure

Trainer notes

Page 138 (trainer)


Charge air temperature and charge pressure Camshaft position Engine coolant level Air temperature and air pressure Engine coolant temperature Crankshaft position and engine speed Oil temperature and oil pressure

Notes

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Page 139


Trainer notes

Page 139 (trainer)

Intake and exhaust system > Intake and exhaust system > Intake and exhaust system

Intake and exhaust system  Separated from the fuel system  Clean air through the intake system  Inlet manifold - cast in aluminium  O-rings - silicon-sealant  Air filter  Turbocharger  Charge air cooler  The exhaust manifold - heat-resistant material with high nickel content  Two -or three piece unit  Sealing rings  Exhaust pipe  Silencer  All Volvo engines are boosted with a turbocharger

Notes

Page 140

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Intake and exhaust system > Intake and exhaust system > Intake and exhaust system

Key points  Intake and exhaust system  Separated from the fuel system  Clean air through the intake system  Fuel from a separate fuel system  Intake manifold - cast in aluminium  Sealing  Rubber O-rings  Silicon-sealant  Air filter  Turbocharger  Charge air cooler  Air resistance  A large through-flow area is of prime importance  Exhaust manifold  Considerable stress  Heat-resistant material with high nickel content  Two -or three piece unit  Sealed with sealing rings or a special sealing compound


Trainer notes

Page 140 (trainer)

Intake and exhaust system > Intake and exhaust system > Air filter

Air filter  Reliability and life length  Clean  Pollutants  20 cubic metres per minute  Large through-flow area  10 square metres  Paper filter  Air filter housing

Notes

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Intake and exhaust system > Intake and exhaust system > Air filter Key points

        

Air filter Reliability and life length Clean Pollutants 20 cubic metres per minute Large through-flow area 10 square metres Paper filter Air filter housing


Trainer notes

Page 141 (trainer)

Intake and exhaust system > Intake and exhaust system > Cyclone filter

Cyclone filter  Difficult conditions  Desert climate  Option  Cyclone tubes  Air rotates  Centrifugal force  Dust particles  Rubber valve

Notes

Page 142

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Intake and exhaust system > Intake and exhaust system > Cyclone filter

Key points  Difficult conditions  Desert climate  Cyclone filter  Cyclone tubes  Air intake  Air rotates  Dust particles  Centrifugal force  Rubber valve


Trainer notes

Page 142 (trainer)

Intake and exhaust system > Intake and exhaust system > Starter element

Starter element  Intake manifold  Warm the air  Helps the engine start  White smoke  Cold starts  Starter element  Electrically heated

Notes

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Intake and exhaust system > Intake and exhaust system > Starter element

Key points  Starter element  Intake manifold  Warm the air  White smoke  Electrically heated  Two or three heater coils


Trainer notes

Page 143 (trainer)

Intake and exhaust system > Intake and exhaust system > Exhaust pressure governor

Exhaust pressure governor  Exhaust pressure governor (EPG)  Compressed air  Restricts the flow  Back pressure  Braking effect  Compression brake ·

Notes

Page 144

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Intake and exhaust system > Intake and exhaust system > Exhaust pressure governor

Key points  Engine brake  Exhaust pressure governor (EPG)  Compressed air  VEB - Volvo Engine Brake  Compression brake


Trainer notes

Page 144 (trainer)

Intake and exhaust system > Intake and exhaust system > Compression brake VEB

Compression brake - VEB  Compression brake  Camshaft  Rocker arms  Hydraulic piston  Lubrication system  Hydraulic valve  Rocker arm pistons

Notes

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Intake and exhaust system > Intake and exhaust system > Compression brake VEB

Key points  Compression brake  Camshaft  Rocker arms  Hydraulic piston  Lubrication system  Hydraulic valve  Rocker arm pistons


Trainer notes

Page 145 (trainer)

Intake and exhaust system > Intake and exhaust system > Compression brake VEB+

Compression brake - VEB+  VEB+ Volvo Engine Brake  Camshaft with four cam lobes  Brake cam - VEB+ function

Notes

Page 146

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Intake and exhaust system > Intake and exhaust system > Compression brake VEB+

Key points  VEB+  EPG (Exhaust Pressure Governor).  D16E EPG - butterfly type  VEB+ Volvo Engine Brake  Camshaft with four cam lobes  Inlet cam  Injector cam  Exhaust cam  Brake cam - VEB+ function  VCB  Engine braking control in position 2  Engine speed above 900 rpm  Vehicle speed above 5 km/h  Clutch pedal released completely  Engine oil temperature above 55°C  Turbocharging pressure below 0.5 bar  Accelerator pedal released completely


Trainer notes

Page 146 (trainer)

Intake and exhaust system > Intake and exhaust system > Compression brake JAK

Compression brake JAK  Energy-absorbing air compressor  Mounted above the rocker arm bridge  Operate on the exhaust valves  Always in combination with the exhaust brake · _

 Solenoid valve  Control valve  Pressure piston

Notes

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Intake and exhaust system > Intake and exhaust system > Compression brake JAK

Key points  Compression brake - Jake brake  1.Control valve  2.Pressure piston  3.Solenoid valve  4.Adjustment screw, pressure piston  Energy-absorbing air compressor  Reducing the load on the service brakes  Mounted above the rocker arm bridge  Operate on the exhaust valves  Always in combination with the exhaust brake


Trainer notes

Page 147 (trainer)

Intake and exhaust system > Intake and exhaust system > Engine brake function

Engine brake function  Engine brake function  Compression stroke  Power stroke  Exhaust stroke

Notes

Page 148

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Intake and exhaust system > Intake and exhaust system > Engine brake function

Key points  Engine brake function  Compression stroke  Power stroke  Exhaust stroke

Working procedure Go through the text in the student material and also add your own experience/knowledge. Be sure that the participants have understood the main purpose of this information. Ask question to be sure that the participants have understand the main purpose of this information/text. Show the participants the engine parts and explain how they are connected to each other, do not forget to tell them what is happen if they do not understand the basic when they shall e.g. fault tracing

Trainer notes

Page 148 (trainer)

Intake and exhaust system > Intake and exhaust system > Diesel engine fundamentals. Test 8

Diesel engine fundamentals. Test 8 The inlet system of a diesel engine is entirely separated from the fuel system. True False The quantity of air to be cleaned in a large engine is: approx. 5 m3/min. approx. 10 m3/min. approx. 20 m3/min. An engine which has to work in surroundings where the air is strongly polluted has an extra air filter known as a centrifugal filter cyclone filter sand separator What is this?

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Introduction to diesel engines. Test 8 Key The inlet system of a diesel engine is entirely separated from the fuel system. *True False

The quantity of air to be cleaned in a large engine is: approx. 5 m3/min. approx. 10 m3/min. *approx. 20 m3/min.

An engine which has to work in surroundings where the air is strongly polluted has an extra air filter known as a centrifugal filter *cyclone filter sand separator

What is this? a magnetic air filter a cyclone filter *a starter element a filter cleaner

Page 149 (trainer)


a magnetic air filter a cyclone filter a starter element a filter cleaner The exhaust manifold is subjected to considerable thermal stress. It is therefore made of a material with a high nickel content. True False

Notes

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GT120017A v.1.0.01_en


The exhaust manifold is subjected to considerable thermal stress. It is therefore made of a material with a high nickel content. *True False

Trainer notes

Page 150 (trainer)

Turbocharger > Turbocharger > Turbocharger history

Turbocharger history

Notes

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Turbocharger > Turbocharger > Turbocharger history Key points

Turbo charger history Working procedure

Her it is time to run the movie “THE VOLVO TURBO HERITAGE 1954-2004”. This is like a teaser for the participants. The movie explains the development of the turbocharged engine through the years.

Trainer notes

Page 151 (trainer)

Turbocharger > Turbocharger > Turbocharging

Turbocharging  More air into the cylinder  Not steal power  Volvo turbo engines - 1954  40 to 50% higher output  Cleaner exhaust gases  Lower fuel consumption  Quieter engine operation  Turbocharger function  Boost pressure - 150 kPa (1,5 bar)  Speed - 1250-1670 rps (75,000-100,000 rpm)  Top speed - 2200 rps (130,000 rpm)

Notes

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Turbocharger > Turbocharger > Turbocharging Key points  Turbo charging  Compressor air  Turbocharger  Powered by the flow  1954  Extending the engine's power  40 to 50%  Cleaner exhaust gases  Lower fuel consumption  Quieter engine  Turbine housing  Exhaust system  Turbine wheel  Compressor wheel  Shaft  Compressor housing  Air filter  Inlet manifold  150 kPa (1,5 bar)  1250-1670 rps (75,000-100,000 rpm)  2200 rps (130,000 rpm)


Trainer notes

Page 152 (trainer)

Turbocharger > Turbocharger > Turbocharger bearing

Turbocharger bearing  Rotor shaft  Bearing  High speed  Lubrication  Cooled  Clean oil

Notes

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Turbocharger > Turbocharger > Turbocharger bearing Key points  Rotor shaft  Slider bearings  Reliable lubrication  Lubricated and cooled by engine oil  Clean oil


Trainer notes

Page 153 (trainer)

Turbocharger > Turbocharger > Wastegate

Wastegate  Engine torque requirements at low engine speeds  Temperatures  Emissions  Boost pressure  Bypass  Overspeed  Pneumatic actuator ·

Notes

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Turbocharger > Turbocharger > Wastegate Key points  Wastegate  Requirements at low engine speeds  Producing good air flow  Reduces exhaust temperatures  Reduces emissions  Boost pressure  Bypass into the exhaust system  Overspeed  Pneumatic actuator  Valve- bypass flap


Trainer notes

Page 154 (trainer)

Turbocharger > Turbocharger > Turbocharger system

Turbocharger system  Intake system  Exhaust system  Turbocharger  Starter element  Exhaust pressure governor EPG  Blue exhaust smoke

Notes

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Turbocharger > Turbocharger > Turbocharger system Key points  Intake  Exhaust  Turbocharger  Starter element  Exhaust pressure governor - EPG  Reducing white and blue exhaust smoke


Trainer notes

Page 155 (trainer)

Turbocharger > Turbocharger > Exhaust pressure governor

Exhaust pressure governor  Exhaust pressure governor EPG  Turbocharger  Two functions  Pneumatic cylinder  Vehicle's pneumatic system  Solenoid  Butterfly

Notes

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Turbocharger > Turbocharger > Exhaust pressure governor Key points  Exhaust pressure governor - EPG  Below the turbocharger  Two functions  Counterpressure  Kept warm  White exhaust smoke  Shutter housing  Shutter  Pneumatic cylinder  Compressed air  Solenoid



Butterfly, see D16E, design and function.

Trainer notes

Page 156 (trainer)

Turbocharger > Turbocharger > Turbocharger type VGT

Turbocharger type VGT  Variable Geometry Turbine, VGT  EGR, Exhaust Gas Recirculation  EMS  Movable sleeve  Lever  Actuator  Gear ratio  Electric motor

Notes

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Turbocharger > Turbocharger > Turbocharger type VGT Key points  VGT - Variable Geometry Turbine  EGR system  Gas flow  EGR-meter  EMS system  EGR-valve  Axial movable sleeve (1)  Lever (2)  Actuator (3)  Gear ratio (4)  Electric motor (5)


Trainer notes

Page 157 (trainer)

Turbocharger > Turbocharger > Charge air cooling

Charge air cooling There are two types of charge air cooler:  Air to air cooling  Fluid to air cooling The charge air cooler principle  Compressor  Turbine  Charge air cooler (Intercooler)

Notes

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Turbocharger > Turbocharger > Charge air cooling Key points  Charge air cooling  Air to air cooling  Fluid to air cooling  Compressor  Turbine  Charge air cooler (Intercooler)


Trainer notes

Page 158 (trainer)

Turbocharger > Turbocharger > Air to air cooling

Air to air cooling  Common type  Charge air cooler (intercooler)  Reduces the air temperature  Raising engine power output  Higher torque  Lower fuel consumption  Positioned in front of the engine cooling radiator ·

Notes

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Page 159

Turbocharger > Turbocharger > Air to air cooling Key points  Air to air cooling  Reduces the air temperature by roughly 100°C  Raising engine power output by about 10%  Torque is also higher  Fuel consumption drops  In front of the engine cooling radiator


Trainer notes

Page 159 (trainer)

Turbocharger > Turbocharger > Diesel engine fundamentals. Test 9

Diesel engine fundamentals. Test 9 Put the numbers in the appropriate boxes. Turbo pipe Gasket Sealing rings Inlet duct Exhaust manifold Engine turbocharging means that the air intake is positioned above the engine the incoming air is pressed in from below more air is pressed into the engine There are several additional benefits to using a turbocharger. Exhaust gases are cleaner Fuel consumption is lower Inlet noise is lower Engine power increases Exhaust noise is lower Pipe routing is simpler An exhaust pressure governor reduces the white and blue smoke in the exhaust gases.

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Turbocharger > Turbocharger > Diesel engine fundamentals. Test 9 Key points  Question  Answer



Introduction to diesel engines. Test 9 Key Put the numbers in the appropriate boxes. Turbo pipe 4 Gasket 3 Sealing rings 1 Inlet duct 5 Exhaust manifold 2

Engine turbocharging means that the air intake is positioned above the engine the incoming air is pressed in from below *more air is pressed into the engine

There are several additional benefits to using a turbocharger.

*Exhaust gases are cleaner *Fuel consumption is lower *Inlet noise is lower *Engine power increases *Exhaust noise is lower Pipe routing is simpler

An exhaust pressure governor reduces the white and blue smoke in the exhaust gases. *True False

A diesel engine with a turbocharger and intercooler has the best possible efficiency rating. *True False

"Intercooler" is another name for charge air cooler.

Page 160 (trainer)

Turbocharger > Turbocharger > Diesel engine fundamentals. Test 9

rue False A diesel engine with a turbocharger and intercooler has the best possible efficiency rating. True False "Intercooler" is another name for charge air cooler. True False

Notes

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Turbocharger > Turbocharger > Diesel engine fundamentals. Test 9 *True False

Trainer notes

Page 161 (trainer)

Cooling system > Cooling system > Volvo coolant

Volvo coolant  Over heating  Circulates the coolant  Absorbs heat  Radiator  Fluid cooled  Liquid coolant  Glycol  Water

Notes

Page 162

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Cooling system > Cooling system > Volvo coolant Key points  Over heating  Circulates the coolant  Absorbs heat  Radiator  Fluid cooled  Liquid coolant  Glycol Water


Trainer notes

Page 162 (trainer)

Cooling system > Cooling system > Cooling system

Cooling system  Heat  Cylinder block  Cylinder head _

Coolant When the ambient temperature is below 0°C, the coolant should consist of a mixture of water and anti-freeze. On markets where the ambient temperature never drops below 0°C, no anti-freeze is needed but corrosion protection is still essential to prevent engine damage. In such cases, Volvo anticorrosion fluid is added in the ratio of 1:30 (1 litre of fluid to 30 litres of water). All these fluids which circulate inside the cooling system are known as coolants. Referring to them as "water" is incorrect since there is always something added to the water.

Notes

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Cooling system > Cooling system > Cooling system Key points  Cooling system  10-15% - lubricating oil  Radiated from the sides of the engine itself  20-30% - cooling system  Heat from the cylinder block and cylinder heads  Cooling jacket  Cylinders and combustion chambers have the same temperature  Combustion to be as efficient and clean as possible  Correct operational temperature  Light or heavy load  Low flow resistance  Thermo-siphon principle  Pump circulation  Coolant pump  Coolant  0°C  Mixture of water and anti-freeze  Anti-corrosion fluid  "water"



Her it is time to run the movie “AN INTRO TO DIESEL ENGINE” chapter "Cooling system". This is like a teaser for the participants.

Trainer notes

Page 163 (trainer)

Cooling system > Cooling system > External components of the cooling system

External components of the cooling system  Coolant filter  Oil cooler  Coolant pump  Air compressor.  Heating cell package in cab  Expansion tank  Level indicator.  Filling cap.  Thermostat  Radiator

Notes

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GT120017A v.1.0.01_en

Cooling system > Cooling system > External components of the cooling system

Key points  External components  Coolant filter  Oil cooler  Coolant pump  Air compressor  Heating cell  Expansion tank  Level indicator.  Warning lamp  Filling cap - over pressure valves  Thermostat  Return pipe  Radiator


Trainer notes

Page 164 (trainer)

Cooling system > Cooling system > Thermostat

Thermostat Shut. (cold engine) Coolant can only flow through the lower pipe. Open. (warm engine) Coolant can only flow through the upper pipe. .

Notes

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Cooling system > Cooling system > Thermostat Key points  Thermostat regulates  Shut. (cold engine)  Open. (warm engine)


Trainer notes

Page 165 (trainer)

Cooling system > Cooling system > Schematic presentation of the cooling system

Schematic presentation of the cooling system.  Inner circuit  Outer circuit

Notes

Page 166

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Cooling system > Cooling system > Schematic presentation of the cooling system

Key points  Schematic  Inner circuit  Outer circuit


Trainer notes

Page 166 (trainer)

Cooling system > Cooling system > Radiator

Radiator  Heat exchanger  Copper  Brass  Aluminium  Plastic  Upper tank  Lower tank  Honeycomb  Pipes  Thin steel fins

Notes

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Cooling system > Cooling system > Radiator Key points  Radiator  Heat exchanger  Copper  Brass  Aluminium  Two containers  Upper tank  Lower tank  Plastic  Honeycomb  Pipes  Two up to four rows  Steel


Trainer notes

Page 167 (trainer)

Cooling system > Cooling system > Cooling fans in vehicles

Cooling fans in vehicles  Visco clutch  Fan axle  Fan  Drive belt  Automatic belt tensioners

Notes

Page 168

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Cooling system > Cooling system > Cooling fans in vehicles Key points  Cooling fan  10 kW (14 bhp).  Maximum flow  Thermostat-regulated fan  Fluid coupling which senses the temperature of the air which has flowed through the radiator.  Low temperature 25% of full speed  60°C - 95% of full speed  5% slipping of the fluid coupling  Reduces fuel consumption  Less noise 



Cooling fans in industrial engines These engines feature fixed fans which are either pressure or suction fans. The former means that the fan provides a thrust of air from behind the engine, out through the radiator. In a generator set, this flow of air cools both the generator and the engine. Fixed fans are designed to provide an ambient temperature of +50°

Trainer notes

Page 168 (trainer)

Cooling system > Cooling system > Cooling fans in bus

Cooling fans in bus  Electro-hydraulic system  Coolant temperature sensor  PWM-signal  Stepless regulation  Rotational speed induction sensor

Notes

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Cooling system > Cooling system > Cooling fans in bus Key points  Electro-hydraulic system  Coolant temperature sensor  PWM-signal  Stepless regulation  Rotational speed induction sensor


Trainer notes

Page 169 (trainer)

Cooling system > Cooling system > Cooling fans in VCE

Cooling fans in VCE  Articulated Haulers  Wheel loaders  Driven by hydraulic oil  Hydraulic pump  Hydraulic fan motor  Vehicle ECU  Sensors  Valve  Reversible fan

Notes

Page 170

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Cooling system > Cooling system > Cooling fans in VCE Key points  Articulated Haulers  Wheel loaders  Driven by hydraulic oil  Hydraulic pump  Hydraulic fan motor  Vehicle ECU  Sensors  Valve  Reversible fan

Working procedure Go through the text in the student material and also add your own experience/knowledge. Be sure that the participants have understood the main purpose of this information. Ask question to be sure that the participants have understand the main purpose of this information/text. Show the participants the engine parts and explain how they are connected to each other, do not forget to tell them what is happen if they do not understand the basic when they shall e.g. fault tracing. Point out main parts and system layout in vehicle

Trainer notes

Page 170 (trainer)

Cooling system > Cooling system > Diesel engine fundamentals. Test 10

Diesel engine fundamentals. Test 10 Roughly 25% of the energy supplied to the engine is led away by the cooling system. True False How many degrees (roughly) does the coolant temperature drop on its way through the radiator? 10°C 20°C 30°C Since there is an over-pressure in the cooling system, the operational temperature can be higher than 100°C without any risk of the system boiling over. True False It is the thermostat which provides the cooling system's over-pressure. True False Put the numbers in the appropriate boxes.

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Introduction to diesel engines. Test 10 Key Roughly 25% of the energy supplied to the engine is led away by the cooling system. *True False

How many degrees (roughly) does the coolant temperature drop on its way through the radiator? *10°C 20°C 30°C

Since there is an over-pressure in the cooling system, the operational temperature can be higher than 100°C without any risk of the system boiling over. *True False

It is the thermostat which provides the cooling system's over-pressure. True *False

Put the numbers in the appropriate boxes. Filling cap 10 Coolant pump 5 Air compressor 6 Expansion tank 8 Cab heating element 7 Coolant filter 3 Level indicator 9 Return pipe, Cylinder head 2 Thermostat 1 Oil cooler 4

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illing cap Coolant pump Air compressor Expansion tank Cab heating element Coolant filter Level indicator Return pipe, Cylinder head Thermostat Oil cooler The cooling mantle is in the cylinder block and cylinder head. True False The thermostat keeps the pipe leading to the radiator shut until the engine is sufficiently heated. True False The coolant pump is a centrifugal pump. It can pump considerable quantities of fluid at low pressure. True False Decide what is correct as regards the coolant pump. The pump is usually driven by the timing gear Two rubber lip seals ensure pump shaft sealing There is a ceramic slider ring in Volvo pumps Pump shaft sealing consists of a slider ring seal If the ambient temperature never drops below 0°C, there is no need for glycol, but corrosion protection is necessary. True False The piston thermostat has a low flow resistance. True False A coolant filter contains anti-corrosion agent. True False It is an advantage if the radiator fan does not work at all when the vehicle is running at a low road speed or is at a standstill with the engine operating when the ambient air is cold and provides good cooling when the engine is running under high load

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The cooling mantle is in the cylinder block and cylinder head. *True False

The thermostat keeps the pipe leading to the radiator shut until the engine is sufficiently heated. *True False

The coolant pump is a centrifugal pump. It can pump considerable quantities of fluid at low pressure. *True False

Decide what is correct as regards the coolant pump. *The pump is usually driven by the timing gear Two rubber lip seals ensure pump shaft sealing *There is a ceramic slider ring in Volvo pumps *Pump shaft sealing consists of a slider ring seal

If the ambient temperature never drops below 0°C, there is no need for glycol, but corrosion protection is necessary. *True False

The piston thermostat has a low flow resistance. *True False

A coolant filter contains anti-corrosion agent. *True False

It is an advantage if the radiator fan does not work at all when the vehicle is running at a low road speed or is at a standstill with the engine operating *when the ambient air is cold and provides good cooling when the engine is running under high load when the ambient air is hot

A thermostat fan reduces the engine's fuel consumption since it only steals a little power from the engine when it spins at low speed. *True

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hen the ambient air is hot A thermostat fan reduces the engine's fuel consumption since it only steals a little power from the engine when it spins at low speed. True False

Notes

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False Trainer notes

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Emissions > Emissions > Vehicle emissions and environmental impact

Vehicle emissions and environmental impact  Sulphur Oxides (SOx) from sulphur in fuel, engine emissions  Carbon Monoxide (CO) from inefficient combustion  Carbon dioxoide (CO2) from combustion, green house gas  Particulate Matter (PM) from diesel engine emissions  Nitrogen Oxides (NOx) from diesel engine emissions  Hydrocarbons (HC) from inefficient combustion

Notes

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Emissions > Emissions > Vehicle emissions and environmental impact

Key points The most important air pollutants include: - Sulphur Oxides (SOx) from sulphur in fuel, engine emissions - Carbon Monoxide (CO) from inefficient combustion - Carbon dioxoide (CO2) from combustion, green house gas - Particulate Matter (PM) from diesel engine emissions - Nitrogen Oxides (NOx) from diesel engine emissions - Hydrocarbons (HC) from inefficient combustion


Trainer notes

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Emissions > Emissions > Engine emission

Engine emission The diagram above shows the dramatic decrease in NOx and PM necessary to meet the Euro 4 and especially Euro 5 legislations. Stricter emission legislation has caused an increased need for exhaust aftertreatment, in order to remove harmful pollutants, such as NOx and particulates. The NOx emissions from a diesel engine are lowered by adding a reducing agent to the exhaust gas flow, such as urea or diesel fuel. The particulates are typically removed by collecting in a filter device, with continuous or periodic regeneration of the filter.  1st October 2006 - Euro 4  1st October 2009 - Euro 5  Nitrogen oxides (NOx)  Particulate (PM)

Notes

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Emissions > Emissions > Engine emission Key points  Emission  EGR  SCR

Working procedure Talk with the participants about the Volvo engine emission.

Additional information Go through the information shown below.

From 1st October 2007 all new trucks, buses and coaches will be required to be fitted with onboard diagnostics which will monitor the performance of both SCR and EGR systems to ensure emission compliance during use. Enforcement authorities will be able to download faults recorded on the vehicle ECU. Important to do the correct adjustment to get the correct emission. There is more information about emissions on the violin link below. http://violin.volvo.net/volvotechnology/corporate/en/business_functions/business_key_technology _areas

Trainer notes

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Emissions > Emissions > Carbon dioxide and Hydrocarbons

Carbon dioxide and Hydrocarbons Carbon dioxide contributes to the greenhouse effect, also called global warming. The greenhouse effect is a natural phenomenon which means that the earth is heated when radiated heat is captured by greenhouse gases in the atmosphere. Carbon dioxide is one of the most important greenhouse gases. Since the industrial revolution human beings have added to the greenhouse effect through increased greenhouse gas emissions. This is expected to lead to climate change. Carbon dioxide is generated by burning material that contains carbon, and is not poisonous. Diesel, the most common fuel for vehicles, consists of hydrocarbons and during combustion generates carbon dioxide. Carbon dioxide emissions are directly related to how much fuel is consumed. Compared with the petrol engine, the diesel engine has a considerably greater degree of efficiency. This means that the energy content of the fuel is utilised better, keeping down emissions of carbon dioxide. Hydrocarbons are chemical compounds that contain hydrogen and carbon. Most motor vehicles and engines are powered by hydrocarbon-based fuels such as gasoline and diesel. Hydrocarbon pollution results when unburned or partially burned fuel is emitted from the engine as exhaust, (or from the crankcase ventilation) and also when fuel evaporates directly into the atmosphere. Hydrocarbons include many toxic compounds that cause cancer and other adverse health effects. Hydrocarbons also react with nitrogen oxides in the presence of sunlight to form ozone. Hydrocarbons, which may take the form of gases, tiny particles, or droplets, come from a great variety of industrial and natural processes. In typical urban areas, a very significant fraction comes from cars, buses, trucks, and non-road mobile sources such as construction vehicles and boats.

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Emissions > Emissions > Carbon dioxide and Hydrocarbons Key points  Carbon dioxide  Greenhouse effect - global warming  Greenhouse gases  Industrial revolution  Climate change  Carbon - not poisonous  Diesel  Hydrocarbon  Fuelconsumption


Trainer notes

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Emissions > Emissions > Nitrogen oxides (NOX)

Nitrogen oxides Nitrogen oxides (NOx) is a collective name for nitrogen monoxide (NO) and nitrogen dioxide (NO2). Nitrogen oxides contribute to a number of different environmental issues. These include the formation of tropospheric ozone and the acidification of land and water. Nitrogen oxides are also irritating when they are breathed in, and can in high concentrations cause damage to the respiratory system. Nitrogen oxides are formed during all combustion where air is present, as the oxygen and nitrogen in the air react with each other. At ambient temperatures, the oxygen and nitrogen gases in air will not react with each other. In an internal combustion engine, combustion of a mixture of air and fuel produces combustion temperatures high enough to drive endothermic reactions between atmospheric nitrogen and oxygen in the flame, creating various oxides of nitrogen. The high degree of efficiency of the diesel engine is achieved through high pressure, high temperature and excess air during combustion. This increases the formation of NOx. However, these characteristics also contribute to low emissions of carbon dioxide. Developments in engine technology have lead to considerable reductions in NOx emissions from diesel engines. In areas of high motor vehicle traffic, such as in large cities, the amount of nitrogen oxides emitted into the atmosphere can be quite significant..

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Emissions > Emissions > Nitrogen oxides (NOX) Key points  Nitrogen oxides - NOX  Nitrogen monoxide (NO)  Nitrogen dioxide (NO2)  Tropospheric ozone  Irritating  Respiratory system


Trainer notes

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Emissions > Emissions > Particulate matter

Particulate matter Particulates, alternatively referred to as particulate matter (PM) or fine particles, are tiny particles of solid or liquid suspended in a gas. In contrast, aerosol refers to particles and the gas together. Sources of particulate matter can be man made or natural. Some particulates occur naturally, originating from volcanoes, dust storms, forest and grassland fires, living vegetation, and sea spray. Human activities, such as the burning of fossil fuels in vehicles, power plants and various industrial processes also generate significant amounts of aerosols. Averaged over the globe, anthropogenic aerosols -those made by human activities -currently account for about 10 percent of the total amount of aerosols in our atmosphere. Increased levels of fine particles in the air are linked to health hazards such as heart disease, altered lung function and lung cancer. Particles from a diesel engine consist primarily of soot, various hydrocarbons and sulphur. When they are breathed in the particles are transported into the lungs carrying with them harmful substances. Particles can exacerbate existing respiratory problems and high concentrations can probably lead to reduced pulmonary function. Particulate matter also contributes to poor visibility and soot deposition. Particulate matter is generated by the incomplete combustion of fuel; however engine lubricating oil is also a factor. Various technical measures have reduced particulate formation in modern diesel engines. For really good combustion good fuel must be used. Fuel with a low sulphur content reduces particulate formation. Good fuel quality also provides greater opportunity for the use of aftertreatment equipment. From January 1, 2005 low sulphur fuel with a sulphur content of maximum 10 mg/kg (0.1%, 100 ppm) must be available in all member states of the EU. The USA is also introduced requirements for greater access to low sulphur vehicle fuel from 2006. Low sulphur fuel does not only produce lower emissions of particulates and oxides of sulphur, but is also a prerequisite for certain types of exhaust after-treatment, e.g. particulate filters.

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Emissions > Emissions > Particulate matter Key points  Particles  Soot  Hydrocarbons  Sulphur  Harmful substances  Respiratory problems  Reduced pulmonary function  Poor visibility  Soot deposition  Incomplete combustion of fuel  Engine lubricating oil  Good fuel  Low sulphur


Trainer notes

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The recommended sulphur content for Euro 5 is 50 ppm, (0,05%).

Notes

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Trainer notes

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Emissions > Emissions > Diesel engine fundamentals. Test 11A

Diesel engine fundamentals. Test 11A Which pollutants is lower in Euro 5 comparing to Euro 4. Nitrogen oxides (NOx) Particulate (PM) Carbon monoxide (CO) Carbon dioxide (CO2) Sulphur oxide (SOx) The recommended sulphur content for Euro 5 is 50 ppm, (0,05%) 30 ppm, (0,03%) 500 ppm, (0,50%) 5 ppm, (0,005%)

Notes

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Emissions > Emissions > Diesel engine fundamentals. Test 11A Key points  Question  Answer



Introduction to diesel engines. Test 11A Key Which pollutants is lower in Euro 5 comparing to Euro 4. *Nitrogen oxides (NOx) *Particulate (PM) Carbon monoxide (CO) Carbon dioxide (CO2) Sulphur oxide (SOx)

The recommended sulphur content for Euro 5 is *50 ppm, (0,05%) 30 ppm, (0,03%) 500 ppm, (0,50%) 5 ppm, (0,005%)

Trainer notes

Page 180 (trainer)

EGR > EGR > Emisson control, schematic description of the system

Emisson control, schematic description of the system  Emisson control  Cooled-EGR  EGR-valve  EGR-cooler  EGR-meter  VGT turbocharger  After treatment  Stainless container  Oxidizing catalytic converter  Ceramic particulate filter

Notes

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EGR > EGR > Emisson control, schematic description of the system Key points  Emisson control  Schematic  Cooled-EGR  Reducing of the nitrogen oxide  EGR-valve (A)  EGR-cooler (B)  EGR-meter (C)  VGT turbocharger (D)  Good driveability  Turbine geometry  EMS system  After treatment  Muffler (E)  Stainless container  Oxidizing catalytic converter  Ceramic particulate filter


Trainer notes

Page 181 (trainer)

EGR > EGR > EGR system

EGR system  EGR valve  Rear exhaust pipe  EGR cooler  Differential pressure sensor  Venturi tube  EGR temperature sensor  EGR pipe  Mixing chamber  Charge air sensor

Notes

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EGR > EGR > EGR system Key points  EGR system  EGR valve  Rear exhaust pipe  EGR cooler  Differential pressure sensor  Venturi tube  EGR temperature sensor  EGR pipe  Mixing chamber  Charge air sensor  EGR = Exhaust Gas Recirculation  Nitrous oxide (NO x)  Combustion temperature  Cooled exhaust  Maximum EGR


Trainer notes

Page 182 (trainer)

EGR > EGR > I-EGR, Large engine platform

I-EGR, Large engine platform  Internal exhaust Gas Recirculation - I-EGR  Reduce nitrogen oxide emissions - NOx  Specially designed exhaust rocker - double rocker arm  Controlled by the engine ECU ·

Notes

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EGR > EGR > I-EGR, Large engine platform Key points

 Internal exhaust Gas Recirculation - I-EGR  Added to the air-fuel mixture  Reduce nitrogen oxide emissions - NOx  High temperature  Peak combustion temperature  Specially designed exhaust rocker - double rocker arm  Exhaust valve lift during the inlet stroke  PWM controlled solenoid Controlled by the engine ECU Working procedure

Go through the text in the student material and also add your own experience/knowledge. Be sure that the participants have understood the main purpose of this information. Ask question to be sure that the participants have understand the main purpose of this information/text. Show the participants the engine parts and explain how they are connected to each other, do not forget to tell them what is happen if they do not understand the basic when they shall e.g. fault tracing.

Trainer notes

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EGR > EGR > I-EGR, Medium engine platform

I-EGR, Medium engine platform  Medium range engines  Construction equipment  Mounted on top

Notes

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EGR > EGR > I-EGR, Medium engine platform Key points

 Medium range engines  Construction equipment  Mounted on top

Working procedure

Go through the text in the student material and also add your own experience/knowledge. Be sure that the participants have understood the main purpose of this information. Ask question to be sure that the participants have understand the main purpose of this information/text. Show the participants the engine parts and explain how they are connected to each other, do not forget to tell them what is happen if they do not understand the basic when they shall e.g. fault tracing

Trainer notes

Page 184 (trainer)

EGR > EGR > I-EGR Function, Medium engine platform

I-EGR Function, Medium engine platform  Inlet rocker arm  Exhaust rocker arm  Slave piston  Control valve  Low-pressure channel  Solenoid valve  From engine lubrication system  High-pressure circuit  Master piston

Notes

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EGR > EGR > I-EGR Function, Medium engine platform Key points

 When the I-EGR is to be turned on/off is controlled by the engine ECU  1. Inlet rocker arm  2. Exhaust rocker arm  3. Slave piston  4. Control valve  5. Low-pressure channel  6. Solenoid valve  7. From engine lubrication system  8. High-pressure circuit  9. Master piston

Working procedure

Go through the text in the student material and also add your own experience/knowledge. Be sure that the participants have understood the main purpose of this information. Ask question to be sure that the participants have understand the main purpose of this information/text. Show the participants the engine parts and explain how they are connected to each other, do not forget to tell them what is happen if they do not understand the basic when they shall e.g. fault tracing

Trainer notes

Page 185 (trainer)

EGR > EGR > Diesel engine fundamentals. Test 11B

Diesel engine fundamentals. Test 11B Put the numbers in the appropriate boxes. EGR valve Rear exhaust pipe EGR cooler Differential pressure sensor Venturi tube EGR temperature sensor EGR pipe Mixing chamber Charge air sensor

Notes

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EGR > EGR > Diesel engine fundamentals. Test 11B Key points  Question  Answer



Introduction to diesel engines. Test 11B Key Put the numbers in the appropriate boxes. 1. EGR valve 2. Rear exhaust pipe 3. EGR cooler 4. Differential pressure sensor 5. Venturi tube 6. EGR temperature sensor 7. EGR pipe 8. Mixing chamber 9. Charge air sensor

Trainer notes

Page 186 (trainer)

SCR > SCR > SCR - Selective Catalytic Reduction

SCR - Selective Catalytic Reduction  SCR (Selective Catalytic Reduction) - catalytic exhaust gas cleaning  Euro 4 - 1 October 2006  Difference between Euro 4 and Euro 3  Nitrogen oxides (NO x) reduced by 30%  Particle emissions reduced 80%  AdBlue  Exhaust gases  Catalytic converter  Nitrous oxides - nitrogen gas and steam  Euro 4 - 3-4% AdBlue  Euro 5 - 4-5% AdBlue

Notes

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SCR > SCR > SCR - Selective Catalytic Reduction Key points  SCR (Selective Catalytic Reduction) - catalytic exhaust gas cleaning  Euro 4 - 1 October 2006  Difference between Euro 4 and Euro 3  Nitrogen oxides (NO x) reduced by 30%  Particle emissions reduced 80%  AdBlue  Exhaust gases  Catalytic converter  Nitrous oxides - nitrogen gas and steam  Euro 4 - 3-4% AdBlue  Euro 5 - 4-5% AdBlue


Trainer notes

Page 187 (trainer)

SCR > SCR > Main components in the Volvo SCR system

Main components in the Volvo SCR system  Urea tank (AdBlue tank)  Pump unit  Dosing unit  Catalytic converter

Notes

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SCR > SCR > Main components in the Volvo SCR system Key points  EU emission  Reductions  Emissions  Particulates (PM)  Nitrous oxides (NOx)


Trainer notes

Page 188 (trainer)

SCR > SCR > Solution principle for the Volvo SCR system

Solution principle for the Volvo SCR system Exhaust gas cleaning in accordance with the SCR technology is a system with only a few components.  Solution principle

Notes

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SCR > SCR > Solution principle for the Volvo SCR system Key points  Main component  SCR system  Urea tank (1)  Pump unit (2)  Dosing unit (3)  Silencer (4)  SCR catalytic converter  Solution principle  Sprayed into the exhaust gases  Atomised form  Before the catalytic converter (5)  Spraying is controlled by the EMS (Engine Management System)  Optimal reduction of emissions  Urea into ammonia and carbon dioxide  Nitrous oxides (NO x) converted into harmless nitrogen gas and steam  200°C


Trainer notes

Page 189 (trainer)

SCR > SCR > Overview of the exhaust gas processing system

Overview of the exhaust gas processing system  Urea tank (AdBlue tank)  Urea tank level sensor  Urea tank temperature sensor  Urea solution pump  Urea solution filter  Urea solution pressure sensor  Urea solution temperature sensor  MID233 control unit, urea dosing system  Filter  Flow direction valve  Cooling control valve  Non-return valve  Dosing unit  Exhaust temperature sensor  Catalytic converter  NOx sensor (only used for OBD - On Board Diagnostics)

Notes

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SCR > SCR > Overview of the exhaust gas processing system Key points  Principles diagram  1. Urea tank (AdBlue tank)  2. Urea tank level sensor  3. Urea tank temperature sensor  4. Urea solution pump  5. Urea solution filter  6. Urea solution pressure sensor  7. Urea solution temperature sensor  8. MID233 control unit, urea dosing system  9. Filter  10. Flow direction valve  11. Cooling control valve  12. Non-return valve  13. Dosing unit  14. Exhaust temperature sensor  15. Catalytic converter  16. NOx sensor (only used for OBD - On Board Diagnostics)  MID128 (EECU - Engine Electronic Control Unit)  Normal operation  10°C  15°C Diesel Oxidation Catalyst, DOC (1) Diesel Particulate Filter, DPF (2) Muffler Stainless steel Carbon monoxide (CO) and Hydrocarbons (HC) Carbon dioxide (CO2) and water Nitrogen oxide (NO) Nitrogen dioxide (NO2) 250 and 450 degrees. Pressure sensor (3) Temperature sensor (4)


Trainer notes

Page 190 (trainer)

SCR > SCR > Diesel engine fundamentals. Test 11C

Diesel engine fundamentals. Test 11C Put the numbers in the appropriate boxes. Urea tank/AdBlue tank Pump unit Dosing/metering unit Catalytic converter Where in the exhaust system is the Adblue sprayed Just before catalytic converter Just before the turbocharger Just before the outlet from the catalytic converter Put the numbers in the appropriate boxes. Urea tank level sensor Urea tank temperature sensor Urea solution pump Urea solution filter Urea solution pressure sensor

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SCR > SCR > Diesel engine fundamentals. Test 11C Key points  Question  Answer



Introduction to diesel engines. Test 11C Key Put the numbers in the appropriate boxes. 1. Urea tank/AdBlue tank 2. Pump unit 3. Dosing/metering unit 4. Catalytic converter Where in the exhaust system is the Adblue sprayed *Just before catalytic converter Just before the turbocharger Just before the outlet from the catalytic converter Put the numbers in the appropriate boxes. 2. Urea tank level sensor 3. Urea tank temperature sensor 4. Urea solution pump 5. Urea solution filter 6. Urea solution pressure sensor 7. Urea solution temperature sensor 8. MID233 control unit, urea dosing system 9. Filter 10. Flow direction valve 11. Cooling control valve 12. Non-return valve 14. Exhaust temperature sensor 16. NOx sensor (only used for OBD - On Board Diagnostics)

Page 191 (trainer)


Urea solution temperature sensor MID233 control unit, urea dosing system Filter Flow direction valve Cooling control valve Non-return valve Exhaust temperature sensor NOx sensor (only used for OBD - On Board Diagnostics)

Notes

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Trainer notes

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CCV > CCV > CCV - CrankCase Ventilation - Closed

CCV - CrankCase Ventilation - Closed  Hose connection  Connector  Turbine  Drive shaft  Discs  Pressure regulator  Diaphragm

Notes

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CCV > CCV > CCV - CrankCase Ventilation - Closed Key points  CCV = Closed Crankcase Ventilation  Hose connection (1)  Connector (2)  Turbine (3)  Drive shaft (4)  Discs (5)  8 000 rpm  Pressure regulator (6)  Diaphragm (7)  Clean gases  Oil and heavier particles  Function


Trainer notes

Page 193 (trainer)

CCV > CCV > Diesel engine fundamentals. Test 11D

Diesel engine fundamentals. Test 11D Put the numbers in the appropriate boxes. Hose connection Connector Turbine Drive shaft Discs Pressure regulator Diaphragm What is CCV stands for? Closed crankcase ventilation Clear combustion valve Cooled crankcase by Volvo What is the maximum revolution for the disc inside the separator? 8 000 rpm 18 000 rpm 6 000 rpm

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CCV > CCV > Diesel engine fundamentals. Test 11D Key points  Question  Answer



Introduction to diesel engines. Test 11D Key Put the numbers in the appropriate boxes. Hose connection (1) Connector (2) Turbine (3) Drive shaft (4) Discs (5) Pressure regulator (6) Diaphragm (7) What is CCV stands for? *Closed crankcase ventilation Clear combustion valve Cooled crankcase by Volvo What is the maximum revolution for the disc inside the separator? *8 000 rpm 18 000 rpm 6 000 rpm Where are the clean gases led after the CCV? *The clean gases are led to the turbocharger inlet side via connector. The clean gases are led to the turbocharger outlet side via connector. The clean gases are led to the inlet side just before air filter.

Trainer notes

Page 194 (trainer)


Where are the clean gases led after the CCV? The clean gases are led to the turbocharger inlet side via connector. The clean gases are led to the turbocharger outlet side via connector. The clean gases are led to the inlet side just before air filter.

Notes

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Trainer notes

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New Generation Volvo Diesel Engine Fundamentals Classroom Training En

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