TOPIC 1

Components of Diesel Engine

INTRODUCTION

Image 1
Caterpillar develops and manufactures four-stroke diesel engines for
to meet the needs of Caterpillar machinery and to fulfill
equipment needs made by other manufacturers.

In order to perform diagnosis, repairs, and maintenance effectively, then

a complete and comprehensive understanding of the working principles and
construction engine diesel.

The Caterpillar 3406 engine is used as an example in this learning.

(Image 1). Functions and names of engine components used by Caterpillar
Basically the same as that used by other manufacturing plants.

Engine 3406 is a diesel engine for heavy-duty tasks, which has 6 cylinders.
inline. This engine has a cylinder diameter (bore) of 162.56 mm
(5.4 inch), stroke length 165.1 mm (6.5 inch) and cylinder volume
(displacement) 14,633 cc (893 [Link].).

This type of engine is used in on-highway trucks, in Caterpillar products.

others, such as Genset and Marine.
CYLINDER BLOCK AND COMPONENTS
Cylinder Block

Image 2
The block is one of the main components of the diesel engine as a place
generate power. This component must have strength and durability.
high, because the results of force, pressure, and heat from the combustion process are transferred
engine block. To achieve high strength, the block is cast with
precision using mixed materials.

Image 3

The engine block (Image 3) has two types, namely:

1. In-line engine, where the arrangement of the cylinders is in a row.
2. V-engine, has two cylinder banks, uses one crankshaft.
at the bottom and the block is in the shape of the letter V.
 Image 4
Blocks are usually made of cast iron, where there are holes inside.
for the cooling water channel (1) and the lubricant oil channel (2).

Cylinder Liner

Image 5

The cylinder liner is made from a cast mixture of iron, steel, and molybdenum for
experiencing high stiffness. The inner surface of each liner
hardened through induction, then honed in a cross-hatch form
hatched) to assist with oil regulation.

The O-ring is used to seal the bottom part of the liner with the water chamber.
The liner block cooler is used as a partition.
This rigid and hard engine block allows for a tight seal.
sit to provide a good barrier.

The function of the liner is as a house and guide for the movement of the piston, forming
combustion chamber and absorbs heat. The liner also has one that directly integrates with
block, referred to as parent bore, Figure 5(1), and which can be assembled and disassembled.
(removable cylinder liner), Figure 5(2).

Image 6

The cylinder liner forms the water jacket wall between the coolant and the piston.
Image 6.

Image 7

Wet liner has a ring to seal the water jacket and prevent leaks.
cooling air (Figure 7, left). Dry lining is used for repairs
engine parent bore, the bilacylinder is damaged or worn out. This liner
tightened (dry) because it is directly attached to the block (Figure 7, right).
Piston

Image 8
The piston (Figure 8) functions to transfer the force generated by combustion, made from
several components, namely:

1. Crown, which forms the combustion chamber

2. The ring groove and its (land) as the piston ring holder
3. Piston pin or gudgeon pin bore as a connection between the piston and
connecting rod
4. Retaining ring, to keep the piston pin always in the pin bore.
5. Thrust skirt as a side load supporter

In the piston section (Figure 9) and beneath the crown, there is a cavity (1) and
On some pistons, there are oil holes at the bottom of the piston crown.

Image 9
The piston has several constructions:

Image 10
1. Cast aluminum crown with iron band for compression ring and
forged aluminum skirt welded using electron beam.
[Link], dimanasteel crowndanaluminium skirtdiikat menjadi satu
using a bolt.

Image 11
3. Two-pieces articulated, consisting of a combination forged steel crown with a pin
bored and bushing cast aluminum separate skirt, combined together
same by wrist pin (Image 11).
4. Cast aluminum single piston with iron band for piston ring seat.
This model is the most common model (Figure 10, left).

The piston is installed in each cylinder liner and moves up and down during engine operation.
working. The top part of the piston functions as the base surface of the space
burning.

The piston functions as:

 • Transferring the energy from combustion to the connecting rod and subsequently
kecrankshaft
• Blocking the combustion space
• Transferring/absorbing heat from the combustion chamber and transferring it to
the cylinder liner is then moved to the cooling water.

Image 12
Figure 12 shows 2 types of pistons:

1. Cylinder head using a pre-combustion chamber, using

the piston has a heat plug on its crown (the right side piston)
2. Piston direct injection does not have a heat plug

The piston is an important component for design, lifespan and

overall engine performance.

Ring Piston

Image 13
The piston set has two or more piston rings located in the piston groove.
The piston ring has 3 main functions:
 • Blocking the combustion chamber
• Setting up lubrication for the cylinder wall
• Cooling the piston by transferring the heat generated to
burning time.

There are two types of piston rings (Figure 13, left):

• Compression ring (1) functions to seal the part

under the combustion space by preventing any gas from
leak through the piston.
• Oil ring(2) that functions to control the oil film on the wall.
The cylinder piston moves up and down to minimize wear.
piston ring, oil control ring has an expander spring
helping to arrange the film (Image 13, right).

The cylinder has a hard layer to be durable. Every piston ring

having a gap between the two ends. To prevent leaks,
The gap placement at the end of each ring must not be arranged in a line (Figure
14, left).

Image 14
The 3 piston rings in the 3406 engine are made of aluminum.
alloy casting with cast-in nickel for compression ring. This layer
functions to enhance groove strength and resistance to
keausan (Figure 14, right).

The piston rings are designed to provide perfect compression and

oil setting while reducing friction and the heat generated. The result,
the increasing age of piston, rings, and liners while reducing maintenance costs
before overhaul.
The ring piston is made from ductile iron, ensuring its strength and durability are maintained.
The oil intermediate ring is chrome-plated, while the top ring is coated with
plasma. Both types of layers provide resistance to wear and
a very good scuff.

Connecting Rod

Image 15
The connecting rod (Figure 15) connects the piston to the crankshaft and
transferring the combustion force to the crankshaft.

The parts of the connecting rod consist of:

1. Rod eye, gudgeon-end as a pin bushing holder

2. Piston pin bushing. The bushing is a type of bearing that is ...
distribute the load and can be replaced when worn.
The shank is the part of the connecting rod between the small and big end, shaped like an I.
beam strong and stiff.
4. The crankshaft journal bored is located at the big end.
connecting rod. This component wraps around the crankshaft bearing journal
and connecting the connecting rod to the crankshaft.
5. The bolt nut of the rod connecting the crankshaft is called the crank end.
Connecting rod.
6. Big-end bearing connecting rod is located at the crank-end. Crankshaft
rotating in the bearing of the connecting rod, which carries the load.
The connecting rod transfers the force from combustion to the crankshaft.
change the up and down motion into rotational movement.

The connecting rod is a forged iron that has been hardened and shot peened.
removing voltage. The end is designed to be tapered to provide additional
the field of contact between the hearing aid and the input power. This produces
extra strength and durability of the piston and rod assembly.
Bearing Connecting Rod

Image 16
The upper part of the connecting rod bearing is installed on the connecting rod and is called
upper half shell. The other half is attached to the cap and is called lower
half shell. Normal upper half shell can withstand greater loads. Locating lug
is an inseparable part of the bearing shell and is used
to ensure the bearing sits correctly on the connecting rod to the cap.

Crankshaft 3406

Image 17

The crankshaft is made of carbon steel forging.

hardened.

Big end connecting rod rotates the crankshaft (Image 17), which is located
at the bottom of the engine block. The crankshaft transfers rotational motion to
flywheel and others (clutch, transmission and others) and provide power
suitable for work.
The parts of the crankshaft consist of:
Connecting rod bearing journal
2. Counterweight
3. Main bearing journal
4. Web

The crankshaft of a line engine typically has one connecting rod.

bearing journal for each cylinder, while in the V-engine for each
connecting rod bearing journal handling two cylinders.

Image 18

Connecting rod bearing journal determines the position of the piston and when the piston
is at the top dead center position

Some connecting rod bearing journals have a lightening hole

lighter) to reduce weight and assist crankshaft balance
(Image 18).

The crankshaft has oil holes to flow oil from the main bearing journal.
towards connecting rod journal bearing. These channels are closed at some
one end uses a cup plug with a screw (Figure 18).

Counterweights are used to help balance the crankshaft and

reducing vibration when the engine is running. Counterweights can be
one with the crankshaft or separate and fastened with bolts with
crankshaft.

The main bearing supports the crankshaft in the block and is aligned with each other.
the others.
Thrust Bearing Surface

Image 19

The surface main thrust bearing (Figure 19) is located on one of the main bearings.
The [Link] crankshaft has side main bearing journal.
a wide surface that limits the forward and backward movement of the crankshaft,
referred to as play.

Shell Main Bearing

Image 20

There are two parts on each main bearing called the shell (Figure 20).
The lower shell is installed on the bearing cap and the upper shell.
mounted on the bearing bore of the block. The upper part of the shell has
holes and oil grooves so that oil flows continuously to the bearing journal.
Some diesel engine manufacturers harden the crankshafts by induction only.
on journal and fillet. This process can result in increased stress.
in the area between the hardened and the non-hardened. Caterpillar
hardening the entire surface of the crankshaft, so that it can
improving the lifespan and strength of the crankshaft. With the hardening process
By being comprehensive, the possibility of the crankshaft cracking can be reduced.

Vibration Damper
The vibration damper is a component that eliminates torsional vibrations.
torsional vibration caused by variations in force (usually from around 3
up to 10 tons (2,724 to 9,080 kg) at the piston and after the crank. Torsional
vibration is a rhythmic force that occurs between two
The steps of the force. The disappearing and reappearing of the force on the crankshaft causes the crankshaft

alternately pivoting. If the measurement is not conducted to prevent this.

This, the sound will be rough and the crankshaft will break.

The viscous rubber vibration damper is installed at the front.

Crankshaft. Considering that torsional vibrations vary in each engine design,
The vibration damper is made to match the characteristics of each engine.

Image 21

On the front part of the 3406E engine crankshaft, we will find vibration.
dampers that control torsional vibrations on the crankshaft. This is a
miniature flywheel that is pressed or bolted to the front part
crankshaft
There are two types of vibration dampers:

1. Rubber damper (Figure 21, left) uses rubber to absorb

vibration
2. Viscous damper (Figure 21, right) uses heavy oil and free-
floating steel ring to absorb vibration.
 Image 22
Rubber dampers are made of inner iron-alloy steel flanges that have a seat.
danouter cast-iron weight assembly(inertial mass). The inner flange is tied.
with the outer weights using a rubber mixture (Figure 22).

Image 23

The viscous damper has two housings. Inertial mass and

A type of fluid similar to grease is found in both housings that are welded together. Width
The gap between the housing and the weight is approximately 0.010 in (0.25 mm). This gap is...
filled with viscous fluid (Figure 23). Viscous damper
must be handled with care. If dented, it must be replaced.
Flywheel Assembly

Image 24
Flywheel (Figure 24) consists of

Flywheel
2. Ring gear, which is located around the flywheel and is used to
start engine
Flywheel housing

This component is a connector between the engine and the load. The flywheel is tied.
on the back of the crankshaft. The crankshaft rotates the flywheel at the stroke
the energy and momentum in the flywheel make the crankshaft rotate with
smooth during the occurrence of 3 other steps in each cylinder in the engine
many cylinders.

The flywheel functions to:

1. Storing energy for momentum between power steps.

2. Minimizing torsional vibrations in the crankshaft
3. Transferring power to the machine, torque converter, load or equipment
other transmission.
Camshaft

Image 25

The camshaft is made of a special alloy steel that is forged and hardened for reliability.
and durable. The camshaft gear is heated and pressed during
its installation. The entire camshaft has a bearing journal and lobe for each
or a pair of valves and fuel injectors.

The camshaft regulates the process of opening and closing the intake and exhaust valves.
some applications also control the fuel injector. This component is called the camshaft
the cam lobe is egg-shaped or cam. When the camshaft rotates, the cam will
moving up and down, pressing the follower and valve train components for
opening and closing the engine valve. At the time above, the valve will open
full.

Image 26

On each lobster there is (Figure 26):

Base circle
 2. Ramp
Nose

The distance between the base diameter of the circle and the top part of the nose is called the lift.

determining how far the valve opens.

Image 27
The shape determines how quickly the valve opens or closes and
The shape determines how long the valve lasts in the open position.
(Image 27).

Fast opening
2. Long open period
Fast close
4. Slow close
Pushrod and Valve Lifter

Image 28
The valve train components as seen in Figure 28 consist of:
 Camshaft lobe
2. Valve lifter or cam follower
3. Pushrod
4. Rocker arm

The push rod (3) is a steel tube or rod with a seat on

Both ends. The valve lifter or cam follower (2) is situated on each cam lobe (1).
When the camshaft rotates, the lifter follows the shape of the cam. Valve lifter
moving the camshaft movement to the push rod (3) that previously moved the movement
the rocker arm (4) to open and close the valve.

Image 29
There are two types of follower cams, namely:

• Roller follower (Figure 29, left), with a hardened roller and

rolling on the camshaft lobe
• Slipper follower (Figure 29, right), which has a wear face that
touching with the lobe
Engine Component Location

Image 30
At the front of the engine 3406B (Figure 30) there is:

• Water compressor cover

• Penultimate timing advance
• Vibration damper
• Pompacoolant (cooling air)

Image 31

On the right side of the engine 3406B (Figure 31) viewed from back to front.
engine, there is:
 • Turbocharger
• Exhaust manifold
• Oil filter
• Oil cooler
• Breather duct assembly

Image 32
On the left side (Figure 32) there is:
• Location of the air compressor seat
• Fuel injection channel
• Hand priming pump
• Locomotive starter motor
• Fuel filter
• Fuel transfer pump
• Fuel injection pump

Depending on the application, the engine can be equipped with a fuel filter and
priming pump at different locations.

Oil Cooler Transmission

 Image 33

If necessary, the transmission oil cooler (Figure 33) is installed on the right side.
engine. This component is used in machine applications and functions
maintaining the transmission temperature within the permitted limits

Cylinder Head Assembly

Image 34
The cylinder head is also designed with a structure that has strength and
high rigidity. The cylinder head passed the deep thermal cycle shock test.
research to ensure its durability. Thus resulting in the cylinder head that
has resistance to cracking.

The spacer plate made of aluminum or steel is used between the cylinders.
head and block to reduce the depth of the counterbore on the cylinder block.

Counterboring will reduce the structural integrity of the block and

easy to crack. In the old model, a counter bore is needed for adjustment.
and supporting the line.

The cylinder head assembly (Figure 34) consists of:

Cylinder head
2. Valve cover
3. Bridge
4. Valve spring assembly
5. Valve guide
6. Valve seat insert
7. Valve
8. Rocker arm

Cylinder Head

Image 35
The cylinder head (Figure 35, left) is a separate casting that partitions
the upper part of the engine block where there are valves, injectors or pre-combustion
chamber (when used), also water channels, train valve and system components
fuel.
Depending on the design, the cylinder head can be in the form of a single casting.
single), or consisting of several molds that cover a single cylinder or
more.

Cylinder head (1) (Figure 35, right) and engine block attached with gasket
(2), spacer plate (3).

Valve Cover

Image 36
The valve cover is installed on the valve cover base which is attached to the cylinder head.
head. Some engines have more than one cover. Valve train components
located under the valve cover.

Rocker Arm

Image 37
The rocker arm (Figure 37) consists of:
 [Link] screw for setting valve lash, which is the gap
Antararocker armdanvalve bridge to ensure the valve can
closing perfectly. This adjustment is one of
the most critical tuning on the valve train.
2. Lock nut, to secure the screw in position after adjustment.
done
3. Wear seat, insert that is hardened for durability.
4. Rocker shaft bushing that functions as a bearing between the rocker arm.
danshaft

These components connect the camshaft or valve train.

with valves and converting the rotary motion of the camshaft into a vertical motion
padavalve. The arm of the rocker pushes up at one end, the other end will
pushed down, pushing and opening the valve.

Image 38
Bridge (Image 38, left) consists of:

[Link] seat, the area where the rocker arm presses the bridge
2. Bridge adjusting screw (screw to adjust bridge) as compensation
for height differences of the valve stem
[Link] nut to set bridge adjusting screw
4. Bore as a guide for the pinataubridge dowel (Figure 38, right) which
installed on the cylinder head.
Valve

Image 39
Each valve (Figure 39) contains:

1. Keeper groove (alu keeper), dimana keeper (often referred to as collet)

holding valve stem in spring
Valve stem, which moves on the valve guide
3. Valve fillet, connecting the head to the stem
4. The valve sealing face has a hardened surface for
reducing wear and sealing the combustion chamber.
5. Valve head

The valve (Figure 39) regulates the flow of air and exhaust gases from the combustion chamber.
When the intake valve opens, air enters the combustion chamber and when the exhaust valve
opening, exhaust gases exit the combustion chamber.

The exhaust and intake valves in most diesel engines are made from anti-material.
from agar durable. There are three materials used in the exhaust valve. Stem
made from hardened stainless steel. A special metal mixture is used.
for the head to withstand high temperatures and the sealing face made of hard
facing alloy (a mixture with a hardened surface). Headdanstempada
The intake valve is made of stainless steel and hardened to be resistant to
wear and tear.
Valve Spring Assembly

Image 40

The valve spring (Figure 40) keeps the valve closed again.
This component is mounted on top of the valve and is held by a keeper (or collet) (1) and
retainer(2) or rotator. Valve spring is installed on top of the valve stem. Retainer or
The rotary motion keeps the valve grooved and serves as a seat for the valve.
spring presses and closes the valve.

Image 41
Each valve has a rotator (Figure 41), which will rotate the valve around 3.o
relative to the valve seat insert each valve works. This is for
ensuring even wear and prolonging the lifespan of the valve
help prevent valve burning.
Valve Seat Insert

Image 42
If a perfect combustion chamber seal is achieved, at each valve
it has a seat insert (Figure 42), located on the cylinder head. When closed,
The valve head touches the valve seat insert.

Valve seat inserts can be replaced when worn or damaged. The seat insert is made of material.
made from a mixture of stainless steel and seat insert for exhaust
made from nickel.

Valve Guide

Image 43
The valve moves up and down within the valve guide (Figure 43) that is located
inside the cylinder head. The valve guide keeps the valve movement straight and
helps absorb heat from the valve. The valve stem extends out of the guide.
at the top part of the cylinder head.

Valve, valve seat insert, and valve guide experience the most wear because
high combustion temperature and pressure.

All of these components can be replaced.

Valve Train Design

Different engine models have different valve train designs.

1. Push rod engine (Image 44), uses camshaft, valve lifter, push
roddanrocker arm

Image 44

2. Overhead cam engine (Image 45) has a camshaft (1) on the cylinder
The valve lifter (2) is directly connected to the top of the valve stem.
When the cam lobe rotates, the lifter follows the movement and opens the valve.
When the camshaft moves, the valve spring (3) will close the valve.
 Image 45

3. Cam in head engine (Image 46), where the rocker arm moves on the lobe.
The camshaft rotates, the rocker presses, and opens the valve.

Image 46
Fuel Injection Nozzle

Image 47

The fuel nozzle (Image 47, left) is also located at the head between the valves.
(Image 47, right). This component is held in place using
sleeve, washer, adapter and retainer. Injection nozzle can be replaced in the field.
The six holes at the nozzle tip will vaporize the pressurized fuel.
There is a combustion chamber height to achieve perfect and efficient combustion.

Gear Train Assembly

Image 48

The gear train (Figure 48) can consist of:

Crankshaft gear
2. Idler gear
Camshaft gear
Fuel injection pump gear
 5. Oil pump gear
Water pump gear
7. Air compressor gear

Image 49

The gear train assembly (Figure 49) is a series of gears that...

transferring power from the crankshaft to other main engine components.

The gear train can be located at the front or the back of the engine.

The gear train shown in the image above is located at the front of the engine.
between backing plate and timing gear housing.

The gear train functions to synchronize all components related to

combustion in the engine (crankshaft, camshaft, and fuel injection pump) so that
all these components can work simultaneously at each step of the cycle
burning.
Timing Mark

Picture 50

The timing mark (Image 50) is used to align the gears and assist.
ensuring the valve and injection timing is accurate.

Crankshaft Gear

Image 51

The crankshaft gear (Figure 51) is installed on the crankshaft and serves as a driver.
for other gears.
Idler Gear

Image 52

The idler gear (Figure 52) is a gear cluster designed with

the comparison of gears that causes the crankshaft to rotate half of
the speed of the crankshaft. The cluster gear has two gears installed
to become one in a smaller dimension (hidden behind the gear)
the larger one in this image) is linked and moves the camshaft gear.

Camshaft Gear

Image 53

Camshaft gear (Figure 53) is connected to the idler gear and rotates half.
from the crankshaft rotation speed to ensure the intake and exhaust valve
open and close at the right time, for example once every round
enginepadaengine4-steps.
Fuel Injection Pump Gear

Image 54

Camshaft gear drives the fuel injection pump gear (Figure 54). Considering
both have the same size, both rotate at the same speed. Fuel injection
pump gearmemutarkanfuel pump camshaft, which drives the components-
fuel system components to deliver fuel to the cylinder
pada waktu yang tepat.

Balance Gear

Image 55

Some engines are equipped with a balance shaft.

driven by the camshaft through the oil pump gear and idler gear (Image 55)

In the image above, there is a balance shaft on each side of the engine for
eliminating excessive crankshaft vibration.
Oil Pump Gear

Image 56

The oil pump gear (Figure 2.56) is driven by the crankshaft gear. Oil pump
flowing oil to all parts of the engine that require oil.

Water Pump Gear

Image 57

The water pump gear (Figure 57) is usually driven and rotates with
the same speed as the crankshaft. The water pump circulates the coolant.
to all parts of the engine that require cooling.
Air Compressor Gear

Image 58

In some engines, air compressors are used to obtain air.

pressure for the brakes and other components. The air compressor is driven by
The idler gear rotates at a speed according to the manufacturer's recommendation.
(Image 58).

Pulley Assembly

Image 59

The pulley assembly (Figure 59) is installed on the crankshaft and drives.
components such as fans and alternators.
Timing Gear Housing

Image 60

The timing gear housing (Figure 60) protects all the timing gears in the engine.
and blocking the front of the engine block.