Module 5: 3512 Details
Engine Data
Relate 3512 to previous sections
3512 Data
Firing order (injection sequence)
Engine SAE standard rotation SAE opposite rotation
3508 1-2-7-3-4-5-6-8 1-8-7-2-6-5-4-3
3512 1-12-9-4-5-8-11-2-3-10-7-8 1-4-9-6-5-2-11-10-3-6-7-12
3516 1-2-5-6-3-49-10-15-16-11-12-13- 1-6-5-4-3-10-9-16-15-12-11-14-13-
14-7-8 8-7-2
SPECIFICATIONS ENGINE
3508 3512 3516
Number and arrangement of 600 V - 8 600 V - 12 600 V - 16
cylinders
Valves per cylinder 4 4 4
Displacement 34.5L 51.8L 69.1L
Bore 170mm
Stroke 190mm
Compression ratio 13 : 1
Type of combustion Direct injection
Valve setting Intake 0.38mm
Exhaust 0.76mm
The Fuel System Components
Fuel transfer pump is located on the right side of the engine.
At the lower shaft of the engine oil pump drives the gear type
transfer pump.
Fuel from the supply tank is pulled through a primary fuel filter by
the transfer pump and sent to the fuel filter housing .
The transfer pump has a check valve and a by-pass valve
The check valve prevents fuel flow back through the transfer pump
when priming pump is used
The by-pass valve limits the maximum pressure of the fuel. It will
open the outlet side of the pump to the pump inlet if the pressure
goes up to 860 pa (125 psi ). This prevents damage to the fuel
system caused by too much pressure.
Fuel flow
Fuel system
The injector delivers the fuel used for combustion into the
combustion chamber.
Excess fuel passes through the return lines to the tank.
The transfer pump pushes fuel to the fuel filter housing and to the
fuel manifold
The fuel manifolds has two sections. The flow through the top
section to the inlet fuel line connected to the right of the cylinder
head
Approximately 41/2 times as much a fuel as needed for normal
combustion flows through the chamber to a drilled passage in the
left side of the cylinder head
This passage is connected by outlet fuel lines to the bottom section
of the fuel manifold. This constant flow of fuel around the injectors
helps to cool them .The fuel flows back through the bottom section
of each fuel manifold and back to the tank
1. Injector
2. Control shaft left side
[Link]
[Link] rod
[Link]
[Link]
7. Governor shaft
[Link] shaft right
[Link]
Fuel Injection Control linkage
The position of rack controls the amount of fuel
injected into the cylinder. Pull the rack out for more
fuel, push it in for less fuel .
The rack position is changed by the bell crank, the bell
crank is moved by the control rod 4)
Each control rod on the right side of the engine is
connected by a lever6) to control the shaft 8)
When the rotation of the governor shaft 7) is
clockwise, as seen from in front of the engine
The action of the governor linkage moves control shaft
8) clockwise this is the fuel increase direction.
The linkage between the injectors on the left side of
the engine and control shaft 2) is similar to the linkage
on the right side.
Fuel Injector operation
1. Screw
2. Rocker arm
3. Clamp
4 Control rod
5. Rack
6 Plunger
[Link] assembly
8. Camshaft
Injection Cycle On Cat.3512
When the plunger is at the top of its stroke, fuel flows from the fuel supply
chamber, around the injector and through both the lower and the upper part
of the barrel.
As plunger is moved down by rocker arm
Fuel is pushed into the supply chamber through the lower port.
The fuel can now go up through a passage in the center of the plunger and
out through the upper port of the barrel
As the lower port is closed by the end of the plunger 6) fuel can still flow
through the upper port until it is closed by the upper scroll on the plunger
At this point injection starts and the effective stroke begins.
During the effective stroke, fuel is injected into the cylinder until the
downward movement of plunger 6) causes the lower scroll to open the lower
port and release the fuel pressure.
Fuel goes through the center passage of plunger 6) and the lower port
during the remainder of the down stroke .
After Cooler
Cooler pressurized air supplied to the engine
results in a more thermally efficient engine (better fuel economy
engine, or the ability of the engine to increase its power)
Since the combustion process starts at a lower temperature,
both peak temperature and peak pressures are reduced
This results in an increase in engine power output without
increasing the thermal and mechanical loads on the engine
The after-cooler is located at the center of the vee and has
coolant charge core assembly.
Coolant from water pump flows through the core assembly and
back out of the aftercooler rear of the cylinder block.
After Cooler
Air inlet from the compressor side of the turbocharger
flows into the aftercooler
This air passes through the fins of the core assembly,
which lowers the temperature. The cooler air goes out of
the bottom of the aftercooler
Into the air chamber, and then up through the elbows to
the inlet valves though the cylinder head.
One drain plug is located between the No1 and No 3
cylinder heads and another plug is located between the
last two cylinder heads on the left side of the engine.
These plugs can be used to check for coolant level in the
aftercooler
3512 Inlet and Exhaust
There is a separate turbocharger and exhaust
manifold on each side of the engine .
A common after-cooler is located between the
cylinder heads in the center of the engine .
Two camshafts, one in each side of the block,
control the movement of the valve system
components
Clean inlet air from the air cleaners is pulled
through by the compressor wheel .
The rotation of the compressor wheel causes
compression of the air and forces it through the
tube to after-cooler.
3512 Inlet and Exhaust
The after cooler lowers the temperature of the compressed
air before it goes into the inlet chambers in each cylinder.
There are two intake and two exhaust valves for each
cylinder.
When the piston is near the top of compression stroke, fuel
is injected into the cylinder .The fuel mixes with the air and
combustion starts.
The exhaust gases from the exhaust manifold go into the
turbine side of the turbocharger and cause turbine wheel to
turn. The turbine wheel is connected to the shaft that drives
the compressor wheel.
The exhaust gases then go out of the exhaust outlet
through the exhaust elbow.
Lubrication system
Lubrication system
This system uses gear pump driven by the front gear train
oil is pulled from the pan through suction bell by the oil pump
The suction bell has a screen to clean the oil.
The oil pump pushes oil through oil cooler and the oil filter to oil
galleries in the block.
The fin and tube type oil cooler lowers the temperature of the oil
before the oil is sent onto the filters.
A bypass valve lets oil flow directly to the filters if the oil becomes
thick enough to increase the oil pressure differential by an amount
of ( 26 psi )
Cartridge type filters are located in oil filter housing at the front of the
engine
A single bypass valve is located in the oil filter housing
Clean oil from the filters goes into the block
Part of the oil goes to the camshaft oil gallery
Lubrication system
The camshaft oil galleries are connected to each camshaft bearing by
drilled holes.
The oil goes around each camshaft journal through the cylinder head
and rocker arm housing to the rocker arm shaft
The Main gallery is connected to the main bearings by drilled holes.
Drilled holes in the crankshaft connect the main bearing oil supply to the
rod bearings
Sequence valvest let oil from main oil gallery go to the piston cooling jet
oil galleries
The sequence valve opens at 20 psi. The sequence valve will not let oil
into the piston cooling jet oil galleries until there is pressure in the main
oil galleries.
This decreases the amount of time necessary. For pressure build up
when the engine is started
It also helps hold pressure at idle speed.
Lubrication system
There is a piston cooling jet below each piston. Each cooling jet has
two openings. one opening is directed at a passage in the bottom of
the piston.
This passage takes oil to a manifold behind the ring band of the
piston. A slot is in the side of both piston pin bores and connects
them with the manifold behind the ring band
The other opening is directed at the center of the piston. This helps
cool the piston and gives lubrication to the piston pin.
Line 6 send oil to the turbocharger
The turbocharger drain lines is connected to the flywheel housing on
each side of the engine. Oil sent to the front and rear gear groups
through drilled passages in the front and rear housing and cylinder
block faces.
Cooling system
Coolant goes through the radiator or heat exchanger
The coolant flow is divided at the outlet of the water pump
Part of the coolant flow is sent to the after-cooler, while most of the coolant
is sent through the oil cooler
Coolant sent to the aftercooler goes through the core, and is then sent
through an elbow into a passage in the block near the center of the vee at
the rear of the block
The coolant sent to the oil cooler goes through the oil cooler and flows into
the water jacket of the block at the right rear cylinder
The aftercooler coolant mixes with the hotter coolant and goes to both side
of the block at the right rear cylinder.
The coolant flows up through the water jackets and around the cylinder
liners from the bottom to the top. Near the top of the cylinder liners, where
the temperature is the hottest, the water jacket is made smaller
The smaller area causes the coolant to flow faster for better liner cooling..
Cooling system
Coolant from the top of the liners goes into the cylinder head, which sends
the coolant around the parts where the temperature is the hottest.
Coolants then goes to the top of the cylinder head and out through an
elbow, one at each cylinder head, into water manifolds at each bank of the
cylinders.
Coolant goes through the manifolds to the temperature regulator housing.
Regulator housing has an upper and lower flow section, and uses four
temperature regulators. The sensing bulbs of the four regulators are in the
coolant in the lower section of the housing. Before the regulators open, cold
coolant is sent through the lower section of the housing and through the
bye-pass line back to the inlet of the water pump
As the temperature of the coolant increases enough to make the regulators
start to open, coolant flow in the bypass line is stopped and coolant sent
through the outlets to the radiator or heat exchanger. Total system coolants
capacity will depend on the size of the heat exchanger.
Engine construction
The cylinders in the left side of the block make an angle of 60 0 with
the cylinders in the right side of the block
The main bearing caps are fastened to the block with four bolts per
cap
The cylinder liners can be removed for replacement
The top surface of the block is the seat for the cylinder liner flange.
A filler band goes under the liner flange and makes a seal between
the top of the liner and the cylinder block.
The engine has a separate cylinder head for each cylinder
Four valves (two intake and two exhaust) controlled by a push rod
valve system are used for each cylinder
The opening for the fuel injector is located between the four valves.
A third lobe on the camshaft moves the push rod system that
operates the fuel injector
Fuel is injected directly into the cylinder.
Pistons, Rings, and con rods
The aluminum pistons have an iron band for the top two rings, this
helps reduce wear on the compression ring grooves.
A chamber is cast into the piston just behind the top grooves.
Oil from the piston cooling jets flows through this chamber to cool
the piston and improves ring life.
The pistons have three rings, two compression rings and one oil
ring. All the rings are located above the piston pin bore. The oil ring
is a standard (conventional) type .Oil returns to the crankcase
through the holes in the oil ring grooves.
The connecting rod has a taper on the pin bore end. This gives the
rod and piston more strength in the areas with the most load. For
bolts set at a small angle hold the rod cap to the rod. This design
keeps the rod cap to the rod. This design keeps the rod width to a
minimum, so that a larger rod bearing can be used and the rod can
still be removed through the liner.
Camshaft
The engine has a camshaft or camshaft group for each side of
the engine, driven at the rear of the engine.
Seven bearings for 3512 support each camshaft or camshaft
group.
The 3512 uses two camshafts per side doweled and bolted
together to make a camshaft group
As the camshaft turns; each lobe moves a lifter assembly.
There are three lifter assemblies for each cylinder. Each
outside lifter assembly moves a push rod that operates the fuel
injector .
The camshaft must be in time with the crankshaft. The relation
of the cam lobes to the crankshaft position cause the valves
and fuel injectors in each cylinder to operate at the correct time.