New Generation Volvo Diesel Engine Fundamentals Classroom Training En
Short Description
Training Material Volvo Diesel Engine Fundamental...
Description
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
Diesel Engine Fundamentals Classroom training
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 Classroom training
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
Diesel Engine Fundamentals Classroom training
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
Diesel Engine Fundamentals Classroom training
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
Diesel Engine Fundamentals Classroom training
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
GT120017A v.1.0.01_en
Page 1
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
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 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
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 5 (trainer)
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
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 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
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 7 (trainer)
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
Page 10
GT120017A v.1.0.01_en
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
GT120017A v.1.0.01_en
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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
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 11 (trainer)
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
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 12 (trainer)
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
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 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
Page 14
GT120017A v.1.0.01_en
General and basic priciples > General and basic principles > Diesel engine - petrol engine
Key points Diesel engine Petrol engine Differences Petrol engine. Electrically generated spark
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 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
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 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
Page 16
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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
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 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
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.
Additional information
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.
Page 18
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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
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.
Additional information
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
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.
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)
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.
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
GT120017A v.1.0.01_en
Page 21
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
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 21 (trainer)
General and basic priciples > General and basic principles > Precombustion indirect-injection engines
Precombustion indirect-injection engines Fuel Pre-chamber Combustion Glowplug
Notes
Page 22
GT120017A v.1.0.01_en
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
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 22 (trainer)
General and basic priciples > General and basic principles > Swirl-chamber engine
Swirl-chamber engine Combustion chamber Swirl-chamber
Notes
GT120017A v.1.0.01_en
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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
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 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
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 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
GT120017A v.1.0.01_en
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
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 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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GT120017A v.1.0.01_en
General and basic priciples > General and basic principles > Diesel engine fundamentals. Test 1
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.
Additional information
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)
General and basic priciples > General and basic principles > Diesel engine fundamentals. Test 1
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
General and basic priciples > General and basic principles > Diesel engine fundamentals. Test 1
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
Page 28
GT120017A v.1.0.01_en
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
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 28 (trainer)
General and basic priciples > General and basic principles > V-engine
V-engine Volvo 8-cylinder engine
Notes
GT120017A v.1.0.01_en
Page 29
General and basic priciples > General and basic principles > V-engine Key points V-engine Forties 400 bhp Military vehicles Truck 120 bhp
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 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
GT120017A v.1.0.01_en
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
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 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
GT120017A v.1.0.01_en
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.
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 31 (trainer)
General and basic priciples > General and basic principles > Cylinder block
Cylinder block Cast in one piece Cast-iron Reinforcement ribs
Notes
Page 32
GT120017A v.1.0.01_en
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
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 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
GT120017A v.1.0.01_en
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
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 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
GT120017A v.1.0.01_en
General and basic priciples > General and basic principles > Camshaft in cylinder block
Key points Location Lifters Pushrods Rocker arms Transmission gears
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 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
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 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
GT120017A v.1.0.01_en
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
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 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
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 37 (trainer)
General and basic priciples > General and basic principles > Diesel engine fundamentals. Test 2
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
General and basic priciples > General and basic principles > Diesel engine fundamentals. Test 2
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.
Additional information
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)
General and basic priciples > General and basic principles > Diesel engine fundamentals. Test 2
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
General and basic priciples > General and basic principles > Diesel engine fundamentals. Test 2
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
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 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
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 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
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 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
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 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
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 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
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 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
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 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
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 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
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 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
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 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
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 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
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 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
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 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
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 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
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 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
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 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
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 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
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 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
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 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
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 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
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 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
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 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
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 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
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 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
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 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
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.
Additional information
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
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 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
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 67 (trainer)
General and basic priciples > General and basic principles > Diesel engine fundamentals. Test 3
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
General and basic priciples > General and basic principles > Diesel engine fundamentals. Test 3
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.
Additional information
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)
General and basic priciples > General and basic principles > Diesel engine fundamentals. Test 3
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
General and basic priciples > General and basic principles > Diesel engine fundamentals. Test 3
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
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 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
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 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
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 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
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 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
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 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
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 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
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 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
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 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"
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 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
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 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
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 80 (trainer)
General and basic priciples > General and basic principles > Diesel engine fundamentals. Test 4
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
General and basic priciples > General and basic principles > Diesel engine fundamentals. Test 4
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.
Additional information
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)
General and basic priciples > General and basic principles > Diesel engine fundamentals. Test 4
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
General and basic priciples > General and basic principles > Diesel engine fundamentals. Test 4
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
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.
Additional information
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
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 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
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 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
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 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
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 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
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.
Additional information
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
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 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
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 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
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 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
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 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
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 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
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 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
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 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)
General and basic priciples > General and basic principles > Diesel engine fundamentals. Test 5
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
General and basic priciples > General and basic principles > Diesel engine fundamentals. Test 5
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.
Additional information
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)
General and basic priciples > General and basic principles > Diesel engine fundamentals. Test 5
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
General and basic priciples > General and basic principles > Diesel engine fundamentals. Test 5
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
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.
Additional information
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
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 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
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 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
Page 102
GT120017A v.1.0.01_en
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
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 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
GT120017A v.1.0.01_en
Page 103
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
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 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
Page 104
GT120017A v.1.0.01_en
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)
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 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
GT120017A v.1.0.01_en
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
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 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
GT120017A v.1.0.01_en
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
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 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
GT120017A v.1.0.01_en
Page 107
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
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 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
Page 108
GT120017A v.1.0.01_en
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
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 108 (trainer)
Lubrication system > Lubrication system > Oil cooler
Oil cooler 10-15% heat 130°C 100°C Common type
Notes
GT120017A v.1.0.01_en
Page 109
Lubrication system > Lubrication system > Oil cooler Key points Oil cooler 10-15% 130°C 100°C Flat oil cooler
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 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
GT120017A v.1.0.01_en
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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Lubrication system > Lubrication system > Diesel engine fundamentals. Test 6
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.
Additional information
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)
Lubrication system > Lubrication system > Diesel engine fundamentals. Test 6
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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Lubrication system > Lubrication system > Diesel engine fundamentals. Test 6
*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
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Lubrication system > Lubrication system > Diesel engine fundamentals. Test 6
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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Lubrication system > Lubrication system > Diesel engine fundamentals. Test 6
*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
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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
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.
Additional information
Her it is time to run the movie “AN INTRO TO DIESEL ENGINE” chapter "Fuel system". This is like a teaser for the participants.
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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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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
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 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
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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
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 116 (trainer)
Fuel system > Fuel system > Supply pump
Supply pump Piston pump Pump camshaft Hand-pump
Notes
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Fuel system > Fuel system > Supply pump Key points Supply pump Specific pressure Piston pump Hand-pump
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 117 (trainer)
Fuel system > Fuel system > Smoke limiter
Smoke limiter Black smoke Legal limits Inlet manifold Turbocharger pressure
Notes
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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
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 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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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
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 119 (trainer)
Fuel system > Fuel system > Pressure pipes
Pressure pipes The pressure pipes - high-pressure leads Steel High pressures Clamps·
Notes
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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
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 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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Fuel system > Fuel system > Injector - copper sleeve Key points Injector Inject Atomised fuel Combustion chamber High pressure Copper sleeve Heat
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.
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
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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
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 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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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
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Fuel system > Fuel system > Diesel engine fundamentals. Test 7B 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.
Additional information
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
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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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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
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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
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 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
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 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
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.
Additional information
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)
Fuel system > Fuel system > Diesel engine fundamentals. Test 7C
Push rods Connecting rods
Notes
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Fuel system > Fuel system > Diesel engine fundamentals. Test 7C
Trainer notes
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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
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 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
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 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
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.
Additional information
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)
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 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
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 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
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.
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
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.
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
Page 138
GT120017A v.1.0.01_en
Engine management system > Engine management system > Diesel engine fundamentals. Test 7A 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.
Additional information
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)
Engine management system > Engine management system > Diesel engine fundamentals. Test 7A
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
GT120017A v.1.0.01_en
Page 139
Engine management system > Engine management system > Diesel engine fundamentals. Test 7A
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
GT120017A v.1.0.01_en
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
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 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
GT120017A v.1.0.01_en
Page 141
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
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 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
GT120017A v.1.0.01_en
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
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 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
GT120017A v.1.0.01_en
Page 143
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
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 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
GT120017A v.1.0.01_en
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
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 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
GT120017A v.1.0.01_en
Page 145
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
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 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
GT120017A v.1.0.01_en
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
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 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
GT120017A v.1.0.01_en
Page 147
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
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 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
GT120017A v.1.0.01_en
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?
GT120017A v.1.0.01_en
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Intake and exhaust system > Intake and exhaust system > Diesel engine fundamentals. Test 8
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.
Additional information
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)
Intake and exhaust system > Intake and exhaust system > Diesel engine fundamentals. Test 8
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
Page 150
GT120017A v.1.0.01_en
Intake and exhaust system > Intake and exhaust system > Diesel engine fundamentals. Test 8
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
Page 152
GT120017A v.1.0.01_en
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)
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 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
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 153 (trainer)
Turbocharger > Turbocharger > Wastegate
Wastegate Engine torque requirements at low engine speeds Temperatures Emissions Boost pressure Bypass Overspeed Pneumatic actuator ·
Notes
Page 154
GT120017A v.1.0.01_en
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
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 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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Page 155
Turbocharger > Turbocharger > Turbocharger system Key points Intake Exhaust Turbocharger Starter element Exhaust pressure governor - EPG Reducing white and blue exhaust smoke
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 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
Page 156
GT120017A v.1.0.01_en
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
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.
Additional information
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)
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 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
Page 158
GT120017A v.1.0.01_en
Turbocharger > Turbocharger > Charge air cooling Key points Charge air cooling Air to air cooling Fluid to air cooling Compressor Turbine Charge air cooler (Intercooler)
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 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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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
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 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.
Page 160
GT120017A v.1.0.01_en
Turbocharger > Turbocharger > Diesel engine fundamentals. Test 9 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.
Additional information
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
GT120017A v.1.0.01_en
Cooling system > Cooling system > Volvo coolant Key points Over heating Circulates the coolant Absorbs heat Radiator Fluid cooled Liquid coolant Glycol Water
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 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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Page 163
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"
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.
Additional information
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
Page 164
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
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 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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Page 165
Cooling system > Cooling system > Thermostat Key points Thermostat regulates Shut. (cold engine) Open. (warm engine)
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 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
GT120017A v.1.0.01_en
Cooling system > Cooling system > Schematic presentation of the cooling system
Key points Schematic Inner circuit Outer circuit
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 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
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 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
GT120017A v.1.0.01_en
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
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.
Additional information
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
GT120017A v.1.0.01_en
Page 169
Cooling system > Cooling system > Cooling fans in bus Key points Electro-hydraulic system Coolant temperature sensor PWM-signal Stepless regulation Rotational speed induction sensor
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 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
GT120017A v.1.0.01_en
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.
GT120017A v.1.0.01_en
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Cooling system > Cooling system > Diesel engine fundamentals. Test 10
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.
Additional information
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
Page 171 (trainer)
Cooling system > Cooling system > Diesel engine fundamentals. Test 10
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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GT120017A v.1.0.01_en
Cooling system > Cooling system > Diesel engine fundamentals. Test 10
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
Page 172 (trainer)
Cooling system > Cooling system > Diesel engine fundamentals. Test 10
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
GT120017A v.1.0.01_en
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Cooling system > Cooling system > Diesel engine fundamentals. Test 10
False Trainer notes
Page 173 (trainer)
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
Page 174
GT120017A v.1.0.01_en
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
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 174 (trainer)
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
Page 175 (trainer)
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
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 176 (trainer)
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..
GT120017A v.1.0.01_en
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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
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 177 (trainer)
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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GT120017A v.1.0.01_en
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
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 178 (trainer)
Emissions > Emissions > Particulate matter
The recommended sulphur content for Euro 5 is 50 ppm, (0,05%).
Notes
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Emissions > Emissions > Particulate matter
Trainer notes
Page 179 (trainer)
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
Page 180
GT120017A v.1.0.01_en
Emissions > Emissions > Diesel engine fundamentals. Test 11A 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.
Additional information
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
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 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
Page 182
GT120017A v.1.0.01_en
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
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 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
Page 183 (trainer)
EGR > EGR > I-EGR, Medium engine platform
I-EGR, Medium engine platform Medium range engines Construction equipment Mounted on top
Notes
Page 184
GT120017A v.1.0.01_en
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
Page 186
GT120017A v.1.0.01_en
EGR > EGR > Diesel engine fundamentals. Test 11B 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.
Additional information
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
GT120017A v.1.0.01_en
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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
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 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
Page 188
GT120017A v.1.0.01_en
SCR > SCR > Main components in the Volvo SCR system Key points EU emission Reductions Emissions Particulates (PM) Nitrous oxides (NOx)
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 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
GT120017A v.1.0.01_en
Page 189
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
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 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
Page 190
GT120017A v.1.0.01_en
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)
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 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
GT120017A v.1.0.01_en
Page 191
SCR > SCR > Diesel engine fundamentals. Test 11C 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.
Additional information
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)
SCR > SCR > Diesel engine fundamentals. Test 11C
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
Page 192
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SCR > SCR > Diesel engine fundamentals. Test 11C
Trainer notes
Page 192 (trainer)
CCV > CCV > CCV - CrankCase Ventilation - Closed
CCV - CrankCase Ventilation - Closed Hose connection Connector Turbine Drive shaft Discs Pressure regulator Diaphragm
Notes
GT120017A v.1.0.01_en
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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
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 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
Page 194
GT120017A v.1.0.01_en
CCV > CCV > Diesel engine fundamentals. Test 11D 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.
Additional information
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)
CCV > CCV > Diesel engine fundamentals. Test 11D
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
GT120017A v.1.0.01_en
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CCV > CCV > Diesel engine fundamentals. Test 11D
Trainer notes
Page 195 (trainer)
GT120017A v.1.0.01_en
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