CAT Diesel Engines Basics

SSKARROUM
Service Training
MALAGA
CAT Diesel Engines
Thorben
November 1997
SSKARROUM CAT DIESEL ENGINES
CHAPTER : Introduction
Caterpillar produces engines for various applications:
EPG
MARINE
INDUSTRIAL
CAPTIVE
The engines are divided in three categories:
Small engines (3000 - 3300)
Medium engines (3400 - 3500)
Large engines (3600 - MAK)
Page: 2
Caterpillar engines can be divided in two types:
IN-LINE ENGINES
ES
VE
IN
E
G
-
EN
Those two types of engines are running on two different

types of fuel:
GAS DIESEL
Page: 3
If you know one, you know them all !
The difference from one engine to another is the fuel

system.
All other systems (cooling , lubrication , air) are fitted to

the different fuel systems.
The fuel system is the heart of an engine. It gives the

engine its power.
Page: 4
CHAPTER : Engine systems
AIR INTAKE & EXHAUST
LUBRICATION
OIL
COOLING
FUEL
Page: 5
Air intake & exhaust
Page: 6
CHAPTER : Air intake systems
Natural Aspirated Turbocharged
Turbocharged Turbocharged Aftercooled
JWAC
Page: 7
CHAPTER : T & TA
Page: 8
CHAPTER : NA & ATAAC
Page: 9
CHAPTER : JWAC & SCAC
Page: 10
CHAPTER : Air intake & exhaus
The use of a turbocharger is to get more power out of an

engine.
More air in the cylinder...
More fuel can be burned...
More horsepower output !
Aftercooling is an addition to turbocharging - this
increases the horsepower again !!
Page: 11
CHAPTER : 4-stroke system
Page: 12
Lubrication system
OIL
Page: 13
CHAPTER : Lub. system functions
An engine oil serves 5 vital functions in a modern diesel

engine:
1. Lubricates friction surfaces by forming a fluid film
2. Cools internal engine parts by absorbing heat.
3. Cleans the engine by flushing away dirt and wear

particles
4. Supprts the crankshaft and bearing
5. Protects the engine from harmfull acids, rust and
deposits
Page: 14
CHAPTER : Lubrication
Viscosity
Internal resistance felt as one layer of liquid moves relative
to another layer - ie: internal liquid friction.
SAE 20 weight 20 at 100C (212F)
SAE 20W weight 20 at -18C (0F)
SAE 20W - 30 weight 20 at -18C (0F)
&
weight 30 at 100C (212F)
Page: 15
CHAPTER : External & internal comp.
Page: 16
CHAPTER : Cross drillings & camshaft lub.
Page: 17
CHAPTER : Oil flow 3406 engine
Page: 18
CHAPTER : Oil pressure relief valve
Page: 19
Cooling system
Page: 20
CHAPTER : Heat transfer
Fuel burning temperature can reach 1927C (3500F).
Page: 21
CHAPTER : Heat sources
Other heat gernerating sources:
- transmission oil coolers
- hydraulic oil coolers
- aftercoolers
- water-cooled exhaust manifolds
- water-cooled turbocharger shields and
housings
- marine gear oil coolers
- torque converter / retarder coolers
Page: 22
CHAPTER : Systems & components
Cooling systems:
- radiator
- keel cooler
- shunt cooling
- heat exchanger cooling
Basic components:
- radiator
- fan
- coolant
- water pump
- engine oil cooler
- water temperature regulator
- pressure cap
Page: 23
CHAPTER : Keel/shunt/heat ex. system
Page: 24
CHAPTER : Coolant flow
Coolant flow:
water pump
oil cooler
cylinder block
cylinder head
(radiator)
water pump
Page: 25
CHAPTER : Pressure cap
Page: 26
CHAPTER : Altitude compensation
Page: 27
Fuel system
Page: 28
CHAPTER : CAT fuel systems
Pump & lines - Multiple plunger pump

- High pressure fuel lines
- Injection nozzles
- Limited injection pressure (18.000 PSI)*

- Limited injection timing
- Limited injection rate capabilities
MUI - Mainly used on large engines to eliminate the need

for long high pressure lines and the related problems
inherent with controlling pressure in these lines.
- Requires an additional cam lobe, lifter, push rod
and rocker arm for each cylinder.
*Current engine emissions and performance requirements demand injection

pressure in excess of 20.000 PSI and greater timing flexibility.
PEEC (Programmable Electronic Engine Control)

- ECM takes over of the functions of the mechanical
governor.
- Fuel pump is still used.
- Throttle linkage replaced by electronic throttle.
- Air fuel ratio control electronically controlled.
- Engine is equipped with various sensors for monitoring.
EUI / MEUI (Mechanical Electronic Unit Injectors )

- Fuel is metered electronically by means of a solenoid
operated poppet valve.
- System still requires a mechanical valve train to
actuate the plunger.
(Mechanically actuated , electronically controlled)
- Fuel transfer pump replaces the "pump & lines".
HEUI (Hydraulic Electronic Unit Injectors )
- Plunger movement is not limited to speed or duration

of a cam lobe.
- Plunger speed is a function of actuation pressure
versus fuel pumping resistance.
(Hydraulically actuated , electronically controlled)
- Injection pressure is +20.000 PSI
CHAPTER : Fuel pumps (pump & lines)
Page: 30
CHAPTER : System components
Page: 31
SSKARROUM
ORIFICE
CHECK VALVE TRANSFER PUMP FUEL FILTER
LIFT PUMP
VENT
WIRE
WATER
AUTOMATIC SEPARATOR
ADVANCE
GOVERNOR PRESSURE
SPRING REGULATOR
RETURN
CHAPTER : Pump & lines fuel system

CHECK METERING
VALVE VALVE
CAT DIESEL ENGINES

FUEL TANK
GOVERNOR
HEAD
PASSAGE
DELIVERY
VALVE
INJECTOR
HOUSING LUBE
ROTOR
Page:
PLUNGERS
32
CHAPTER : Lift pump
Page: 33
CHAPTER : Lift pump operation
Page: 34
SSKARROUM
FUEL RETURN
CHECK VALVE CAM
GOVERNOR
SPRING
METERING VALVE
FUEL OUTLET
ROLLER
PRESSURE
REGULATOR
PISTON
CHAPTER : Standadyne fuel pump

GOVERNOR
WEIGHTS
CAT DIESEL ENGINES

TRANSFER
PUMP
SHOE
ROTOR DELIVERY
AUTOMATIC ADVANCE VALVE
Page:
MECHANISM ORIFICE CHECK

VALVE
35
CHAPTER : Internal tranfer pump
Page: 36
CHAPTER : Metering valve
Page: 37
CHAPTER : Charging passages
Page: 38
CHAPTER : Pumping chambers
Page: 39
CHAPTER : Pumping chambers
Page: 40
CHAPTER : Fuel delivery to injectors
Page: 41
CHAPTER : Delivery valve
Page: 42
CHAPTER : Injection cycle review
Page: 43
CHAPTER : Timing advance
Page: 44
CHAPTER : Governor principle
Page: 45
CHAPTER : Plunger operation
Page: 46
CHAPTER : Standadyne governor
Page: 47
CHAPTER : Throttle lever operation
Page: 48
CHAPTER : Fuel Ratio Control (FRC)
Page: 49
CHAPTER : Shut off solenoid
Page: 50
Shut off solenoidCHAPTER :
Page: 51
CHAPTER : MUI fuel system
Unit
injector
Pressure
relief Secondary
valve fuel filter
Check elements
valve
Filter
change
valve
Secondary
fuel filter
Check elements
valve
Relief valve
Main
fuel Check
pump valve
Check
valve
Hand
Check priming
valve pump
Main Primary
fuel tank Fuel filters
Page: 52
CHAPTER : Mechanical Unit Injector
Page: 53
CHAPTER : MUI cylinder head
Page: 54
CHAPTER : Electronic engines
Input Power Output

Circuit Circuit Circuit
- Signals From Sensor

- Filter Electrical Noise - From Battery - To Rack And Lamps
- To Sensors
- Protect Voltage Levels ( 8vdc Minimum )
Page: 55
CHAPTER : System components (PEEC)
Eng Data Link

Connector
Shutoff Solenoid
J13
Rack Position Sensor

P14 J14
Rack BTM
ECM
Eng Speed Sensor
P7 J7
Atmospheric Pressure P15 J15
Sensor
P17
Boost Pressure P8 J8
Sensor Coolant
Level
Customer
Sensor
Connector
Oil Pressure P9 J9
Sensor
Coolant Temp
Sensor P12 J12
Page: 56
SSKARROUM
BTM
FSOS
RPS
INJECTOR
PRIMING
PUMP
CHECK
VALVE
CHAPTER : PEEC fuel system

CAT DIESEL ENGINES
PRIMARY
SECONDARY
TRANSFER PUMP FILTER TANK
FILTER
Page:
ECM
57
CHAPTER : PEEC fuel rack
SHUTOFF SOLEINOID
PWM
BTM
FUEL RACK
SERVO
FUEL ON
RACK POSITION SENSOR
Page: 58
SSKARROUM
ACTUAL RACK POSITION
RACK ELECTRONIC DESIRED SPEED THROTTLE

CONTROL GOVERNOR POSITION
SENSOR
RACK
BTM
CHAPTER : Control logic (PEEC)

FRC
RACK FRC
LIMIT MAPS RATED
CAT DIESEL ENGINES

TORQUE RACK
MAPS LIMIT
SPEED SENSOR
ACTUAL SPEED
BOOST PRESS. SENSOR

Page:
59
SSKARROUM
CHALLENGER 75C/85C
3176B EUI COMPONENT DIAGRAM
ELECTRONIC ADEM II
CONTROL MODULE CONTROL
(ECM) GROUND
STUD
J2 P2 J1 P1 12V
TIMING CALIBRATION SENSOR CONNECTOR MAIN KEY
POWER RELAY SWITCH
ELECTRONIC UNIT ENGINE MACHINE

INJECTOR HARNESS HARNESS
15 AMP
BREAKER
DATA LINK
ET/ECAP
SPEED/TIMING SENSOR CONNECTOR
CHAPTER : EUI system components

DATA LINK
CAT DIESEL ENGINES

COOLANT TEMPERATURE SENSOR THROTTLE POSITION SENSOR
TURBO OUTLET PRESSURE SENSOR CHECK ENGINE LAMP
ATMOSPHERIC PRESSURE SENSOR LAMP FLASH SWITCH
TRANSMISSION PRESSURE SWITCHES

FUEL TEMPERATURE SENSOR
Page:
60
CHAPTER : Fuel system (EUI)
ELECTRONICAL CONTROLED MECHANICALY ACTUATED
FILTER
RELIEF
VALVE
E C M
Electronic
Unit
Injector
PUMP
FUEL
TANK
Page: 61
CHAPTER : Fuel injection
5
4
9
1. Solenoid Connection
2. Solenoid Valve Assem 10
3. Spring 11
4. Valve
5. Plunger 12
6. Barrel
7. Seal
8. Seal
9. Spring
10. Spacer 1
11. Body
12. Check
2
5
4
10
11
12
Page: 62
SSKARROUM
HIGH PRESSURE OIL MANIFOLD
High Pressure
40 to 210 BAR
Oil Pump
CHAPTER : HEUI fuel system

Regulator Fuel Return Line
Pressure
Control
CAT DIESEL ENGINES

Valve
Engine System
Fuel
Filter
ECM
Oi Fuel
lS Trans
Oil Oil u Vehicle Pump
Oil
Filter Cooler Pump
m System
p
Page:
LOW PRESSURE 3 BAR Fuel Tank

63
TO LUBE
SYSTEM HEUI
HYDRAULIC
TEMPERATURE
SENSOR
COLD START
OIL FLUID MANIFOLD
RESERVOIR OIL PRESSURE HYDRAULIC PASSAGE
SENSOR
COOL DOWN FUEL HYDRAULIC

HYDRAULIC CIRCUIT TEMPERATURE PRESSURE
SUPPLY SENSOR SENSOR
PUMP
OIL GROUP
FILTER FLUID MANIFOLD
HYDRAULIC PASSAGE
SSKARROUM
PUMP
CONTROL HEUI
VALVE ECM
OIL
CHAPTER :
COOLER
FUEL
TRANSFER
SECONDARY PRESSURE
PUMP
FUEL REGULATING
LUBE OIL
FILTER VALVE
PUMP
PRIMARY
FUEL FILTER
WATER
SEPARATOR
OIL
HEUI fuel system
SUMP FUEL TANK
Page:
CAT DIESEL ENGINES
64
CHAPTER : HEUI injector
SPACER
SLEEVE
ARMATURE
VALVE
VALVE BODY SOLENOID
SHIM
BARREL
ADAPTER
PISTON WASHER
UPPER FUEL SEAL
PLUNGER
FUEL INLET
CHECK VALVE
PIN
SLEEVE
SPACER
LOWER FUEL SEAL
CHECK
NOZZLE
Page: 65
CHAPTER : Injection
Page: 66
CHAPTER : Poppet valve open
ARMATURE
SCREW
POPPET
SPRING
Page: 67
CHAPTER : Drain
Page: 68
CHAPTER : Poppet valve closed
POPPET VALVE
SOLENOID
ARMATURE
INLET EXHAUST
VALVE SEAT VALVE SEAT
Page: 69
CHAPTER : Nozzle group
NOZZLE GROUP
REVERSE FLOW
CHECK VALVE
CHECK VALVE
FUEL
ATOMIZATION
Page: 70
CHAPTER : Injection cycle
CROSS SECTION
OF PLUNGER
FINAL
START OF INJECTION PRESSURE DROP PRESSURE INCREASE
INJECTION
RATE
START OF END OF
INJECTION DURATION INJECTION
TIME (MILLISECONDS)
Page: 71
SSKARROUM
PRIMING PORT COMPENSATOR
VALVE
ORIFICE VALVE BASE
DRAIN PASSAGE
TRANSFER PUMP
RESERVOIR
CHAPTER : Variable displacement pump

CAT DIESEL ENGINES
Page:
SWASHPLATE
72
SSKARROUM
INJECTION PRESSURE
CAT DIESEL ENGINES
CHAPTER : Injection pressure
HEUI
MECHANICALLY ACTUATED
FUEL SYSTEM
IDLE
ENGINE SPEED
Page: 73

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SSKARROUM

CAT Diesel Engines

Caterpillar produces engines for various applications:

The engines are divided in three categories:

Small engines (3000 - 3300)

Medium engines (3400 - 3500)

Large engines (3600 - MAK)

Caterpillar engines can be divided in two types:

Those two types of engines are running on two different

If you know one, you know them all !

The difference from one engine to another is the fuel

All other systems (cooling , lubrication , air) are fitted to

The fuel system is the heart of an engine. It gives the

AIR INTAKE & EXHAUST

Air intake & exhaust

Natural Aspirated Turbocharged

Turbocharged Turbocharged Aftercooled

The use of a turbocharger is to get more power out of an

More air in the cylinder...

More fuel can be burned...

More horsepower output !

Aftercooling is an addition to turbocharging - this

increases the horsepower again !!

An engine oil serves 5 vital functions in a modern diesel

1. Lubricates friction surfaces by forming a fluid film

2. Cools internal engine parts by absorbing heat.

3. Cleans the engine by flushing away dirt and wear

4. Supprts the crankshaft and bearing

5. Protects the engine from harmfull acids, rust and

SAE 20 weight 20 at 100C (212F)

SAE 20W weight 20 at -18C (0F)

SAE 20W - 30 weight 20 at -18C (0F)

Fuel burning temperature can reach 1927C (3500F).

Other heat gernerating sources:

- transmission oil coolers

- hydraulic oil coolers

- water-cooled exhaust manifolds

- water-cooled turbocharger shields and

- marine gear oil coolers

- torque converter / retarder coolers

- heat exchanger cooling

- engine oil cooler

- water temperature regulator

Pump & lines - Multiple plunger pump

- Limited injection pressure (18.000 PSI)*

MUI - Mainly used on large engines to eliminate the need

*Current engine emissions and performance requirements demand injection

PEEC (Programmable Electronic Engine Control)

EUI / MEUI (Mechanical Electronic Unit Injectors )

HEUI (Hydraulic Electronic Unit Injectors )

- Plunger movement is not limited to speed or duration

CHAPTER : Pump & lines fuel system

CAT DIESEL ENGINES

CHAPTER : Standadyne fuel pump

CAT DIESEL ENGINES

MECHANISM ORIFICE CHECK

Input Power Output

- Signals From Sensor

Eng Data Link