BASIC KNOWLEDGE

1. DIESEL ENGINE AND GASOLINE ENGINE

A. Diesel Engine B. Gasoline Engine

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DIESEL ENGINE GASOLINE ENGINE

FUEL FUEL LIGHT OIL GASOLINE

FUEL CONSUMPTION RATIO 170 ~ 210 230 ~ 270

FLASHING POINT 50 DEG CELCIUS MORE -25 DEG CELCIUS MORE

COMPRESSION RATIO 14 ~ 30 KG/CM2 5 ~ 10 KG/CM2

IGNITION SELF BURN ELECTRIC SPARK

ATOMIZER METHOD INJECTION PUMP AND NOZZLE CARBURETOR

WEIGT / OUTPUT RATIO KG/HP 3~9 0.5 ~ 3.5

OUTPUT / VOLUME RATIO, HP/LT ~ 20 30 ~ 50

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2. FOUR CYCLE DIESEL ENGINE

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DIRECT COMBUSTION

. High efficiency
. Easily start
. Compatible with big engine
. Low exhaust temperature
. Sensitively with quality of fuel
. Need high pressure injection
. Need multi hole injector
. Low turbulence and difficult for high speed

PRE COMBUSTION CHAMBER

. Widely fuel type used

. Good turbulence
. Easily of fuel pump maintenance
. Low injection pressure
. Compromise with changing of injection timing
. Less of detonation
. Complex construction of cylinder head.
. Low capability of starting engine
. Wasteful of fuel usage

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PRE COMBUSTION CHAMBER

. Good turbulence when compression stroke

. High speed produce
. Less of nozzle trouble
. Compatible for automobile
. Complex construction of cylinder head
. Low efficiency
. Detonation when in low speed..

FIRING ORDER
. Sequence ignition timing for engine more than 1 cylinder.
. Power produce by combustions flat transmitted to crankshaft.
. Reduce vibrations and twisting in the crankshaft.

TABLE SEQUENCE

. Sequence stroke and ignition process in engine 1 cylinder or more.

. For establish mechanism valve setting.
. For determine every cylinder process.

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SEQUENCE TABLE 1 CYLINDER

TDC BDC TDC BDC TDC
INTAKE COMPRESSION POWER EXHAUST

0 180 360 540 720

SEQUENCE TABLE 4 CYLINDER

. FO 1 3 4 2

. Diff stroke every cylinder :

720 / 4 = 180

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SEQUENCE TABLE 4 CYLINDER

SEQUENCE TABLE 6 CYLINDER

FO : 1-5-3-6-4-2
. Diff stroke every cylinder :
720 / 6 = 120

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VALVE TIMING

. Timing for exhaust valve and

intake valve open and close

EXAMPLE :
. For engine SA12V140

. Intake Stroke = 20+180+30=230

. Compression Stroke = 180-30=150

. Power Stroke = 180-55 = 125

. Exhaust Stroke = 55+180+20 = 255

Total Stroke = 230+150+125+255 = 740

Actually totally 2 times turning

of Crankshaft = 720

. 740-720 = 40

Its mean that 40 is for valve Over lapping

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TABEL SEQUENCE SA12V140

VALVE ADJUSMENT
According to Sequence Table, Valve adjustment can be carry out by knowing about
every process in cylinder from sequence table.

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FUEL COMBUSTION IN DIESEL ENGINE

When Compressed Slowly

. Temperature relatively constant, because the will escape through the wall of cylinder.
. The pressure rises, but the rise is proportional to the extent of volume reduction.
. The manner of compression is called ISOTHERMAL.
When Rapid Compression
. Gives no chance of escape to the heat contained in the trapped and compressed air.
. Will be no exchange of heat between the air being compressed and the outside.
. The manner of compression is called ADIABATIC.
When engine running with a high speed
. Example running at 2000 rpm, each compression is completed in 1,5/1000 second.
. No time for the compressed air to leak out through the valves or the piston rings.
. The heat compression cannot dissipate easily because the engine is generally hot when it is
running fast.
. At high speed running may be regarded as working on ADIABATIC compression.
At the time of starting up a cold engine
. The mode compression is closer to ISOTHERMAL.

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TEMPERATURE AND PRESSURE

. Air is a mixture of molecules oxygen, nitrogen and few others.
. Molecules may be conceived as a ball too small to be seen.
. Billions of these balls are jumping in every which directions, bouncing
against one another in cubic inch of air.
. The velocity with which balls jump about is high when the temperature
is high.
. One way of conceiving heat is to assume each molecular ball to be
vibrating, and emitting and conceiving energy particles.
. When the balls are crowded, the exchange of energy particles goes on
at a higher level. Consequently, each ball becomes more excited,
because of mutual proximity, and jumps faster.
. To heat a given volume of gas is to give it more energy particles than
it gives off to the surrounding object.

. The walls of the vessel containing the gas are constantly bombarded
by billions of tiny balls. The totalized force acting on the unit area of
the wall surface is PRESSURE. The greater velocity with which the balls
impinge on the wall, the higher the pressure.
. If a given volume of gas is compressed, what happens/ This the
question that applies to the air getting compressed in the cylinder
by the piston.

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. The walls of the vessel containing the gas are constantly bombarded
by billions of tiny balls. The totalized force acting on the unit area of
the wall surface is PRESSURE. The greater velocity with which the
balls.
impinge on the wall, the higher the pressure.
. If a given volume of gas is compressed, what happens/ This the
question that applies to the air getting compressed in the cylinder
by the piston.

REQUIREMENT FOR FUEL COMBUSTION

. Fuel oil sprayed into the ordinary atmosphere will not burn.
. Oxygen and high temperature are needed to burn the fuel oil.
. These two requirement are meet by compressing a proper amount
of air within the engine cylinder.
. By burning within the combustion chamber, the fuel oil turns to high
temperature and high pressure.
. The process of burning the fuel may be viewed in three successive
stage. 1) mixture formation (fuel globules vaporize and mix with
the air), 2) ignition, 3) final combustion.
. The very short interval from the moment the fuel oil is injected
until the fuel oil begins to burns is a delay or hesitating period.
. With an easier to burn fuel oil or with finer globules of fuel oil, this
period is shorter.

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FINER THE FUEL PARTICLE, EASIER THE COMBUSTION

. To promote fuel oil vaporization, the totalized surface of a given

portion of fuel must be increased.
. The surface of a droplet can be expanded hundreds of times by
dividing it into the finer particles, this the reason why an injection
nozzle is used to supply fuel into the cylinder.
. If the fuel being injected into the combustion chamber as it happens to
be excessively fine in globule size, vaporization might complete in
an extremely short duration and the entire fuel in mixed state might
burn violently. Such violent combustion is harmful to the cylinder
and piston.
. Large globules of fuel oil will burn slowly.AND WHAT HAPPENS?
. Continuous combustion, as distinguished from violent combustion and
slow combustion results in gradual pressure build up within the
combustion chamber and make greater percentage of mechanical
energy contained in the high pressure gas available for doing
useful work.

. With a given injection nozzle, the higher the injection pressure

(pressure with which the fuel is forced out through the orifice in
the nozzle) the finer are the globules produced by injection.
. With too high injection pressure, the fuel may be spurt out straight
without breaking into finer globules.
. The nozzles are designed to spray at a constant pressure.

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COMPLETE COMBUSTION

. Just before the piston reaches its uppermost position (TDC) some eddying or swirling turbulence is induced
in the combustion chamber. The fuel being injected will thoroughly mix with the compressed air, because
of the turbulence, so that it will burn completely.

. Each diesel engine has its combustion chamber shaped for a certain type of injection nozzle spraying the
fuel in a particular pattern. Too narrow a spraying angle. A crooked spray or cocked spray angle prevents
fuel oil from burning completely and reduce engine horsepower output.

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SOME FUEL OILS ARE HARD TO BURN

. Burning is a chain reaction. A cloud of fuel oil globules catching fire uniformly or simultaneously is
a phenomenon of explosion, not of burning. Ideal combustion means that the first group of globule
introduced into the combustion chamber catch fire or ignite to burn the following groups of globules,
thereby building up pressure rather gradually. With a hard to burn fuel oil, however the first group of
globules hesitate to ignite and the following groups to hesitate for a moment ; then, all of sudden, ignition
occurs here and there almost simultaneously to result in a violent burning, delivering a hammering blow
(knocking) to the walls of the combustion chamber. Such a manner of fuel combustion fails to develop
full power.

CETANE NUMBER
Cetane number represents the ignition quality of a fuel oil. Both ease of starting and combustion roughness
of a diesel engine are influenced by the ignition quality of a fuel oil it uses.

A fuel oil with a higher cetane number burns more easily. The cetane number for a diesel engine is
specified by the engine maker. It is usually the minimum number.

The cetane number of a fuel oil is determined by using the fuel in a special test engine and by comparing
its ignition delay against the ignition delay of the reference fuel (45% cetane 55% alpha-methyl-
naphthaline) whose cetane number is arbitrarily taken 45.

COMPRESSION RATIO
Whycompression ratio diesel engine higher than gasoline engine?
And how about the formula?

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COMPARATION BETWEEN AIR AND FUEL IN DIESEL ENGINE

21% O2

1%
78% N2 Others

A large quantity of air is required for the fuel burn.

Air consist of oxygen (O2) which occupies 20% of air compositions.
Fuel oil consist of many atoms of carbon and hydrogen (HxCx).
Fuel oil burn will produce carbon dioxide gas (CO2), and steam (H2O), if perfect combustion.
In imperfect combustion (lack of oxygen), will produce CO2, CO (carbon monoxide), free carbon and steam.
Carbon monoxide is poisonous and gives no color and smell.
Diesel engine produce less of CO than gasoline engine.
Free carbon consists of carbon grains is not poisonous, and make the exhaust black.
Certain amount of oxygen is indispensable for the complete combustion.
The other words, the air containing such amount of oxygen as above is absolutely necessary.
Required minimum amount is called the theoretical amount of air.
If it is assumed that any amount of fuel oil is made to burn in the theoretical amount of air, so the fuel will
change Carbon dioxide and steam with forming neither carbon monoxide nor free carbon, and oxygen in the air
will be Thoroughly consumed.

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AIR EXCESS RATIO

14,5 gram of air is required for complete combustion of 1 gram of fuel oil, 14,5 gram is theoretical amount of air.
This amount of air corresponds to 12 liters of air in volume at sea level.
In theoretical amount of air can not always be used in combustion effectively, and produce free carbon.
(Thats the reason why, air excess ratio needs for complete combustion).
Air excess air ratio indicates multiplying factor of an excess amount of air against its theoretical amount of air.
For instance in theoretical 1 gram fuel need 14,5 gram air or 12 liters air, for air excess ratio 2, its mean 1 gram
fuel needs 29 gram air or 24 liters air.
As an engine has given size of cylinder, the of air drawn into the cylinder is relatively constant.
Accordingly, the more the amount of fuel is injected, the smaller Air Excess Ratio will be*.
In diesel engine Air Excess Ratio is usually ranged on 1,2 to 1,4 when fuel oil is being fully injected.
When Air Excess Ration comes down, much of fuel oil will burn incompletely and giving the black exhaust.
When Air Excess Ratio goes up, the complete combustion will be recovered, making the exhaust near colorless.
Increasing amount of fuel injection for improve the horsepower but gradually make the black exhaust.
Increasing amount of fuel injection for improve the horsepower, but make combustion gradually incomplete.
At a large Air Excess Ratio, as almost the heat is consumed to raise the temperature of excess air,
and the exhaust gas temperature will kept relatively low. (*Explain contrary condition)
Feeding excessive amount of fuel in order to increase HP, will cause Air Excess Ratio to be lowered extremely.
Lower extremely Air Excess Ratio, result very high temperature of the exhaust, and will cause craks on the piston
and cylinder head.

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EXCESS AIR RATIO

GU / GB
X = Rst

Rst = GU
GB

X = Air Excess Ratio

GU = Weight of air
GB = Weight of fuel
Rst = Air weight theoretical for
Completely burn 1 gram fuel
Rst = 14,5 gram

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SUPERCHARGER
The amount of air to be drawn into the cylinders is dependent on the total displacement and amount of fuel
The amount of air to be drawn into the cylinders is dependent on the total displacement and amount of fuel is limited.
is limited.
When injection of fuel excess, the amount just stated will give black smoke and higher exhaust temperature and fail
When
make theinjection of fuel
increasing excess, the amount just stated will give black smoke and higher exhaust temperature
horsepower.
and fail
Accordingly, the larger the total displacement exists, the more fuel to be injected and more horsepower produced.
In a diesel engine used horsepower.
make the increasing on a construction machine, the horsepower per 1000 cc ranges on 10 17 HP.

Accordingly, the larger
For produced larger horsepowerthe total
in adisplacement exists,
relatively small pistonsthe more fuel toneed
displacement, be supercharging
injected and more horsepower
system.
produced.
Supercharging make forcing when air drawn into the cylinder, and when fuel injected corresponds the amount of
that air to be drawn used
In a diesel engine oncylinder,
into the a construction machine,
the horsepower willthe horsepower
increase per 1000 cc ranges on 10 17 HP.
up to 30%
For produced are
Superchargers larger horsepower
classified in a relatively
into a turbo-type small pistons displacement, need supercharging system.
and rote-type.
Supercharging make forcing when air drawn into the cylinder, and when fuel injected corresponds the
amount of
that air to be drawn into the cylinder, the horsepower will increase up to 30%
Superchargers are classified into a turbo-type and rote-type.
ENGINE AT HIGH ALTITUDES

Higher altitude, is lower atmospheric pressure and thinner the air density.
1 liter air = 1,2 g at sea level and 0,77 g at 3776 m.
In high attitude, the engine operated is same way with lack of air.
Some systems to maintain engine power at high altitude are, Diesel Altitude Control, Air Fuel Control in
Cummins
Automatic Altitude Control in Caterpillar engine.

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THERMAL EFFICIENCY

Thermal efficiency is compare between thermal that convert to effective power in fly wheel with all thermal
that produce by engine in combustion process.
In other words thermal produce by combustion deducted by thermal loosing by cooling, exhaust, and others
mechanical lost.
If thermal produce by combustion = Q1 and Thermal lost = Q2, so thermal efficiency = X 100%
Q1 Q2
THERMAL BALANCE Q1

THERMAL PRODUCE BY COMBUSTION 100% 32% Effective power in flywheel / crank

shaft
31% Thermal lost by temperature of
exhaust gas. Excessive exhaust
temperature, excessive lost power ore
lost thermal.
5% 2%
32% Effective Power 30% Thermal lost by cooling system.
30% Exhaust Lost Lower coolant temperature higher
Cooling Lost thermal lost by water coolant.
Mechanical Lost 5% Thermal lost by mechanical lost (
Pumping Lost instance : Alternator, water pump, oil
31%
pump).
2% Thermal lost by piston movement
when intake, compression and exhaust
process.

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TIMING INJECTION AND PRESSURE IN CYLINDER

Adjustment timing injection is important in engine combustion process, but not so important if :
- Coupling of the injection timing is excessively out of adjustment.
- Advanced timer is defective.
- Improperly assembling timing gear when assembled during overhauling of it.
Some effects when any possible change is made on injection timing.
- Excessive or low pressure in cylinder.
- Knocking, exhaust color, de-rate horsepower etc.
Some effect are varied depending on the following
Circumstances:
- Type or shape of the combustion chamber = Rpm.
- Timing valve = air to fuel mixture rate.
- Type of fuel injection nozzle = Grade of fuel used.
As the effect varies according to each condition under
which the engine operates its very difficult to decide
what will happen when any change is made on the
fuel injection timing. Experience is not enough to
determine the proper injection timing. It is dangerous
to determine the injection timing only by looking at the
exhaust color. It must be adjusted accordance with
instructions of the engine manufacturer.
The proper injection timing of an engine is usually
determined by the manufacturer by taking it into
account to get the most suitable value of the
maximum pressure.

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Injection timing advance maximum pressure in cylinder rise, retard is drops.

Injection timing advance, knocking sound, why?
When the exhaust color is bad, check properly injection-timing tune.
Its important to doubt whether injection timing is correct when a lack of horsepower.

COLOR OF ENGINE DIESEL EXHAUST GASES

Background for analyze exhaust color is cloud or whitish building dont blue sky or trees.
What does black exhaust smokes mean?
- Imperfect combustion excessive fuel or lack of air.
- Un-burnt fuel turns into carbon and mix with exhaust gas.
- Generally exhaust gas gradually become black smoke according to increasing engine loads.
Low air suction efficiency because:
- High attitude
- Air suction resistant increase.
- Supercharges seizes fails to force air to the cylinder.
Leak of the sucked air:
- Air would leak if the cylinder and liner or piston rings wear out and exhaust smoke become bluish.
- Poor contacts or wear out in valve or seat valves.
- Cylinder head not clamped tightly or if gasket breaks.
Fuel is not injected properly into the cylinder:
- Jet pressure is low or a particle of fuel is large.
- Fuel drips from the nozzle at end of injection.
- Nozzle defective, or injector discharge port is clogged.
- Timing injection is out of adjustment.
Excessive amount of fuel is injected into the cylinder:

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- Imperfect combustion, black smoke, piston and cylinder over heat, excessive exhaust temperature.
What does a bluish exhaust smoke mean?
- Indicates engine oil burning with.
- Oil leaks from suction or exhaust valve stem.
- Oil leaks from turbocharger.
What does a whitish exhaust smoke mean?
- There are cases where the color of the exhaust turns white, if the fuel injection timing is out of
Adjustment, the exhaust turns white or this may also happen if water leaks somewhere and
A large amount of vapor mixes with the exhaust, although this happens infrequently.

COMBUSTION PROCESS

a. Period of delayed ignition

b. Period of abrupt combustion
c. Period of normal combustion
d. Period of after burning
(Broken line shows the air expansion)

A. Start of injection
B. Ignition
C. Start of normal combustion
D. End of normal combustion
E. End of after combustion

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KNOCKING

Delay periods too long, causing excessive burning fuel in abrupt periods.
Pressure in cylinder suddenly higher and make knocking sounds.
Knocking preventions:
1. Use fuel with high cetane number.
2. Rise up air temperature in start of injection.
3. Decrease quantity of injection when start of injection
4. Rise up combustion chamber temperature.

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