CATERPILLAR ENGINE SYSTEM

Caterpillar Engine System,

Fuel Air Intake & Exhaust Lubrication Cooling Electrical Starting System System System System System

AGENDA

Engine Operation

Intake

Compression

Combustion

Exhaust

ENGINE STROKE

ENGINE STROKE

FUEL SYSTEM

Two categories of fuel system,

1. Pump & Lines Fuel System Sleeve metering Scroll type New scroll type 2. Unit Injector Fuel System MUI (Actuator) MEUI / EUI HEUI FUEL SYSTEM

Pump & Lines Fuel System

Filter

1. 2. 3. 4. 5. 6.

Fuel tank Fuel filter Transfer pump Low pressure lines Timing advance Injection pump, Governor and Fuel Ratio Control 7. High pressure lines 8. Nozzles 9. Return lines

8 6

5 4

FUEL SYSTEM

Unit Injector Fuel System

MEUI / EUI (Mechanical Electronic Unit Injector) Fuel controlled electronically by means of a solenoid operated poppet valve, still require mechanical valve train to actuate the plunger

FUEL SYSTEM

Fuel delivery,

COMBUSTION SYSTEM

FUEL INJECTION SYSTEM

FUEL SYSTEM

Fuel System Inspection,

1. Dynamic Timing Procedure 2. Timing advance adjustment
Dynamic Timing

3. Timing pin procedures

Timing Pin Engine
Timing Advance

FUEL SYSTEM

Fuel System Inspection, Continuo's.

4. Nozzle or injector test 5. Fuel pressure test 6. Fuel specific gravity test
CAT recommends 35 degrees API minimum of the fuel,

Nozzle Test

FUEL SYSTEM

AIR INTAKE, EXHAUST SYSTEM

AIR INTAKE & EXHAUST

Natural Aspirated,

AIR INTAKE & EXHAUST

Turbocharger,

AIR INTAKE & EXHAUST

Turbocharger Aftercooler,
1. 2. 3. 4. Precleaner 6 4 Air filter Turbocharger Intake manifold 5. After cooler 6. Exhaust manifold 1 2 7. Exhaust stack 8. Muffler AIR INTAKE & EXHAUST

5 7 8

Air to Air Aftercooler,

AIR INTAKE & EXHAUST

Air System Inspection,

1. Inspect air filter indicator. (Visual check Reading or color)

2. Checking air inlet restriction (Engine pressure gauge tool)

AIR INTAKE & EXHAUST

Air System Inspection, Continuo's.

3. Checking boost pressure (Engine pressure gauge)

4. Smoke density test (Gauge sensing tool)

AIR INTAKE & EXHAUST

Engine: OLD Vs MODERN

AIR INTAKE & EXHAUST

LUBRICATION SYSTEM

Lubrication Functions
Lubricate
Reduce wear

Transmit power / Hyd.

Prevent corrosions

Remove heat
Clean surfaces

Dampen shock at gear

Disperse contaminants

Sealant

Prevent foaming

LUBRICATION SYSTEM

6. Oil cooler with bypass valve 7. Main oil gallery 8. Piston cooling jets 9. Crankcase breather

1. Oil pan 2. Suction bell 3. Oil pump 4. Relief valve 5. Oil filter with bypass valve

LUBRICATION SYSTEM

Substance of Additive CAT Oils

LUBRICATION SYSTEM

Faktor penggantian oli,

Jam Pemakaian Oli (lamanya oli dipakai sejak diganti) Service Meter Reading (lamanya jam operasi unit) Kondisi Operasi Mesin / unit yang informasinya

diperoleh dari label

Melihat kondisi oli dan type oli yang dipakai Adanya kontaminasi Bahan Bakar dan air pada oli engine dan non engine Meningkatnya kandungan logam yang tidak normal Bagaimana aplikasi & perawatan praktis dilapangan

LUBRICATION SYSTEM

Contaminant oli & penyebabnya

SOOT : Jelaga yang dapat menyumbat filter oli disebabkan kualitas bahan bakar, perawatan mesin & pengoperasian mesin yang tidak baik Oxidation : Reaksi kimia antara oli dan oksigen, menyebabkan oli mengental, membentuk asam organik, menyumbat filter, deposit piston Nitration : Masalah hanya terjadi pada Mesin Natural Gas Sulfur : Indikasi adanya korosi pada semua bagian mesin, berasal dari bahan bakan yang kurang baik dan menyebabkan korosi pada valve guides, ring dan liner Water : Campuran Air dan oli membentuk emulsi yang dapat menyumbat filter, juga dapat membentuk asam, kemungkinan adanya kondensasi dalam crankcase Fuel : Menurunkan karakteristik oli

LUBRICATION SYSTEM

Lubrication System Inspection,

1. Inspect engine oil level 2. Engine oil pressure test 3. Schedule Oil Sampling

LUBRICATION SYSTEM

Schedule Oil Sampling,

Pemeriksaan contoh oli bekas secara berkala, guna mencegah masalah kecil menjadi besar, Analisa Keausan Analisa Fisik & Kimiawi Analisa kondisi Oli ( Infra Red test) Test kandungan TBN. Menghitung Partikel besar (10 -15 ) mikro per ml LUBRICATION SYSTEM

COOLING SYSTEM

CATERPILLAR SURVEY,

50% kerusakan dini dari Engine dapat di-akibatkan oleh Problem-problem pada Cooling System
COOLING SYSTEM

Pentingnya cooling system,

Pabrik Diesel Engine Dunia telah meningkatkan standar Temperature Operasi Engine utk meningkatkan efisiensi Engine. Perawatan Cooling System yg baik sama pentingnya dengan kualitas dari Oli maupun Bahan bakar

Overheating, Overcooling, Pitting, Cavitation, Erosion, Cracked Heads, Piston Seizures & Radiator Buntu adalah problem klasik dari Cooling System Failures
Effective Preventative Maintenance (PM) dapat mencegah pemborosan biaya dari hal2 diatas

COOLING SYSTEM

Flow of system,
1. 2. 3. 4. 5. 6. 7. Radiator Water pump Cooler Engine block Cylinder head Bypass valve Water Temperature Regulator

COOLING SYSTEM

Fungsi cooling system,

Membuang panas hasil pembakaran
Temperature pembakaran dpt mencapai 1,937 Deg. C

Transfer panas dari,

Transmission Oil Coolers Hydraulic Oil Coolers Water Cooled Exhaust Manifolds Water Cooled Turbocharger Shields / Housings Marine Gear Oil Coolers Torque Converter / Retarder Coolers Jacket Water After Coolers

COOLING SYSTEM

Perbandingan panas yang dilepaskan engine,

COOLING SYSTEM

Cooling system Inspection,

1. Check coolant level 2. Test antifreeze concentration 3. Coolant test kit

4. Adjusting coolant mix

5. Radiator cap test 6. Water temperature regulator test COOLING SYSTEM

Cooling system problem,

OVERHEATING
OVERCOOLING LOSS OF COOLANT

COOLING SYSTEM

Typical penyebab Overheating

Low Coolant Level Plugged Radiator Core Loose Fan Belts Reduced Air flow Through Radiator Insufficient Cooling System Pressure Coolant Overflow High Inlet Air Temperature Or Restriction Exhaust Restriction Excessive Engine Load Water Pump Or Temperature Regulator Failure

COOLING SYSTEM

Overheating effects,
Cracked Or Warped Cylinder Heads

COOLING SYSTEM

Typical penyebab Overcooling

Low Ambient Air Temperatures Water Temperature Regulators Stuck Open or Removed Defective Temperature Gauge

Overcooling effects,
Jika temperatur dibawah 80 derajat Celcius akan mengakibatkan peningkatan sulfur pada fuel dan keausan pada komponen engine Engine tidak mencapai temperatur operasi yang memadai sehingga performance tidak maksimal

COOLING SYSTEM

Coolant function,
Transfer panas dari komponen engine yang panas ke Radiator atau heat exchanger untuk dibuang.

Karakteristik yg dihasilkan,
High Boiling Temperature Freeze Protection Corrosion Resistance Deposit Prevention Non Foaming Minimum Sediment Maintain pH

Coolant effects,
Rust, (karatan) Iron Oxidation, (oksidasi metal) Scale and Deposit Formation, (jumlah dan formasi deposit) Aeration, (kemasukan udara) Acid Alcalinity Imbalance, (tidak seimbangnya tingkat keasaman dalam cooling system Pitting, Cavitation Corrosion / Erosion COOLING SYSTEM

Cooling system problem,

Contoh dari dinding Liner yang terkikis karna Kavitasi

Failure - Menyebabkan korosi di Pre-combustion Chamber

COOLING SYSTEM

 Supplemental Coolant Additive Test Kit - 8T5296 Checks Concentration SCA Checks Ethylene Glycol Range Only Takes A Few Minutes To Perform Coolant Testers - 5P3514 Accurate Reading Of Freezing Temperature Blowby / Air Flow Indicator Group - 8T2700 Hand Held Digital Indicator And Remote Pickup Measure Air Velocity Through Radiators

COOLING SYSTEM

 OBJECTIVE Improve PM To Prevent Overheating Problems Lower Operating Costs Through Good System Maintenance Lower Cost Per Hour

COOLING SYSTEM

 10 Hour / Daily Check

Inspect Coolant Level Clean Radiator Core

250 Hour / Monthly Check

Perform 10 Hours / daily check Inspect Condition & Tension Of Fan Belts - Adjust / Replace As Required If not Using Cat ELC, Add Supplemental Coolant Additive Test Coolant For Freeze Protection If necessary Inspect Radiator Cap & Gasket Inspect Hoses, Engine Electrical Grounds Check Function Of Water Temperature Regulator

COOLING SYSTEM

 3,000 SMU /24 Months

Perform All 250 SMU Checks Add Cat Extender If Using Cat Extended Life Coolant Otherwise Drain, Clean & Refill The Cooling System Inspect Condition Of Fan Blades & Guards, Hoses & Clamps Tighten All Clamps Perform A Coolant Analysis

6,000 SMU Or 6 Years Whichever Comes First

If Using Cat Extended Life Coolant, Drain, Flush With Clean Water And Refill Otherwise Repeat The 3,000 SMU PM

COOLING SYSTEM

STARTING SYSTEM

Three types engine starting :

1. Electric Starting, - Battery - Cranking motor - Cable/Wires

2. Air Starting,
- Air tank - Push Button Valve - Relay Valve - Cranking motor - Pinion 3. Hydraulic Starting,

STARTING SYSTEM

Starting System circuit 1. Battery 2. Solenoid cranking motor 3. Starter switch

4. Wires & cable

COOLING SYSTEM

Starting System circuit (switch on)

COOLING SYSTEM

Battery,

There are three types:

Conventional
Low maintenance Maintenance-free.

COOLING SYSTEM

Battery electrolyte,
1. Check conventional batteries every 100 operating hours 2. Check Low Maintenance / High Output batteries every 250 operating hours 3. Make sure all vent caps are clean 4. Never remove caps while charging the battery 5. Never need to check the electrolyte level

COOLING SYSTEM