Internal Combustion Engine

Source:3/2/2009
John Deere FOS Series AST335_2000 1
 Engine Components
Cylinder Block
Main housing of Engine
Cylinder Head
Valves, Intake & Exhaust Passages, Injectors (Spark Plugs)
Valve Train
Camshaft, Opens and closes the valves
Rocker Arm
Piston, Connecting Rod
Piston
Connecting Rod
Crankshaft, Flywheels, Balancers
Flywheel, maintains momentum
Balancers,
B l Dampen
D Forces
F
Bearings
Main Bearing
Bearing
B i Inserts
I t

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 Engine Cylinder
Types Cylinders
EnBloc
Dry Liner
Wet
W Liner
Li
Wear
Taper
Larger Dia at Top
Out-of-roundness
Perpendicular to Crankshaft
Major Thrust Face
Minor Thrust Face
Replace 0.005 (0.13mm)
Honing of Cylinders
Cross-Hatch Pattern
Rings catching
Provide Lubrication

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John Deere FOS Series AST335_2000 5
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John Deere FOS Series AST335_2000 6
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John Deere FOS Series AST335_2000 7
 Cylinder Head
Cylinder
C li d Head
H d
Iron and Copper, Aluminium
Oil Ports,, Valves,, Intake & Exhaust Ports
Cylinder Head Gasket

Cylinder
C li d Head
H d Warping
W i
Tightening sequence
Source: John Deere FOS Series
Order of tightening
Multiple stage process
Torque 1, Torque 2
Additional 1/x turns

Leaks and Cracks

Water & Air Method
Magnetic Crack Detector

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John Deere FOS Series AST335_2000 9
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John Deere FOS Series AST335_2000 10
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John Deere FOS Series AST335_2000 11
 Four Stroke Engine
Intake Stroke
Piston TDC Piston BDC
Intake Valve Open (10o before TDC)
Intake Valve Closes (50o after BDC)

Compression Stroke
Piston BDC Piston TDC
All Valves
V l Closed
Cl d

Power Stroke (Ignition/Injection at TDC)

Piston TDC Piston BDC
Exhaust
E h Stroke
S k
Piston BDC Piston TDC
Exhaust Valve Open (50o before BDC)
Exhaust Valve Closes (10o after TDC)
Source: John Deere FOS Series
 Two Stroke Engine (Roots Blower)

Source: John Deere FOS Series

 Two Stroke Engine (Crankcase Scavenging)

Source: John Deere FOS Series

Source: John Deere FOS Series
 Characteristics of Four Stroke
Compression Ignition & Spark Ignition Engines
Characteristics Compression-Ignition Engine Spark- Ignition Engine

Compression Ratio 14-22 : 1 5-8 : 1

Ignition Compression Electric Spark
Thermal Efficiency 30-60% 25-30%
Fuel induction Injector Carburettor (Fuel Injection)
Fuel System Fuel Oil / Diesel Gasoline (LP gas)
Fi Hazard
Fire H d L
Less G t
Greater
Power Variation Increase in Fuel Increase in Air/Fuel Mixture
Air Induction Constant Variable
Air-Fuel Ratio 15-100 : 1 10-20 : 1
Relative Fuel Consumption Lower Higher
Energy per litre of fuel Higher Lower
Manifold Throttle Absent Present
o o
Exhaust Gas Temperature 482 C / 900 F 704 C / 1300 F
Starting Harder Easier
Lubricants Heavy duty oils Regular and Premium Oils
Speed Range Limited (600-3200 rpm) Wide range (400-6000 rpm)
Engine Mass per Horsepower 8 kg (17.5 lb) Average 4 kg (9 lb)
Initial Cost High Much Lower
Lugging ability (Torque) Excellent Less
Time Before Maintenance Good Fair
Continuous Duty Good Fair
 The Valve Train
Valve Actuation
Valve Timing Camshaft
Camshaft Profile
Base Circle, Flank, Nose, Valve Lift

Valve Sealing Cam Follower (Tappet)

Hydraulic Lifter
Push Rod
No used in overhead cam
Rocker Arm
Valve Clearance (Adjustment Screw)
Hot Clearance, Cold Clearance

Valve Seating
Valve Face, Valve Seat
Tight
g Sealingg of air ((narrow contact area))
Heat Transfer (wider contact area
Valve Inserts
Valve Stem Clearance
Valve guides
Cooling, Oil consumption
Valve Rotators
Release, Positive Rotators
Crush Deposits
Even Temperature

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John Deere FOS Series AST335_2000 19
 Valve Timing and Cam Profile

Source: John Deere FOS Series

Valve Overlap
Intake & Exhaust valve open
Valve Profile
Base Circle
Flank
Nose
Valve Lift

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 Valve Actuation
Valve Lift
Distance the valve lifts off the valve seat
Valve (Tappet) Clearance
The gap betweem the top of the valve
stem and rocker arm when the valve
follower is on the camshaft base
Typical
i l Clearance
l (Hot/Cold
( / ld ?))
Intake 0.25-0.50mm (0.010-0.020)
Exhaust 0.3-0.75mm (0.12-0.030)
Clearance too small
Valve opens early, closes late
Valve may not close
Clearance too large
Valve open late, closes early
Valve may remain closed

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John Deere FOS Series AST335_2000 22
 Valve Seating and Cooling
Valve Seating
Valve Face, Valve Seat
Valve Inserts
Seating Width
Wide Seating Width (3/32), Better Cooling
Narrow Seating Width (1/64), crushing of deposits
Interference Seating, good crushing but hotter valve

Intake
ta e / Exhaust
aust Valves
Va ves
Exhaust Valves
Smaller, less heat Transfer
Intake Valves
Reduce ppressure losses causingg vacuum

Heat Loss
Valve Seat / Valve Guides
Heat Transfer to head
Incorrect Seating / Valve Clearance
Hot gas blow-bay, Greater Heating
Burnt Valves

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 V l R
Valve Rotators
t t

Wiping Action
Heat Distribution

Source:3/2/2009
John Deere FOS Series AST335_2000 24
 Major Cause of Valve Failures
Distortion of Valve Seat
Cooling,
C li Out O t off Round
R d & loose
l seats,
t Warped
W d Head/Block,
H d/Bl k Incorrect
I t grinding
i di
Deposits on Valve
Blow-by, weak springs, tappet clearance, sticking valves, wide valve seats, lack valve
rotation
Burnt Valves
Cooling system, Tappet clearance,
Pre-ignition
Timing,
g, Chamber deposits
p ((Longg Idling,
g, Rich mixtures,, Oil Burning,
g, High
g Heat pplugs,
g,
Compression ration, fuel

Valve Erosion
Incorrect fuel, Incomplete burning, Lean Air/Fuel Ratios
Cracked Valves
Thermal Fatigue
Temperature & Pressure
Impact Damage
W
Worn guides,
id valve
l clearance
l

Warn Guides
Consequences
Bad Seating, Impact at angle, oil burning, carbon deposits
Causes
Worn rockers, poor lubrication, carbon deposits, cocked springs

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John Deere FOS Series AST335_2000 30
 Piston and Connecting Rod
Piston
Eye, Shank, Head, Cap, Bearing Inserts, Piston Pin

Major
j Thrust
h Face (Left
( f off Piston)
i )
Greater side thrust
Connecting Pin slightly Offset
Minor Thrust Face

Major Diameter (Perpendicular to Piston Pin

Minor Diameter (Parallel to Piston Pin)
Uneven expansion of piston as it heats up
Round when hot

Top Piston slightly smaller than bottom skirt

Uneven expansion

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John Deere FOS Series AST335_2000 32
Source: John Deere FOS Series
Source:3/2/2009
John Deere FOS Series AST335_2000 34
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John Deere FOS Series AST335_2000 35
 Piston Design
Direct Combustion
Low Surface area per unit vol
Higher Premix Combustion
Swirl

Swirl Ratio = Swirl Speed (rpm) / Engine Speed

(rpm)

Indirect Combustion
Precombustion Chambers
20% to 30% clearance volume
High Temp (600 to 750C).

Swirl Chambers or Turbulence Chamber

50% to 90% clearance volume
clean burning low levels of smoke, NOx, and HC

Air Cell or Energy Cells

5% to 15% clearance volume
Ignition occurs in the main chamber
60% of the unburned fuel into the auxiliary chamber.
Lower peak pressures Low indicated thermal efficiency
 Piston Rings
Compression Rings, Oil Ring

g
Rectangular
Inexpensive
Taper Ring
Good Wiping
p g of oil on down stroke, Seats qquickly,
y only
y fair control blowby
y
Barrel Ring
Small contact area (low friction), Greater sealing pressure, lower blowby
Inside Barrel
Twists in groove to form tighter seal during combustion
Keystone Ring
Resist stickingg of ring
g in carbon deposits
p

Ring require both side clearance and end clearance

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Source:3/2/2009
John Deere FOS Series AST335_2000 38
 Oil Consumtion and Blow-By
Causes
Pumping by worn rings
See figure
Rings incorrectly installed
Stuck Rings, plugged oil ring
Deposits freeze rings
Heat, Unburnt fuel, oil breakdown
(sludge), PreIgnition, Broken Rings,
worn grooves
g
Wear Piston, rings, cylinder
Abrasive wear
Scuffing & scouring
Corrosive wear
Physical Damage

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 Major Cause of Piston Failures
Stuck Broken Rings
S ffi and
Scuffing d scouring
i off Pi
Piston
Local Hot spot
Corrosive wear
Physical Damage
Piston Pin locking
Pre-Ignition
Lean Mixture, Low Octane, Advanced Timing, Over-fuelling, High Torque, Over-heating

Major Cause of Bearing Failures

Dirt, (85%)
Dirt
Lubrication (15%)
Assembly (14%)
Misalignment (10%)
Overload (8%)
Corrossion (5%)

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John Deere FOS Series AST335_2000 45
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John Deere FOS Series AST335_2000 46
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John Deere FOS Series AST335_2000 47
 Firing Interval & Order
Average Firing Interval
Av. Interval = (B * 180o) / (# cylinders)
b=4 Four stroke, b=2 Two Stroke

Firing Order (4 stroke)

2 Cylinder
1,2
12
3 cylinder
1,2,3
4 cylinder
1,2,4,3 or 1,3,4,2
6 cylinder
1,5,3,6,2,4
Source: John Deere FOS Series
Source: John Deere FOS Series
 Crank Dynamics

TDC
s = r + l r cos l cos
2 2 2
s l cos = sqrt
q (l r sin )
s = r + l r cos sqrt (l 2 r 2 sin 2 )
Stroke

l
BDC
r 2
2 sin t cos t
M
ds/dt = r sin t + *
2 sqrt (l 2 r 2 sin 2 t )
l

r 2
sin( 2t )
ds/dt = r sin t + *
r q (l 2 r 2 sin 2 t )
2 sqrt
2

r 2 2 cos(2t ) r 2 sin 2 (2t )

/d = r cos t +
2
d s/dt 2 2
*{ + }
2 sqrt (l 2 r 2 sin 2 t ) 4 * sqrt (l 2 r 2 sin 2 t )3
 Crank Dynamics

Position
Velocity
0 50 100 150 200 250 300 350 400 Accel_1
 Crank Dynamics

Accel_1
Accel_2
Accel_3
0 50 100 150 200 250 300 350 400 Accel_4
_Accel
 Types of Engines
Fuel Type
Spark Ignition (Gasoline, LP-gas)
Compression Ignition (Diesel)
Cylinder Arrangement
In-Line
V-Type
Opposed
Valve Arrangement
I-Head
H Head
H-Head
L-Head
T-Head
Source: John Deere FOS Series
 Intake and Exhaust Systems
Intake
Air Filters
Blower/Supercharger Intercooler
Blower/Supercharger,
Intake Manifold
Intake Valves
Exhaust
E h t
Exhaust valves
Exhaust Manifold
Turbocharger Turbine
Muffler
Source: John Deere FOS Series
 Cooling System
Regulate Engine Temperature
Prevent overheating

Air Cooling
Small engines,
engines aircraft,
aircraft Deutz

Liquid Cooling
Water (anti-freeze)
Radiator
Pump
Source: John Deere FOS Series
 Lubrication
Reduce Friction
Dissipated Heat
Seal Piston Rings and Walls
Clean and Flush Parts
R d
Reduce N i
Noise
Source: John Deere FOS Series
Source: John Deere FOS Series
Source: John Deere FOS Series
Source: John Deere FOS Series
Source: John Deere FOS Series
Source: John Deere FOS Series
Source: John Deere FOS Series
Source: John Deere FOS Series