Republic of the Philippines

CAVITE STATE UNIVERSITY

Don Severino delas Alas Campus
Indang, Cavite

COLLEGE OF ENGINEERING AND INFORMATION TECHNOLOGY

Department of Agricultural and Biosystems Engineering

ABEN 50 – AB Power Engineering

Name: Princess Mariel B. Medina Student Number: 201816736

Course, Year and Section: BS ABE 4-2 Old Date: October 18, 2022

Laboratory 3
Auxiliary Engine System

Introduction

An engine, specifically a heat engine, is a powerful machine that performs work

through the conversion of thermal energy and chemical energy from a fuel into mechanical
energy, which creates motion in the process. There are two types of heat engines: the
internal combustion engine and the external combustion engine. In an internal combustion
engine, the ignition of air and fuel occurs inside the cylinder. Whereas in the external
combustion engine, the combustion takes place outside of the engine. Also, it utilizes fluid,
such as water or other low boiling fluid, to produce steam as the heat energy is applied by
burning fuel. For the engines to perform their function, several auxiliary systems are running
accordingly. For instance, an engine requires six systems such as fuel, exhaust, ignition,
combustion, cooling, and lubrication. However, the discussion of this activity primarily
focused on the three systems of an internal combustion engine, such as the ignition system,
lubrication system, and cooling system.

Objectives

After this laboratory exercise, the student will be able to:

 illustrate the parts and components of different auxiliary engine system;

 discuss how the auxiliary engine system works; and,
 identify the common problems and maintenance in auxiliary engine system.

Methodology

The students conducted an observation of different engine assemblies at the

Department of Industrial Engineering and Technology (DIET) last September 28, 2022, at
Cavite State University-Main Campus. Moreover, given the guidelines for this laboratory
research activity, the student gathered necessary inputs from online references like articles,
journals, and websites, for further data regarding the internal combustion engine. The
information gathered was presented and discussed in descriptive form through figures and
paragraphs.
Discussion

The engine consumes fuel to produce power. The quality of fuel must be considered
before applying it to an engine to avoid mechanical problems. The properties of good fuel to
use are good volatility, high antiknock value, chemical purity, and freedom from the gum.
The common fuel used for Internal Combustion Engines is petrol, power kerosene, and high-
speed diesel. The fuel is delivered in an engine with the following process based on the
presentation of Chouhan (2020).

Conventional Diesel Fuel System Model at DIET

In a spark ignition engine, the fuel supply system consists of the fuel tank, sediment
bowl, fuel lift pump, carburetor, and fuel pipes. The fuel is supplied in either gravity flow or
forced flow. The fuel tank is placed above the carburetor, which allows the fuel to flow due to
gravity. Between the fuel tank and carburetor, oil filters are present, as well as a transparent
sediment bowl to hold the dust and dirt of the fuel. If the fuel tank is positioned below the
carburetor, a lift pump is used to force the flow of the fuel. Through pipes, the fuel will flow to
the carburetor and then goes to the cylinder through the inlet manifold. The mixing of air and
fuel is away from the cylinder but occurs in the carburetor. The mixing process is called
carburation.
 Spark Ignition Fuel Supply System (learnmechanical.com, n.d.)

On the other side, the fuel supply system in a compression engine is composed of
the fuel tank, lift pump, filter, injector pump, high-pressure pipe, overflow valve, and fuel
injector. The fuel is drawn by the lift pump from the tank to the injection pump, passing
through an oil filter. Then, the injection pump supplies high-pressure fuel to injection nozzles
through delivery valves and high-pressure pipes. Afterwards, the fuel is injected into the
cylinder to expose it to compressed air to start the combustion. The leaks from the nozzles
will return to the tank through the overflow pipe. The overflow valve is installed at the top of
the filter to keep the pressure under a specified limit.

Compressi
on Ignition
1. Ignition System Fuel
Supply
The ignition system in an internal combustion engine induces the explosion of the air
and fuel mixture.System
This mixture is ignited inside the cylinder at the end of the compression
stroke. Correct timing of ignition is necessary in order for the engine to work properly (Saif,
2022). There are two types of systems to ignite the fuel. First, an ignition by an electric spark
or spark ignition. Second, an ignition by the heat of compression or compression ignition.

A spark ignition system works through the use of a spark plug. The spark plug
provides a high-voltage electrical discharge between two electrodes, which ignites the air
and fuel mixture. On the other hand, combustion in a compression ignition system occurs
due to high temperature in the cylinder caused by high compression.
 Development of an Advanced Spark Ignition System Instructional Trainer at DIET

1.1 Parts and Function of Ignition System (Chouhan, 2020)

The basic components of an ignition system consist of a battery, ignition coil, ignition
switch, spark plug, distributor, condenser, dynamo, battery, and associated switches and
wiring.

Spark Plug
and Spark

Distributor Ignition Coil

 Ignition Coil. The ignition coil acts as a small transformer in a system to jump
the gap of the spark plug by setting up a low voltage to a very high voltage. It is
composed of two sets of winding, the primary and secondary windings, and the iron
core. This component produces a magnetic field and is sealed to prevent the entry of
moisture that might cause a short circuit. 

Ignition Switch. The ignition switch served its purpose in starting and

stopping the engine. It is either a push-pull type or a key type.

Spark Plug. The spark plug ignites the air-fuel mixture in the combustion
chamber. It is a device for the high voltage current to jump and ignite the charge.
Based on the presentation posted by KIT-Kalaignar Karunanidhi Institute of
Technology (2022), the ignition system produces about 30,000 volts of spark across
the spark plug. This high-voltage spark is distributed to the spark plug sequentially
once the piston is near on top dead center (TDC). Further, each spark plug consists
of a threaded outer shell with an outside electrode, insulator, and a copper gasket.
Typically, the gap settings of the spark plug should be between 0.5 mm and 0.85 mm
otherwise, the component will not work efficiently. 

Distributor. The distributor refers to a rotary switch that is driven by the gears

at half the speed of the engine. It is also used for interrupting the low-voltage primary
current and distributing the resulting high-voltage current to the engine system in
proper sequence and timing. 

Condenser. The condenser is used to produce a quick collapse of the

magnetic field in the coil to obtain extremely high voltage. It consists of a pair of flat
metal plates which is separated by air. The condenser in the distributor is connected
across the contact breaker points. The condenser prevents sparking across the
contact breaker points to avoid burning.

Dynamo. The dynamo keeps the battery fully charged, and supplies direct
current for ignition, light, and other electrical accessories. 

Battery. The battery is the main source of power that supplies the whole
system. Lead acid type of battery is commonly used for internal combustion engines
for tractors and automobiles. The battery consists of plates, separators, electrolytes,
a container, and a terminal wire. 

Switching Devices and Wires. The switching device triggers the ignition coil,
while the wires distribute spark throughout the system.

1.2 Types of Ignition System

There are several types of the ignition system. Two of which are the Conventional
Ignition System and the Electronic Ignition System. The working principle of Conventional
Ignition systems works on the mutual electromagnetic induction principle and is further
divided into two: The Battery or Coil ignition System and the Magneto Ignition System.

1.2.1 Conventional Ignition System

1.2.1.1 Battery Ignition System

Battery Ignition System (The Engineers Post, 2022)

Generally, this system can be used in either 4-wheelers or 2-wheelers in which 6V or

12V batteries will supply the necessary current in the primary winding. When the ignition
switch, crank, and contact breaker are closed, a low-voltage current flow through the primary
winding. In one revolution, the contact breaker cam opens and closes the circuit four times
for four cylinders. When the contact breaker is open, the magnetic field will collapse, and
thus the current will be induced in the secondary winding. Approximately, about 21000 turns
occur in the secondary circuit, which is why the voltage in the system is ranging from 28000
to 30000 volts. This high-voltage current will flow through the distributor rotor. The distributor
rotor will start to rotate in order to supply the charge to the spark plug considering the engine
firing order. As the high voltage current reached the spark plug gap, the spark is produced,
and the combustion will occur to generate power. The battery ignition system is used in cars
and buses for which it is required to crank the engine (KIT-Kalaignar Karunanidhi Institute of
Technology, 2022). For the record, a battery is ultimately important in an engine as it stores
energy and supplies current in the system to power the operation. More so, it serves as an
alternator to keep the functionality of the sound system, air-conditioning, wipers, headlights,
or even the airbag system. It also acts like a voltage regulator (auto-Xpress.co.ug, 2020).

1.2.1.2 Magneto Ignition System

Magneto Ignition System (The Engineers Post, 2022)

 The arrangement in this system is similar to a battery ignition system, but in this
case, no battery is needed. The magneto ignition system is used only in 2-wheelers such as
motorcycles and scooters. The magneto acts as a generator that will produce and supply the
required current to the primary winding through a rotating magneto with a fixed coil or
rotating coil with a fixed magneto (KIT-Kalaignar Karunanidhi Institute of Technology, 2022).

The battery ignition system definitely requires a battery to supply current in the
primary circuit, hence, battery maintenance is necessary, including recharging whenever it
gets discharged or a replacement. In terms of size, this system occupies more space, unlike
the magneto system, which is very compact. Contrary to the battery ignition system, the
magneto ignition system does not need a battery, thus, no battery maintenance problems
are expected. However, the quality of the spark during starting is poor due to low speed. In
contrast, the battery ignition system has a good quality spark even at a low speed.

1.2.2 Electronic Ignition System

Electronic Ignition System (The Engineers Post, 2022)

An electronic ignition system uses transistors, capacitors, diodes, resistors, and

sensors. Technically, the sensor controls the transistor to create an electric pulse, which
further works to generate a high-voltage spark necessary for the combustion process. This
kind of system has lower emissions than conventional ignition systems. The advantage of an
electronic ignition system is that it is entirely electronically controlled. Instead of contact
breaker points in the battery ignition system, the electronic ignition system used armature to
generate the magnetic field in the system. The brain of this system is the Electronic Control
Module or ECU, also called as Control Unit, in which electronic work starts as it switches the
primary current on and off. The ECU receives voltage signals from the armature and turns
the primary coil on and off. It also accurately monitors and determines the timing as well as
the intensity of the current supply to the distributor’s spark plugs.

The working principle of an electronic ignition system is that the timer, either a Hall
effect sensor or pulse generator, transmits electrical pulses to ECU, which turns off the
primary winding's current flow. As for a breaker point ignition system, a high voltage is
consequently induced in the secondary winding and distributed to the spark plugs and starts
the combustion process in the chamber or cylinder. Afterwards, the ECU enables the
primary circuit to receive current so that it can prepare for the next cycle. The other few
types of commonly used timers in electronic ignition are pulse generators, Hall effect
switches, Optical switches, and Capacitor Discharge methods (Yousef, 2022).

1.3 Advantage and Disadvantages of Ignition System

One of the drawbacks of conventional ignition engines is arcing, which is caused by

the contact breaker point. As the current flows through the air from one conductive point to
another, arcing may occur. Also, a poor starting of an engine might experience in
conventional due to inaccurate timing once an engine has operated for a few thousand
kilometers. More so, the performance is poor at a very high engine speed because the
inertia affects the moving parts in the system. There is also an instance that the spark plug
may not produce a spark due to wear. Conversely, the electronic ignition system is quite
more advantageous than the conventional one. It requires no maintenance and arcing
because there are no moving parts and contact breaker points since the solid-state
electronics control all operations of the system (Yousef, 2022). In addition, the service life of
the spark plug is longer by 50%, which can be used for about 60000 km without any
problem. More importantly, this system has more power output and is more efficient as the
combustion is about 90% to 95% compared to 70% to 75% in conventional.

1.4 Problems and Maintenance of Ignition System

Some common problems in ignition systems are difficulty starting the engine,
engine misfires, and worn components. A complete or partial failure of an ignition system
can be prevented by following the recommended maintenance by the manufacturers and
engine experts. The following maintenance is recommended (what-when-how.com, n.d.):

 The ignition system should be checked after every 10,000 km of use.

 Activities during checking:
 The contact breaker is replaced and adjusted. 
 Spark plugs are cleaned and tested.
 Wiring is checked for condition and security.
 Dirt and moisture are removed from the coil and any other surface
exposed to HT charges.
 Lubrication of the cam face and moving parts of the automatic
advance system is carried out.
 Contact Breaker. The condition is checked by measuring the voltage drop across
the contact while fully closed. The wiring from the coil to the contact breaker is
necessary during testing. The correct contact gap is set using a feeler gauge or dwell
gauge.
 Spark Plug. The condition of the spark plug is checked by removing the plugs. First,
the HT leads are removed by withdrawing the connectors. Then, the plug is removed
by using a suitable plug socket. Care must be taken to avoid cranking the ceramic
insulator. Inspection of the plug before cleaning often provides information on the
state of tune of the engine. The condition of the spark plug is either normal, carbon
fouling, split core nose, or overheating.
 Ignition Timing. Test lamp method (or static timing) is performed to determine
where the contact breaker opens. The test lamp should indicate that the contact
points have just opened.
 Generally, timely lubrication of the system should be provided.

2. Lubrication System

Moving parts of an engine require regular lubrication to prevent engine problems. As

provided by Dr. Chouhan (2020) in his presentation about farm machinery and power, the
purpose of lubrication is to reduce wear and prevent the seizure of rubbing surfaces, reduce
the power to overcome friction, and remove dirt and other foreign material between the
engine parts. The lubrication also has a cooling effect in which the heat is removed from the
piston and other parts. In addition, it acts as a seal between piston rings and cylinder.
Moreover, the parts of an engine that requires lubrication are cylinder walls, piston,
crankshaft, connecting rod bearings, valve opening, water pump, piston pin, camshaft
bearings, cooling fan, and ignition system.

Lubricant is an oil fluid made from animal fat, vegetables, and minerals. However, a
lubricant made of animal fat is observed to be not suitable for engine use as it becomes
waxy and gummy, it does not stand the heat. Meanwhile, vegetable lubricant is extracted
from seeds, fruits, and plants. Some common kinds of vegetable lubricants are cotton seed
oil, olive oil, linseed oil, and castor oil, which are used in small engines. Further, the most
popular lubricant for engines and machines is the mineral lubricant that is obtained from
crude petroleum. But the most suitable for IC engines is petroleum lubricants.

2.1 Parts and Function of Lubrication System (Hall-Geisler, 2021)

Lubrication System of an Engine (Google Images)

Oil pan. It serves as oil storage while the engine is off. The oil pan can hold 4
to 6 quarts of oil.

Pickup Tube. It is a passageway of the oil that transports oil from the oil pan
to other parts.

Oil Pump. A gear-type pump driven by the camshaft is used to force oil into
the oil pipe.

Pressure Relief Valve. It prevents the build-up of high pressure in oil by

controlling the oil flow to the bearing chambers.

Oil Filter. It filters out and removes the dirt and debris of the oil.

Spurt Holes and Galleries. These are the holes present in engine parts that
allow the oil to coat the bearings and cylinders.

Sump. After the lubrication process, the excess oil is collected in the sump
and waited to be used in the next operation.
2.2. Types of Lubrication System

2.2.1 Splash Lubrication System

In a splash lubrication system, a dipper is placed at the bottom of every connecting

rod of the cylinder to gather up lubricating oil from an oil sump or pan. The connecting rod
moves up to the engine parts, loading up oil from the bottom. As moving parts create
mechanical turbulence in the crankcase, which further causes the oil to spread in the form of
mist in the crankcase, certain oils are also distributed to various components, such as
bearings and connecting rods by a splash. This also penetrates cylinder walls, pistons, and
piston pins, among other engine parts, as well as the camshaft and valves (E-courses
Online, 2014).

Splash Lubrication System (Google Images)

2.2.2 Forced Feed System

Forced Feed System (Google Images)

In a forced feed system, the lubricant is directly pumped into all moving parts of the
engine through a lubricating oil pump. This pump is a gear or vane pump that is driven by
the camshaft. The oil first enters the main gallery by means of a pipe or channel. Then, the
oil passes to the bearing through holes towards other parts of the engine that requires
lubrication. The lubrication of the timing gear is separated. Consequently, the excess oil from
the cylinder head will flow back to the crankcase. This system is usually used in a high-
speed multi-cylinder engine in tractors, trucks, and automobiles (Chouhan, 2020).

2.3 Advantage and Disadvantage of Lubrication System

A splash system of lubrication is limited to small engines or single cylinders only. The
distribution of lubricants is not widely extended to the critical components of an engine.
Contrastingly, the forced feed system is way better than splash due to the additional
pressure applied, which makes the oil reach all the essential moving parts that need
lubrication. This helps in efficient lubrication of engine components and hence in achieving
better engine performance.

2.4 Problems and Maintenance of Lubrication System

Some problems that may encounter regarding the lubrication system are the
malfunction in pressure and the amount of lubricant dispensed in the system. Once the
pressure is low or no pressure at all, the system may have leakage, or the lubricant has
thinned out. Conversely, if the pressure is high, there may be a clogged in-line filter, or the
flow apportioning units are incorrect. This may lead to an increase in the amount of lubricant
dispensed. In addition, if the amount of lubricant decreases, the pump may be worn out, or
there must be a change in operating speed.

Regular lubrication maintenance of engine parts helps to prevent clogs in the system.
The filtration components of the lubrication system, such as filters, screens, and strainers
should be regularly cleaned and replaced. More importantly, visual inspections should be
done from time to time to ensure that no leakage is happening. Otherwise, the engine must
be repaired to prevent serious problems. Thus, some maintenance of the lubrication system
is provided below (fluidlinesystem.net, n.d.).

 Frequently clean the lubrication reservoir but never use cotton or fiber rags.
 Replace the filter and clean the screen annually or if necessary.
 The pressure filter should be replaced annually.
 Inspect the hose or piping for possible holes and cracks.
 Check the tightness of the connections but do not over-tight.
 Only recommended lubricants should be used. Lubricants with additives that could
clog filters or flow apportioning devices should be avoided.
 Seek a check-up of the lubrication system from an authorized expert.

3. Cooling System

As the engine works to convert chemical and thermal energy to mechanical energy, a
high amount of heat is produced and released. Typically, the temperature reached up to
1600°C. For the record, about 40% of the total heat produced is emitted to the atmosphere
via exhaust, and 30% is the heat removed by the cooling system. Roughly only 30% is used
to produce useful power. In line with that, the cooling system is present in an engine to
maintain the optimum temperature of the engine. It also protects the component of the
engine from overheating. The cooling system also helps to maintain the lubricating property
of oil inside the engine. 
 Radiator Cooling Fan

Coolant Thermostat
Hose Valve
Sample of a Cooling System at DIET

3.1 Parts of Cooling System (StudentLesson.com, 2020)

Water pump (Centrifugal Pump). It draws the cooled water from the bottom
of the radiator and delivers it to the water jackets surrounding the engine.

Radiator. It is to be used to provide a strong draft of air through the radiator

to improve engine cooling.

Fan. The fan is mounted on the water pump shaft. It is driven by the same
belt that drives the pump and dynamo.

Water Jacket. It refers to passages cored out around the engine cylinder as
well as around the valve opening.

Thermostat Valve. It is a control valve used in a cooling system to control the

flow of water when activated by a temperature signal.

Temperature Gauge. It indicates the temperature of the system, which

provides a warning of overheating. It consists of a sensor and a gauge. 

Hose Pipe. It is the passageway of the fluid that allows circulation from the
radiator to an internal part of the engine back to some associated components. 

3.2 Types of Cooling System

3.2.1 Air Cooling System

Air Cooling System (Google Images)

In an air cooling system, the engine heat is removed by means of the atmosphere
while the engine is working. The design of the system is intended for air contact. For
instance, the cylinder has fins to increase the area of air of contact for speedy cooling. Also,
the flywheel has blades projecting from its face acting like a fan. It harnessed the air through
a hole in the cowling and directed it around the finned cylinder.

3.2.2 Water Cooling System

Water Cooling System (Google Images)

The water-cooling system uses water as a medium to cool the engine. Simply, the
fluid circulated inside the cylinders to absorb heat from the cylinder walls. Then, the heated
water is conducted through a radiator to remove the heat a cool the water. One of the
methods that involve water is the forced circulation system. As cited in eagri.org (n.d.), “a
water pump is used to force water from the radiator to the water jacket of the engine. After
circulating the entire run of the water jacket, water comes back to the radiator where it loses
its heat by the process of radiation. To maintain the correct engine temperature, a
thermostat valve is placed at the outer end of the cylinder head. Cooling liquid is bypassed
through the water jacket of the engine until the engine attains the desired temperature. The
thermostat valve opens and the by-pass is closed, allowing the water to go to the radiator.”

As an alternative, an engine can still operate without the thermostat at a certain

distance. However, the thermostat is an important component of the cooling system as it
regulates the temperature inside the engine. Without it, the engine will lose heat to the
radiator and may take a longer warm-up. The heating and cooling process of an engine will
become inconsistent and will never reach the optimum temperature. The system will thrive to
reach an optimum temperature which is why the engine will work at high revolution. Serious
mechanical problems may occur without the thermostat.

3.3 Advantage and Disadvantage of Cooling System

An air cooling system has a simple design and construction, which is why it is more
compact and lighter in weight. It does not have other components such as water jackets,
radiator, water pump, thermostat pipes, and hoses, thus, the maintenance in the system is
lesser. However, during the process of the air cooling system, the distribution of cooling is
uneven, and the temperature is generally high during the operation (Chouhan, 2020). In
addition, the noise level in this system is higher the general performance is considered less
efficient. On the contrary, the water cooling system is more efficient as it has a higher rate of
heat transfer. It can also be used in heavier operations. More so, the thermal conductivity is
greater in this system, and the water is easily available. On the other hand, this system
requires more attention in cleaning and maintenance because corrosion might easily occur
inside the radiator or pipe, or storage. It may also malfunction after the long run due to the
scaling heat transfer rate (Dey, n.d.).

3.4 Problems and Maintenance of Cooling System

Some common problems in cooling systems are radiator leakage, water pump
failure, poor lines and connections, and thermostat failures. Once these issues arise,
immediately check the system to prevent serious problems. The maintenance of the air
cooling system is done by cleaning the passage of air and removing accumulates using a
stiff brush or compressed air. When a separate fan is provided, the belt tension is to be
checked and adjusted if necessary. For the water cooling system, assure that only clean and
fresh water must be used to fill in the radiator. The tension of the fan belt should be checked
regularly because a loose belt may cause overheating. Conversely, if the belt is very tight, it
may cause wear on the pulley of the pump and dynamo. It is also necessary to keep the oil
and grease away from the belt. And the bearing of the water pump should be lubricated
regularly.

Conclusion

An engine is a series of auxiliary systems that perform repetitive moving actions to

provide power. Here is why the engine is easily subjected to wear, generation of heat, and
loss of power. In this laboratory, the three systems of an engine were discussed, including
the ignition system, lubrication system, and cooling system. An ignition system refers to the
arrangement of different components for the ignition of the fuel mixture at the proper time
inside the chamber of an engine. Whereas, the lubrication system pertains to the application
of a substance called lubricant to minimize the friction between moving components of an
engine. Lubricant is in the form of oil that is distributed to the parts of an engine. Lastly, the
cooling system keeps the engine at optimum temperature while working because, during the
process of conversion of energy, the temperature, pressure, and voltage is high, which
makes the engine heat up. More so, the working principle of each system was discussed
accordingly, including their parts and function. In addition, several types of every system
were provided as well as the common problems and maintenance in the auxiliary engine.
After all, an engine helps the mechanical operations to be easier and faster, hence, proper
care and maintenance are necessary to keep an engine functional for a long time.
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Dey, A. (n.d.). Cooling System of IC Engine: Definition, Types, Advantages, Disadvantages,

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eagri.org (n.d.). Different Systems of IC Engine – Cooling, Lubricating, Fuel Injection

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http://ecoursesonline.iasri.res.in/mod/page/view.php?id=100978

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http://ecoursesonline.iasri.res.in/mod/page/view.php?id=125449

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