5S ELEMENTS

We should follow the 5s system for organizing

spaces so work can be performed efficiently.

SEIRI - Clear Out.

SEITON - Put In Order.
SEISO - Clean and Check.
SEIKETSU - Standardize.
SHITSUKE - Sustain.
 ENGINE

Engine is the power unit.

Engine converts chemical energy into
heat energy and in turns converts into
mechanical energy.
 ENGINE

Internal combustion External combustion

Spark Ignition Compression Ignition

N Series H Series
 Working of Four Stroke Diesel Engine
Following are the four strokes:-
1 - Intake/Suction stroke
2 - Compression stroke
3 - Expansion stroke
4 - Exhaust stroke
1. Intake Stroke
In suction stroke piston starts at TDC of the cylinder and moves to the BDC. Outlet valve will
be closed and inlet valve will be open to allowing the fresh charge mixed Fuel & air into the
cylinder.
2 . Compression stroke
In compression stroke, Once piston reaches BDC & moves back TDC, inlet valve will be
closed. As the piston moves towards TDC. It compress air inside the cylinder & compression
take place. Hence it is called compression stroke.
3. Power Stroke
In expansion stroke, Both the valves are closed. When piston reaches top of its stroke.
the fuel is sprinkled by the Fuel Injector and the fuel mixture is ignited due to high
temperature & pressure generated inside the cylinder & push down the piston to BDC.
Hence it is known as Power or expansion stroke. The Power generated in this stroke is
stored in the flywheel for its further utilisation in the other strokes.
4. Exhaust stroke
In this stroke exhaust valve is opened when piston reaches to BDC & moves to upward.
Piston pushes out the burnt gases to the atmosphere through the exhaust valve.
Hence called exhaust stroke & the engine is ready to begin the cycle again.
COMPONENTS 13. Belt
1. Crankshaft 14. Water pump
2. Cam shaft 15. Turbo charger
3. Cylinder head 16. Oil cooler & oil filter
4. Piston 17. Intake & exhaust
5. Common rail system(CRS) manifold
6. Air compressor 18. ECU
7. Fuel pump 19. Rocker mechanism
8. Dip stick 20. Timing mechanism
9. Viscous fan 21. Fuel injectors
10. Alternator 22. Cylinder liner
11. Vibration damper 23. Flywheel
NOMENCLATURE :
Type – Diesel four stroke six cylinder water cooled, direct injection, inline over
head valve.
Aspiration – Turbocharger with intercooler.
Maximum Output – 2400 rpm
Bore and Stroke – 104*113
Piston Displacement – 5.759 liters
Compression Ratio – 16.2:1
Firing Order : 1-4-2-6-3-5
Direction of rotation – Counter clockwise viewed from flywheel.
Idling revolution – 600 ± 50 rpm
Valve Clearance
Intake : 0.30 mm
Exhaust : 0.45 mm
Fuel Injection Equipment – Common Rail System
Thermostat – Single thermostat opens at 82° ± 2°c
Crank Shaft End Play – 0.05 to 0.125
Engine oil – 15W40
 SUB SYSTEMS

• LUBRICATION SYSTEM
• COOLING SYSTEM
• FUEL INJECTION SYSTEM (CRS)
• AIR INTAKE SYSTEM and EXHAUST SYSTEM
 LUBRICATION

• Reduction of the resistance to relative motion

between the surfaces.
• Prevention of seizure
• Reduction of the rate of wear of the sliding
surfaces.
S
 COOLING SYSTEM
• To maintain engine operating temperature. Cooling system
circulates coolant through the engine components which
absorbs heat transfers it to the atmospheric air through heat
exchanger.
 FUEL SYSTEM
• Cleaning of dirt and separate water from fuel
• Control the quantity of fuel to be injected and the timing
at which it is injected.
• Common Rail System : This is an EDC system which has
high pressure inline pump with electronic fuel metering,
common rail, set of sensors, ECU and injectors.
• Fuel from the pump is sent to common rail and from
there to all the injectors. Upon receiving the signals from
ECU, the injector needle lifts and delivers fuel as per
firing order.
 AIR INTAKE
It supplies clean air to the engine, air is drawn from
atmosphere after filtration , it is compressed and cooled .
Then enters into the engine.
 EXHAUST GAS RECIRCULATION
In EGR Engines , meter quantity of exhaust gas after cooling is
re circulated to the engine cylinders. As the EGR reduces the
air intake, it controls the pollutant NOx is controlled with in
the engine.
 SAFETY :

• Wear the gloves, helmet, shoes

• Remove watches, rings, bracelets.

ENGINE INSPECTION :

• Check the oil level

• Check the coolant level
• Drain the engine oil. Before draining the engine oil it must be
in warm condition.
• Clean the engine with waste cloth.
 ENGINE DISMANTLE

• At first, remove all the electrical connections.

• Remove all peripheral parts.
• Remove parts in sequence wise
• Remove Timing Region
• Remove cranking region
 PERIPHERAL PARTS
• Fuel pump
• Starter Motor
• Air Compressor
• Alternator
• Water Pump
• Vibration Damper
• Turbocharger
• Thermostat
• Oil Filter & Oil cooler
 TOP PARTS (Removal)

• Intake Manifold
• Exhaust Gas Recirculation System
• Common Rail System
• Fuel Injectors
• Tappet cover
• Rocker Shaft
• Cylinder head
• Tappets
• Oil Sump
 TIMING REGION
• Remove the timing casing.
• Remove all the gear system.

CRANKING REGION

• First we have to remove the pistons in proper

sequence
• Remove main bearing cap from crankshaft
• Remove crank shaft
• Remove liner using liner removal tool
• Remove flywheel housing and flywheel.
 CHECKING PROBLEMS

• Each time during engine overhauling we have to

check
• Fuel tank mounting strap, clean the fuel tank and
suction strainer
• Adjust fuel injector nozzle opening pressure.
• Check injection timing.
• Check and replace fuel hoses if necessary.
• Check and adjust valve clearance
• Check vibration pulley for any damages.
• Coolant radiator leakages, radiator mounting
bolts.
• Check and tighten front and rear engine
mounting.
• Check turbocharger mounting.
• Check air cooler hoses for leakages.
• Visually inspect cooling fan for dust and clean
if necessary clean.
 ASSEMBLE PROCEDURE

• Put all the liners

• Replace old washers with new washers.
• Put the crank shaft
• Put the washer thrust (maintaining play of
0.05 to 0.125 mm)
• Matching the notch and spread in thrust
bearing.
• Put the main journal bearing cap.
• Displace the piston ring gaps relative to each other
by 120°.
• Tight the piston ring by pressure joint tool.
• Put the piston. Make sure the O mark should be
towards the cam shaft side and arrow mark should
be towards front side of timing mechanism.
• Check the end play of crank shaft by dial gauge.(0.05
– 0.125).
• Assemble the timing region gears in proper
sequence.
 GEAR TRAIN
• Idler gear having 3 number system
11 is matched with crank shaft gear
22 is matched with oil pump gear
33 is oil pump gear
• The valve clearance for inlet valve is 0.30 mm
and outlet valve is 0.45 mm.
• Put the rocker arm shaft assembly.
• Attach the flywheel housing and the flywheel.
• Set the flywheel order 1/6 2/5 3/4
• Put the engine head, peripheral parts and the
oil sump tank.
 TIGHTENING TORQUES
Normal Torque Angular Torque

FLYWHEEL 105 NM 120°

CONNECTING ROD 100 NM 60°

CYLINDRICAL HEAD 70 NM 180°

BOLTA

ROCKER SHAFT 70 NM 90°

 OIL CAPACITY AND GRADES
AGGREGATES GRADES CAPACITY
QTY (liter)

ENGINE OIL GULF DURAMAX 18( H Series)

15W40 26(N Series)

COOLANT DURAMAX PINK 22.5 ± 1

•Coolant must be changed every 2,00,000 km.

•Oil must be changed after 80,000 km.
 H SERIES VS N SERIES
N SERIES H SERIES

BORE * STROKE = 112*135 mm BORE * STROKE = 104*113

WET LINER DRY LINER

D - Type rings O - type rings

OBLIQUE CUT NORMAL STRAIGHT CUT

GALLERY COOL PISTON NORMAL COOL PISTON

OVER HEAD CAM DOWN CAM

TOP TO DOWN COOLING DOWN TO TOP COOLING

TRUSS CONCEPT NO

SKRIT AREA NO

QUILL CONNECTOR NO

USED FOR TIPPER , TIP TRAILER USED FOR HAULAGE , BUSES

REAR TIMING GEAR SYSTEM FRONT TIMING GEAR SYSTEM

Firing order 1-5-3-6-2-4 Firing order 1-4-2-6-3-5