INJIN DISEL

Oleh

RAIS BIN MA’AT

Ketua Program Kejurteraan Elektrik
Institut Latihan dan Pembangunan
Infrastruktur Ikram

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 WHAT IS DIESEL ENGINE
Is an internal combustion engine, which
derives its power from the heat generated
when a compressed air-fuel mixture is
ignited within its cylinder

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 OPERATING PRINCIPLES
It is based on fundamental law of physic
which states that gas will expand upon
application of heat. If the gas be confines,
however with no outlet for expansion, then
the pressure of the gas will be increased
when the heat is applied as the result of
igniting the compressed gas in an internal
combustion engine

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 FOUR STROKE DIESEL
ENGINE
• Induction stroke/Intake stroke
• Compression stroke
• Power stroke/Combustion stroke
• Exhaust stroke

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 FOUR STROKE CYCLE

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 INDUCTION STROKE

As piston moves down the

cylinder block, due to the
suction effect, it draws air into
the cylinder through the open
inlet valve. The exhaust valve
remain closed during this
stroke

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 COMPRESSION STROKE

The piston moving up

the cylinder with both
inlet and exhaust valves
closed, compresses the
air to about 600 degrees
C

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 POWER STROKE

The high temperature of the

compressed air ignites the
fuel spray and the resulting
pressure forces the piston
downwards in its working
power stroke

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 EXHAUST STROKE
Near the end of the power
stroke, the exhaust valve
opens and as the piston
returns toward the cylinder
head, the burnt gases are
pushed out. At the top of the
stroke, the exhaust valve
closes and the air inlet valve
opens
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 IN LINE CYLINDERS

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 V CYLINDER ENGINE

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 CIRCULAR
CYLINDER

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 FIRING ORDER
• Firing order ialah turutan sistematik
diantara silinder-silinder injin dalam proses
membakar bahan bakar (fuel) untuk
mendapatkan kuasa
• Untuk injin 6 silinder ia tidak mengikut
turutan 1,2,3,4,5,6
• Firing order ini berbeza-beza mengikut
jenama-jenama injin

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 ENGINE CLASSIFICATION
• Horse power (3h.p to 40,000h.p)
• Number of cylinder (1 to 24 cylinders)
• Cycles of operation (2 or 4 stroke)
• Arrangement of cylinders
• Action of the piston
• Types of fuel ignited

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 DIESEL ENGINE
EFFICIENCY
• Today diesel engine is up to 42 %, better
than petrol engine without fuel injection

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 NATURAL AIR ASPIRATED
ENGINE
The flow of air depends entirely on the
piston induction stroke and the inlet valve
opening. Due to the resistance to the flow of
air through the manifold and valve, the air
obtained by the naturally aspirated method
is often insufficient to provide complete
combustion of the fuel. To overcome the
problem turbocharged has been developed.
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 AIR INTAKE

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AIR INTAKE & EXHAUST

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 AIR DUCT

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 TURBOCHARGED ENGINE
Is a device consisting of an engine exhaust
operated turbine, which drives a common
shaft, centrifugal compressor. The air is
compressed by the compressor and forced
into the combustion chamber with bigger
volume so that better combustion and better
power can be achieved

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 CIRCULATION OF AIR

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 TURBO-
CHARGER
UNIT

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 TURBO-
CHARGER
CUT-OUT

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 TURBO-
CHARGER

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 ADVANTAGES OF
TURBOCHARGED ENGINE
• Increased horsepower from an engine of a
given capacity
• Increase fuel economy
• Usually cost less than a naturally aspirated
engine of the same horsepower

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CIRCULATION OF AIR

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 SUPERCHARGED ENGINE
Where the exhaust power is not adequate or
it may affect engine efficiency or because
of technical reason other means of driving
the compressor such as electric motor is
used. This is called supercharger and
applicable to larger size diesel engines.

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INTERCOOLER/AFTERCOOLER
Cold air has greater density than warm air, it
thus contain more oxygen molecules per
unit of volume. By cooling the charging air,
more fuel can be burnt which means that a
greater output can be obtained. Furthermore
the cooling reduces the thermal stresses on
the combustion chamber. Air can be cooled
by either the radiator fan, engine coolant or
fan.
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 SISTEM BAHAN API
• Storage tank Governor
• Day tank High pressure pipe
• Strainer Injectors
• Feed pump Returned pipe
• Fine fuel filter
• Water separator
• Bleeding pump
• Fuel supply valve
• Fuel injection pump
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 FUEL
Storage
SYSTEM Tank

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FUEL
SYSTEM
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 DAY TANK

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 FUEL INJECTION PUMP

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 FUEL INJECTION PUMP

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 FUEL
INJECTION
PUMP

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 FUEL INJECTION
PUMP AND
INJECTOR

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 FUEL INJECTOR

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 FUEL
INJECTOR

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 FUEL INJECTOR

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 FUEL SYSTEM

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 FUEL INJECTION SYSTEM
• Fuel must be metered in the correct quantity
• Correct opening pressure
• Injected at the right time
• Injected in fine atomized form

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 PRE-HEATER

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 FUEL SOLENOID
Fuel solenoid adalah sebuah gelong yang
mengawal injap bekalan bahan api.
Pemberhentian enjin adalah dengan
memutuskan bekalan bahan api iaitu dengan
menutup injap tersebut melalui tindakan
gelong fuel solenoid melalui litar kawalan
didalam papan AMF

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 FUEL SOLENOID

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 FUEL VALVE (SOLENOID)

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 KELAJUAN ENJIN
Kelajuan enjin dikawal dengan mengawal
banyaknya bahan api yang dibekalkan
kepada injector. Tugas ini dilakukan oleh
governor. Governor mengesan kejatuhan
kelajuan atau terlebih laju dan menambah
atau mengurangkan bekalan bahan api
supaya kelajuan dapat dikekalkan pada
tahap yang ditetapkan

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 MECHANICAL GOVERNOR

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 GOVERNOR

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 GOVERNOR

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 TIMING
GEAR

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 BLEEDING PUMP
A small pump attached to the governor to
flush out trapped air bubble in the fuel
system

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 ELECTRONIC GOVERNOR

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 JENIS TANGKI
DAY TANK – small quantity, for daily
consumption

STORAGE TANK – bigger quantity,

for
one or a group of generators, monthly
consumption

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 TRANSFER PUMP

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 FUEL INLET
PIPE

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 KEMAMPUAN TANGKI
Secara purata setiap 10 kW menggunakan 1
gelen minyak disel untuk 1 jam. Jadi untuk
set 60 kW kita akan menggunakan 6 gelen
minyak disel untuk tiap-tiap jam ia
beroperasi. Day tank yang standard
berkapasiti 1000 liter. Jika bekalan sebulan
sekali minyak diperlukan 6gelen x 8jam
sehari x 30hari +5% tambahan = 1500gelen

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 FUEL TRANSFER PUMP
• Electric fuel pump - to pump fuel from
storage tank to daily tank if required
• Gravity feed – fuel from storage or daily
tank flow freely based on gravity pressure
to daily tank or to the engine
• Normally back up by manual pump

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 SISTEM PELINCIRAN
• Sump
• Oil pump
• Oil filter/Strainer (primary & secondary
filter)
• Oil cooler
• Oil pressure switch
• Jenis minyak/kelikatan minyak (30/50)

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 LUBRICATING SYSTEM

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LUBRICATING SYSTEM

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 OIL FILTER

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 STARTING SYSTEM
• Electric starter motor – 12V, 24V
• Hydraulic starter – sparkless starter,
hydraulic pump
• Compressed air starter – sparkless starter,
air pressure vessel

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 STARTER MOTOR

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 STARTER MOTOR

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 AIR START

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 CHARGING SYSTEM
• Static charger – normal supply, bila
janakuasa tidak beroperasi
• DC alternator charger, bila janakuasa
beroperasi (prime power)
• Constant voltage charger
• Constant current charger
• Charging current and voltage

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 DC ALTERNATOR
COMPONENTS

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 DC ALTERNATOR COMPONENTS

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 DC ALTERNATOR CIRCUIT

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 SISTEM PENYEJUKAN
• Radiator cooled (engine mounted)
• Remote radiator cooled (hot well/break
tank)
• Heat exchanger cooled – raw water
• Air cooled

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 COOLING
SYSTEM

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 COOLING
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 COOLING SYSTEM

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 WATER LEVEL INDICATOR AND GAUGE

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COOLING SYSTEM

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 COOLING SYSTEM

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 HOT WELL

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 HOT WELL

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 HEAT EXCHANGER

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 HEAT EXCHANGER

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 SISTEM EKZOS
• Membuang gas hasil pembakaran
• Mengurangkan bunyi bising
• Flexible hose untuk mengelak gegaran
• Jenis silencers – industrial silencers (tidak
kritikal), residential silencers (sensitive
area), absortive silencers (standard
attenuation tinggi), spark arrestor silencers
(hazardous area)

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 ENGINE PROTECTION
• Low oil pressure – alarm & trip
• High water temperature – alarm & trip
• Over speed – trip
• Over crank – trip
• Fail to start – alarm
• Low fuel level - alarm
• Lack of fuel - trip

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 FLOAT SWITCHES

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 ENGINE INSTRUMENT
• START/STOP Key switch / Emergency Stop
• Oil pressure gauge (43 – 71psi)
• Temperature gauge 75 – 95 deg. C
• Engine speed meter (rpm)
• Hour run counter
• Charging ampere meter (ampere)
• Battery volt (volt)
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 ENGINE INSTRUMENT

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 ENGINE NAME PLATE
• No of cylinders & arrangement
• Horsepower
• Engine oil standard
• Serial number

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 ROOM VENTILATION
• Louvered door c/w insect netting
• Exhaust fan
• Fresh air passage – adequate volume
• Exhaust gas outlet

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 PENGUDARAAN BILIK

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 PENGUDARAAN BILIK

Fresh air intake

Exhaust
Gas

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 MEMULAKAN INJIN
• Periksa bahan api (disel)
• Periksa minyak pelincir
• Periksa air penyejuk
• Periksa air bateri
• Periksa voltan bateri
• Periksa semua belting
• Pemerhatian am, kebersihan, keselamatan

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 SENGGARAAN ENJIN
• Minyak pelincir
• Penapis minyak
• Air radiator
• Penapis udara
• Elektrolid bateri
• Minyak hidraulik governor
• Habok, kotoran & sawang

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 POINT
SENGGARAAN

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