07 Januari, 2022

Fundamental Engine
Isi Pelatihan

• Sejarah mesin disel

• Cara kerja mesin disel
• Komponen utama mesin disel
• Sistem utama dan tambahan pada
mesin disel
Tujuan Pelatihan

• Memiliki pemahaman yang baik tentang

pengetahuan dasar mesin disel secara teori dan
praktek.
• Melakukan pekerjaan denga aman, tanpa
merusak peralatan,komponen, kendaraan atau
orang.
Pengantar

• Aplikasi mesin disel pada industri

• Penggerak utama pemasok daya mekanis
• Genset
• Pompa
• Alat tranportasi darat dan laut
• Alat pendukung (ancillary)
• Alat berat
• kuat dan tangguh serta hemat bahan bakar dan
efisien
Sejarah Mesin Disel
Sejarah Mesin Disel

• Dikembanh=gkan awal abad ke 19

• Oleh Dr. Diesel
• Bahan bakar debu batu bara
• Tekanan kompresi tinggi 1500 Psi
• Tanpa Cooling system
• Mesin meledak
• Bahan bakar solar
• Tekanan kompresi diturunkan 550 Psi
Mesin Disel Pada Kendaraan
Dibutuhkan upaya penelitian yang cukup besar
dan uji coba yang tak terhitung banyaknya
sebelum mesin disel siap dipasang di kendaraan
yang bergerak.
Mesin kendaraan pertama datang pada awal
1920-an. Salah satu yang pertama, Benz dari
tahun 1922. Itu memiliki dua silinder dan
menghasilkan hanya 22 kW atau 30 tenaga kuda.
Cara Kerja Mesin Disel
Internal Combustion Engine

• Internal Combustion Engine (ICE) yang

berarti mereka membakar campuran
bahan bakar-udara di dalam silinder.
• Reciprocating engine, digerakkan oleh
piston yang bergerak lateral dua arah.
Proses Pembakaran
• Compressed air
• Ignited Pressure
• Fuel injected
• Pressure icrease rapidly
Gaya Linear ke Gaya Putar

• Piston
• Considere linear force
• Connecting rod
• Crankshaft
• Rotate in a circle
Output Crank Shaft
• Transmission components
• Driveline
• Driven wheels
• Vehicle move
Hasil Pembakaran Bahan
Bakar Menjadi Energi
• Cooling losses
• Exhaust losses
• Friction losses
Perbedaan Mesin Disel – Mesin Bensin
(Mesin Bensin)
Spark Ignition (SI)
• Ready-mixed blend of petrol and air
• Compressed
• Spark
• Ignited
Perbedaan Mesin Disel – Mesin Bensin
(Mesin Disel)
Compression Ignition (CI)
• Unblended air
• Hot air Compressed
• Ignite the diesel fuel
• Peak pressure
• Diesel engine 7 and 20 MPa
• Petrol engine 3 to 5 MPa
Perbedaan Mesin Disel – Mesin
Bensin (Komponen)
komponen mesin diesel jika dibandingkan dengan
mesin bensin dengan tenaga kuda (Horse Power) yang
sama, komponennya akan lebih kuat dan lebih berat
karena harus mampu menahan gaya dinamis yang
lebih besar dari tekanan pembakarannya
Perbedaan Mesin Disel – Mesin
Bensin (Rasio Kompresi)
• Ukuran seberapa banyak enjin dapat memampatkan
gas dalam silinder.
• Pada mesin bensin rasio kompresi kurang dari 10:1.
• Pada mesin diesel, rasio kompresi mulai dari 14:1
sampai setinggi 24:1
Perbedaan Mesin Disel – Mesin Bensin (Pengaturan
Kecepatan Mesin Bensin)
• Kecepatan (daya) adalah fungsi langsung dari jumlah bahan bakar
dan udara yang dibakar di dalam silinder.
• Katup kupu-kupu membatasi jumlah udara yang masuk ke ruang
bakar.
• Laju aliran udara menentukan jumlah bensin yang akan bercampur
dengan udara.
• Dengan membatasi jumlah udara yang masuk ke ruang bakar ,
menambahkan lebih banyak bahan bakar tidak akan meningkatkan
kecepatan mesin melampaui titik di mana bahan bakar membakar
100% udara yang tersedia (oksigen).
Perbedaan Mesin Disel – Mesin Bensin (Pengaturan Kecepatan Mesin
Disel)
• Udara (oksigen) yang masuk ke ruang bakar selalu dalam jumlah maksimal.
• Kecepatan mesin hanya dibatasi oleh jumlah bahan bakar disuntikkan ke dalam
silinder ruang bakar.
• Kondisi tanpa beban kecepatan mesin bisa berakselerasi melebihi 2000 RPM ,
• Pengaturan jumlah bahan bakar secara manual tidak memungkinkan,
• Membutuhkan perangkat pembatas kecepatan yang biasa disebut “governor”.
• Governor bekerja mencegah putaran mesin melebihi batas kemampuannya (over
speed).
Cara Kerja Mesin Disel 4 Langkah Untuk Satu Siklus
Proses Pembakaran
• Saat tertundanya pembakaran (ignation delay) (A-B)
• Saat perambatan api (flame propagation) (B-C)
• Saat pembakaran langung (direct injection) (C-D)
• Saat pembakaran lanjut (after burning) (D-E)
Valve Timing
Valve Timing Diagram
Urutan Pembakaran (Firing Order)
Empat Langkah – Empat Silinder
• Direction the piston is moving
• Position of the valves
• 1-3-4-2
Urutan Pembakaran Empat Langkah – Enam Silinder
• Firing order is 1 - 5 - 3 - 6 - 2 - 4
• Three operating strokes
• Once the crankshaft has rotated twice, combustion has taken place
in all the cylinders
• Absolute precision is essential for the engine to run perfectly
Combustion Chamber Type
• Direct-injection engines
• Indirect-injection engines (Pre Combustion and Swirl-chamber
engines)
Direct Combustion Chamber
• Small losses
• Higher efficiency
• Lower fuel consumption
InDirect Combustion Chamber
• Combustion is quick
• Greater losses
• Lower efficiency
• High fuel consumption
Engine design (In Line)
• In-line engine or straight engine
• Vengine
Istilah Dalam Mesin disel
Bore, Stroke & Displacement
• Bore = Diameter dari cylinder
• Stroke = Jarak antara langkah piston saat diposisi TDC dan
BDC
• Piston displacement = Volume pergerakan piston (cc atau
liter)
• Engine displacement = Volume piston X jumlah cilinder
engine (cc atau liter)
Compression Ratio
• Compression ratio = perbandingan volume ruang
bakar saat piston di BDC dan TDC
• Compression ratio = 18 :1 (contoh)
Volumetric Effisiensi
• Jumlah udara yang dapat masuk keruang bakar
dibandingkan dengan volume ruang bakar
• Naturali aspirated engine = 80 sampai 90%
• Torbo charger engine = lebih dari 100%
Heat Effisiensi
• Jumlah panas yang dihasilkan dari pembakaran
bahan bakar yang terkonversi menjadi tenaga
• 30-40 % panas menjadi tenaga
• Coolant loss = 30%
• Ehhaust loss = 30%
• Friction loss = 10%
Horse Power

• James watt = inventor (penemu mesin uap)

• Membandingkan tenaga yang dihasilkan oleh kuda
dengan mesin uapnya
• 1 ekor Kuda mengangkat 200lb muatan 165 ft lurus
ke atas dalam waktu satu menit atau sama dengan
33.000ftlb/menit
Brake Horse Power

• Tenaga aktual yang dapat digunaka yang dihasilkan

sebuah mesin
• Tenaga yang tersedia pada Flywheel
Torque
• Torsi adalah ukuran seberapa besar gaya yang diberikan pada sebuah objek hingga objek tersebut berputar
pada sumbunya
• Satuan torsi = lb.ft (N.m)
Horse Power dan Torque Curve

• Horse Power
• Torque
Komponen Utama
 Komponen Utama
• Cylinder Block
• Cranking mechanism
• Cylider Head
• Valve Train
• Timing gear (Gear Train)
Cylinder Block
Komponen Utama
• Cylinder Block
• Cranking mechanism
• Cylinder head
• Valve Train
• Timing gear (Gear Train)
Cylinder Block
Function :
• Struktur utama sebuah
enjin
• Tempat diletakkannya
komponen mekanisme
cranking
• Membentuk ruang bakar

Fitur :
• Cast in one piece
• Cast-iron
• Reinforcement ribs
Cylinder block - inside
• Coolant jacket
• Cylinder liners
• O-rings
• Main bearings
• Bearings for the camshaft
• Lubricating oil ducts
• Piston cooling duct
Cylinder Liner
Function :
▪ Membentuk ruang bakar
▪ Menyekat ruang bakar dan cairan pendingin

Design Liner :
▪ Directly in the block
▪ Pressed into recesses in the block
▪ Direct contact with the coolant
Cylinder bore
• High degree of precision
• Cylinder bore
• Milled
• Honed
• Plateau honing
• Checked pattern

1. Oil pockets
2. Tapered profile
Cylinder head and cylinder liner seals
• Top ring (A)
• 3 Lower rings (B)
• 2 Atas = Coolant seal
• 1 Bawah = Oil seal
• Different colours for securing correct mounting
• Liner and cylinder head gasket (C)
Camshaft in cylinder block view
• Camshaft
• Lifters
• Pushrods
Cranking Mechanism
Cranking mechanism
Function :
• Mentransfer tenaga hasil pembakaran
menuju fly wheel
• Mengubah gaya linear menjadi rotsi

Components :

• Piston • Thrust washers (axial

• Piston rings bearings)
• Gudgeon pin • Crankshaft
• Connecting rods • Flywheel
• Connecting rod bearing • Vibration damper
• Main bearing
A few facts about loads
• High pressure
• Immense forces
• Peak pressure 11 MPa
• Piston surface - 130 cm2
• 140 kN (kilo Newton), in other words about 14 tonnes
Piston
Function :
• Absorb combustion pressure
• Transfer considerable force

Fitur :
• Piston roof / Crown
• Perfect fit
• Combustion pressure
• Loss of engine power
Piston - Thermal stress and mechanical stress

• Combustion pressure load

• Thermal stress
• Mechanical stress
• Wear against the cylinder wall
• Wear of the ring groove owing to piston ring
movement
• Wear of the gudgeon pin bearing
Piston - Materials
• Aluminium alloy
• Silicon
• Iron
• Nickel
• Manganese
• Copper
• Magnesium
• Extremely durable
• Thermal expansion
Jenis Piston (Articulated Piston)
• Articulated pistons - split pistons
• Separately journal led
• Gudgeon pin
• Top section - steel
• Bottom section - aluminium
Piston rings
Two types
▪ Compression ring (1 dan 2) (menyekat
tekanan kompresi dan pembakaran)
▪ Oil scraper ring (3) (mebersihkan
didnding liner dan memberi pelumasan)
Piston cooling
• Internal piston cooling
• Channel
• Oil sprayed into channel
• Efficient cooling
• Extremely hot
• High load
• Oil-borne piston cooling
• Piston cooling duct
• Piston cooling nozzles Inside of the piston
Gudgeon Pin
▪ Transfer Force from piston to connecting rod
and Crankshaft mechanism
▪ Fasten piston and conn rod
▪ High load
Gudgeon Pin - Journal Led
• Journal led
• Floating fit
• Locking rings
Connecting rod
Function
• Transfer force from piston to crank shaft
Fitur :
• Strong and lightweight I-shaped profile
• Extremely durable
Material :
• High-alloy steel
• Chrome-molybdenum steel
• Chrome manganese silicon steel
• Forged (tempa)
Connecting Rod - Details

• Big end
• Small end
• Bronze bushing
• Marked
• Front marking
• Trapezoidal
• Lubricated via ducts
• Splash lubrication
• Diagonally split
• Angel split
Connecting Rod Bearing
• Two bearing shells
• Guide lugs
• Pressure-lubricated
Crankshaft
Function :
▪ Transform linear force to rotational force
▪ Keeps centrifugal and inertia forces
▪ Counter balances
Fitur :
▪ Immense stress
▪ Stringent quality standards as regards both material and
design
▪ Forged of special steel and undergo a special heat treatment
▪ Fatigue resistance and hard bearing surfaces
▪ Perfectly balance
Power impulse
• Power impulse
• Torsional tendencies
Power impulses
• Six Cylinder power impulses
Crankshaft - Oscillation
• Rapid oscillation
• Vibration damper
• Flywheel
What happens in an in-line six cylinder engine
▪ Pistons 1 and 6 perform their upward and
downward movements simultaneously.
▪ Pistons 2 and 5 move together.
▪ Pistons 3 and 4 move together.
▪ 120 crankshaft degrees
▪ Ignition impulses
Seven Main Bearings
• Seven main bearings
Main bearings Caps and screw
• Upper bearing shell
• Lower bearing shell
• Main bearing cap
• Screw
• Thrust washers
Main bearing
• Journal led
• Main bearing caps
• Replaceable
• Steel core
• Bearing-quality metal
Thrust washers (Support Bearing)
Function :
• Menahan gaya aksial saat akselerasi dan pengereman
• Axial movement
Crankshaft bearing journal
• Sturdy crankshaft bearing
• Large bearing surfaces
• One crankshaft bearing journal and connecting rod between the
main bearings
V-engine, two connecting rods
• Bearing
• Vital difference
• V-engine - two connecting rods
Crankshaft - Lubrication ducts
• Pressure-lubricated
• Drilled oil ducts in the crankshaft
Crankshaft seal
Function :
• Mencegah kebocoran oli pelumas keluar
melalui shaft

Fitur :
• Two different types of crankshaft seal
• The first one is a rubber overlap seal
• The second type is a Teflon overlap seal with
two lips
Flywheel

Function :
• Reduce Vibration due to torsional force
• Keeping inertia force

Contruction :
• Starter ring
• Indication grooves (Speed sensor reading)
Damper
o Reduce Vibration due to torsional force
o Fluid-type damper

• The flywheel mass (damper ring)

• Bushing
• Sealed housing
• Viscous silicon oil
• Steady speed
Cylinder head
Function :
• Membentuk dan menyekat ruang bakar
• Tempat komponen valve mechanism

Fitur :
• Huge stresses
• Cast-iron alloy
Cylinder Head (Inlet and Exhaust Ducts)
• Cooling jacket
• Inlet and exhaust ducts
• Valve seat
• Valve guide
• Injector sleeve
Cylinder head - Copper sleeve
Function :
• Mendinginkan injector

Components ;
• Injector
• Copper sleeve
• Cooling jacket
Cylinder head - Details
▪ Hole for injector
▪ Valve guide
▪ Injector sleeve
▪ Valve seat, exhaust
▪ Valve seat, inlet
Cylinder head and cylinder liner seals
Function :
• Mnyekat coolant dan oli agar tidah bocor keluar atau kedalam ruang
bakar
Fitur :
• High pressure in the cylinder
• Coolant, which also contains chemical additives
• Engine oil, which contains chemical additives
Valve Mechanism
Function :
• Mengatur mekanisme buka tutup katup

2 Type
o Push Rod
o Overhead Camshaft
Pushrod Engine
• Camshaft
• Valve lifter
• Pushrod act
• Rocker arm
• Valve yoke (Valve Bridge)
• Valve
Overhead Camshaft (Directly)
• Camshaft
• Rocker arm
• Valve
Camshaft
Function :
• Menggerakkan mekanisme katup In dan
Ex
• Menekan Injector (unit injector Sistem)

Fitur :
• Forging Casting Steel alloy
• Special cast-iron alloy
• One cam for each valve
• Camshaft bearings
• Surface-hardened
• Pressure-lubricated
• Axial bearing –
• Thrust washer
Camshaft - Design
• Valves open and shut at exactly the right time
• Driven by the crankshaft
• Timing gears
• Engine timing mechanism
Valves, valve guides and valve seats
Function :
• Mengatur aliran udara ke dan dari
ruang bakar
• Mencegah kebocoran tekanan
diruang bakar

Komponen :
• Valve In and Ex
• Valve springs
• Valve guide
• Valve's sealing
• Valve seat
Valve Springs
• Valve spring washer
• Valve locks (dua bagian)
• Valve springs
• Seal

• Beberapa valve memiliki valve

rotator
Valve Seals
Function :
▪ Menyekat pelumas agar tidah bocor ke air duct
▪ Menjaga Pelumasan valve stem
▪ High oil consumption (ada kemungkinan kebocoran seal)

Material :
▪ Rubber seals
Engine Timing Mechanism

Function :
• Menyelaraskan mekanisme gerakan crankshaft
dan camshaft
• Power transmission for additional components
 Gear Train
9. Idler gear, power steering
1. Timing gear plate and feed pump
2. Crankshaft gear 10. Drive gear, lubrication oil
3. Idler gear, double pump
4. Gear for power take off 11. Flywheel damper with teeth
(extra equipment) for the inductive camshaft
sensor
5. Idler gear, adjustable
6. Camshaft gear
A. Camshaft gear timing mark
7. Drive gear, air compressor
B. Crankshaft gera timing
8. Drive gear, power steering
mark
and fuel feed pump
Engine Timing Mechanism Housing
• Timing gear plate
• Timing gear casings
Lubrication System
Lubrication system
Sebuah mesin harus memiliki sistem pelumasan, ini dikarenakan
komponen pada mesin bergesekan satu sama lain saat sedang dalam
kondisi operasi, dengan adanya pelumas setiap komponen yang
bergesekan akan terlapisi oleh lapisan oil film sehingga komponen
tersebut dapat bergerak lebih lancar dan keausan pada komponen
berkurang. Beberapa fungsi minyak pelumas:
• Lubricates
• Cools
• Seals
• Cleans
Engine Oil Quality
Tergantung pada :
• Kualitas oli itu sendiri
• Oil change interval
• Kandungan sulfur dari fuel
Splash Lubrication
• Splash-lubrication
• Crankshaft's rotating motion
Pressure Lubrication system –
schematic

1. Strainer
2. Plastic tube
3. Oil pump
4. Pressure pipe
5. Oil cooler
6. Filter housing
7. Full flow filters
8. Main lubrication gallery
9. Separator turbine
10. VCB valve
11. Air compressor
12. Turbocharger
13. Bypass filter
14. Nozzles
A. Reduction valve
B. Safety valve
C. Thermostat valve for oil cooler
D. By-pass valve for full flow filter
E. Opening valve for piston cooling
F. Control valve for piston cooling
Regulating Valve
The oil flow through the engine is regulated by six valves located
inside the engine block, pump and oil filter housing.

A: Reduction valve
B: Safety valve
C: Thermostat valve for oil cooler
D: By-pass valve for full flow filter
E: Opening valve for piston cooling
F: Control valve for piston cooling:
Oil sump
Function :
• Penampungan minyak pelumas
• Reducing engine noise levels

Fitur :
• Moulded plastic (composite)
• Pressed steel variant
• Sealing strip
• Dry sump
Oil pump - function

Function :
• Circulate oil

Fitur :
• Gear pump type
Oil pump - parts
• Idler gear
• Drive gear
• Driven shaft
• Driving pump gear
• Driven pump gear
Oil filter housing
Function :
• Hold fuel filter
• Number of valves - regulate oil flow

Fitur :
• Spin-on type
Oil flows through the filter
Function :
• Menyaring kotoran dari minyak pelumas
•
Fitur :
• Filter insert (paper)
• Particles down to approx. 40 thousandths
of a millimetre (40 µm)
• Bypass filter - 10 µm
• Oil flow rate is approx. 7 litres/minute
Oil cooler
Function :
• Menurunkan suhu pelumas

Fitur :
• Common type (plate heat
exchanger)
• Didinginkan air radiator
Cooling System
Cooling System

Fungsi
• Menjaga temperature kerja sebuah mesin pada
kondisi idealnya
• Overheat = Kerusakan komponen (Seketika)
• Overcooling = Thermal efisiensi rendah,
kerusakan komponen (jangka panjang)

Cara kerja
• Cairan pendingin disirkulasikan
• Panas dari komponen diserap
• Panas pada cairan pendingin dibuang melalui
radiator
Coolant

• When the ambient temperature is below 0°C, the coolant

should consist of a mixture of water and anti-freeze.
• On markets where the ambient temperature never drops
below 0°C, no anti-freeze is needed but corrosion
protection is still essential to prevent engine damage. In
such cases, Volvo anti- corrosion fluid is added in the ratio
of 1:30 (1 litre of fluid to 30 litres of water).
• All these fluids which circulate inside the cooling system
are known as coolants. Referring to them as "water" is
incorrect since there is always something added to the
water.
External components of the cooling system

1. Radiator 11. Connection for engine

heater (diesel driven)
2. Expansion tank
3. Upper filler cap including 12. Connection for engine
pressure valve heater (220 V, socket)

4. Front fill cap 13. Connection for heating the

urea tank
5. Level sensor
14. Drain plug for coolant
6. Heater in the cab
15. Drain plug for radiator
7. Connection from coolant
thermostat to radiator 16. Connection for gearbox
cooling
8. Temperature sensors
9. Coolant pump
10. Air compressor
Coolant Flow

• Coolant pump (1)

• Lower hole (2)
• Oil cooler (3)
• Upper hole (4)
• Channels (5)
• Thermostat (6)
• Bypass pipe (7)
• Air compressor (8)
Coolant Pump

Fungsi
• Mensirkulasikan cairan
pendingin

Component
1. Housing
2. Impeller
3. Shaft seal
4. Bearing
5. Pulley
6. Ventilated space
7. Open Out (Leak indicator)
8. The rear of the pump
Thermostat
Fungsi
• Mengarahkan aliran cairan pendingin agar suhu kerja engine terjaga

A. Thermostat in closed state (cold engine).

B. Thermostat in open state (warm engine).Open. (warm engine)
Schematic presentation of the cooling system.
• Inner circuit
• Outer circuit
Radiator
Fungsi :
• Membuang panas dari cairan
pendingin yang bersirkulasi

Komponen :
• Upper tank (plastic)
• Lower tank (plastic)
• Pipes or Tube (copper / brass)
• Thin steel fins (aluminium)
Pressure Valve (Radiator Cap)
Fungsi :
• Mengatur tekanan sistem
pendingin
• Menaikkan titik didih

Cara Kerja :
• Over pressure condition
• Vacuum condition
Cooling fans in vehicles
1. Visco clutch
2. Fan axle
3. Fan
4. Drive belt
5. Automatic belt tensioners
Cooling fans Hydraulic

• Electro-hydraulic system
• Coolant temperature sensor
• PWM-signal
• Stepless regulation
• Rotational speed induction sensor
Fan Shroud

Function :
• Meningkatkan efektifitas
pendinginan radiator

Catatan :
• Harus terpasang rapat dengan
radiator
Intake and Exhaust System
Intake and exhaust system

Function :
• Intake sistem = Menyediakan
suplai udara yang cukup dan
bersih menuju ruang bakar
• Exhaust sistem = Mengeluarkan
gas sisa pembakaran
Intake system Type
• Naturraly aspirated
• Force Induction (Turbocharger)
Pre Cleaner (Heavy Equipment)

• Dust ejector
• Ventury sistem
Pre Cleaner and filter
1. Self-sealing rubber bellows
2. Rubber valve
3. Safety net
4. Hose connection to air compressor
5. Filter insert (outer)
6. Warning lamp
7. Extra filter (inner)
8. Sensor for air temperature and low pressure
Charge Air Cooling (After Cooler / Intercooler)

Function
• Mendinginkan udara bertekanan dari turbo
(compressor side)
• Udara dingin kerapatannya lebih baik sehingga
jumlah oksigen untuk pembakaran lebih banyak
• Raising engine power output
• Higher torque
• Lower fuel consumption
Charge Air Cooling Type
• Air to air cooling
• Fluid to air cooling
• Separate circuit aftercooler (Heavy equipment)
Starter Element

• Fungsi : Fitur Cold starts dengan

cara menghangatkan udara masuk
sehingga engine lebih mudah
running serta mengurangi asap
putih
• Terletak pada intake manifold
• Starter element (1) electrically
heated
Turbocharger history

Pada awalnya turbo charger dikembangkan

untuk mesin pesawat terbang. Saat itu pesawat
terbang kehilangan tenaganya saat sudah
berada di ketinggian beberapa kilometer
(14000 kaki). Hal ini diakibatkan karena
menipisnya volume udara yang ada
diketinggian mengakibatkan suplai udara yang
masuk ke ruang bakar berkurang.
Turbocharging

• More air into the cylinder

• Not steal power
• Turbo engines -40% higher output
• Cleaner exhaust gases
• Lower fuel consumption
• Quieter engine operation
• Boost pressure - 150 kPa (1,5 bar)
• Speed - 1250-1670 rps (75,000-100,000
rpm)
• Top speed - 2200 rps (130,000 rpm)
Turbocharger bearing

Components :
• Exhaust side (turbin)
• Inlet side (compressor / Impeller)
• Rotor shaft
• Bearing

Lubrication and Cooling :

• Karena kecepatan dan suhu tinggi
• Dilumasi dan didinginkan dengan
Cooled and Clean oil
Wastegate

Fungsi :
• Mencegah torbo over speed
• Melindungi mechanical componen karena
over speed dan over heat
• Mengurangi emisi
• Engine torque requirements at low engine
speeds

Cara kerja :
• Sensing udara bertekanan dari boost
pressure
• Menekan pneumatic actuator
• Aktuator membypass sebagian gas buang
menuju muffler tanpa melewati torbo
• Mengakibatkan putaran turbo berkurang
dan supplay boost pressure ikut berkurang
Turbocharger type, VGT (Variabel Geometric
Turbine)
Fitur :
• Bekerja bersama sitem EGR (Exhaust Gas
Recirculation )
• Dikontrol oleh EMS

Komponen dan Cara Kerja :

• Movable sleeve
• Lever
• Actuator
• Gear ratio
• Electric motor
Exhaust pressure governor

Fungsi :
• Exhaust brake (engine brake)

Cara Kerja :
• Gas buang bertekanan di tahan oleh
valve yang digerakkan oleh aktuator
• Mengakibatkan aliran gas buang
terhambat sehingga back pressure
meningkat
• Menghasilkan efek pengereman
Fuel System
Fuel System

Function :
Deliver fuel in to combustion chamber with
correct size, amount and time.

Type fuel system:

• Injection pump system
• Unit injector system
• Common rail system
Fuel Injection System (Mechanical Type)
• Tank
• Supply pump
• Fuel filters
• Fuel injection pump
• Pipe
• Overflow valve /fuel return
• Return pipe
• High pressure pipe
• Injectors / nozzle
Fuel Filter
Function :
• Clean fuel

Fitur :
• Clearance - 0.001 to 0.002 mm
• Hair - 20 times thicker
• Filter insert
• Filter housing
• Spin-on filter
Injection Pump (Inline)
• Older fuel system
• One pump element for each cylinder
• Pump-camshaft
• Pressure-valve
• Injector's pressure pipe
• Control rod /Rack
Supply pump / Transfer Pump / Delivery pump
Function :
• Deliver fuel from tank to injection pump

Component :
• Piston pump drive by camshaft
• Hand-pump (priming pump)
Distribution / Transfer Pump
Injection Pump (Inline)
Function :
• Deliver pressurized fuel in correct amount and time

Component :
• One pump element (plunger) for each cylinder
• Drive by pump-camshaft
• Delivery-valve
• Control rod (rack)
Plunger Operation
Fuel Rack Control
Delivery Valve
Function :
• Delivered pressurized fuel to nozzle

Component :
1. Holder
2. Pressure spring
3. Valve cone
4. Delivery seat
5. Support
Mechanical Regulator or Governor

Fungsi
• Mencegah engine overspeed
• Menyeleraskan putaran engine dengan
jumlah beban
Tipe
• Mechanical regulator or governor
• Electronic regulators
Governor Terminology
• Hi idle = maximum rpm No. load = RPM tertinggi yang
diizinkan governor
• Low idle = rpm minimum operasi engine (pedal gas
posisi nol) tanpa beban.
• Rated speed = maximumfullload speed = engine rpm
dimana engine menghasilkan maksimum horse power
yang dicantumkan oleh pabrik pembuat
• Maximum torque speed = RPM dimana engine
menghasilkan torsi tertinggi
• Speed droop = perubahan RPM engine karena adanya
perubahan beban
• Over run = RPM melebihi hi idle speed
Mechanical Regulator or Governor
Centrifugal effect
A. Engine rotation
B. Fly weight
C. Sliding
D. Linkage
Mechanical Regulator or Governor Bosch Type
Aneroid / Smoke Limiter/ Boost Compensator /
Air-Fuel Rasio Control

Function :
• Prevent black smoke when acceleration
• Reduce emision
• Fuel efficiency
• Sensing from turbocharger pressure (boost
pressure)
Smoke Limiter

Boost Pressure

Rack
Automatic Timing advance / Timer

Fungsi :
• Memajukan dan memundurkan
waktu penginjeksian
• Sensing speed (centrifugal)

Bagian
1. Timing adjuster
2. Adjuster housing
3. Timing gear housing
4. FIP Drive gear
5. Screw
6. Cover
Automatic Timing advance /
Timer Work Position

A. Retard
B. Advance
Pressure Pipes

Function :
• Mengirim bahan bakar bertekanan tinggi ke nozzle

Fitur :
• Bahan terbuat dari besi
• Clamp wajib terpasang dengan benar
Injector - copper sleeve
Function :
• Mendinginkan injector / noozle

Components :
• Cylinder head
• Copper sleeve
• Considerable heat
• Efficient heat dissipation
Injector - function
Berfungsi menginjeksikan / mengabutkan bahan bakar ke
ruang bakar
• Pressure pipe
• Return fuel line
• Spring
• Pressure pin
• Needle
• Pressure chamber
• Sleeve
Nozzle sleeve - needle
Bentuknya berbeda-beda tergantung :
▪ Jenis engine
▪ Bentuk ruang bakar
Fuel juga berfungsi:
▪ Lubricates
▪ Cools
Fuel systems with unit injectors
This system has unit injectors (8), and gear type feed
pump(1) replacing the in-line pump and conventional
injectors.
Injection pressure - which is much higher than that in conventional
systems (1500 bar) - is developed mechanically by cams on the engine
camshaft acting, via rocker arms, on the injector pumping units. The
injectors are electronically controlled by signals from the engine ECU,
which control injected fuel quantity and injection timing
Fuel systems with unit injectors
• Gear driven feed pump (2)
• Strainer (3),
• Non-return valve (4).
• ECU cooling loop (5)
• Filter (6),
• Injector gallery (7)
• A manual priming pump (8)
• An overflow valve (9)
• Bleed nipples (10) and (11)
• A drain nipple (12)
• Non-return valve (13)
• Safety valve (14
• Air vent (15)
• Non-return valves (16)
• Non-return valve (4)
Unit Injector - system function
1. Solenoid Connection
2. Solenoid Valve Assem
3. Spring
4. Valve
5. Plunger
6. Barrel
7. Seal
8. Seal
9. Spring
10. Spacer
11. Body
12. Check
Common rail

• Common Rail system

• Electronically controlled (EMS2)
• Injectors 1600 bar
• Two unit pumps
• Sensors
• Low pressure side
• High pressure side
• Feed pump
• Fuel tank
• Pre-filter
• Fuel distributor
• Fuel filter housing
• Return line
Injector
• Solenoid valve
• Injector body
• Nozzle holder

Operating step
• Preinjection
• Main injection
• Post-injection
EMS (Engine Management
System)
EMS (Engine Management System)
• Low fuel consumption
• Noise
• Exhaust emissions
• EMS (Engine Management System)
• EDC (Electronic Diesel Control)
• Unit Injectors
• Electronic fuel injection
• Diagnostics
• Fault tracing Engine control unit Fault code Information link
Display
• Stored
Electronic controller and Sensors on the
engine
▪The engine control unit includes an atmospheric pressure sensor.
▪Normally the engine is equipped with the following sensors:
▪Fuel pressure
▪Charge air temperature and charge pressure
▪Camshaft position
▪Engine coolant level
▪Air temperature and air pressure
▪Engine coolant temperature
▪Crankshaft position and engine speed
▪Oil temperature and oil pressure
Example of communication
When the driver, for example, wants to increase speed and
depresses the accelerator pedal, a signal is transmitted from
the accelerator pedal to the vehicle electronic control unit.
This signal is transmitted over the data link to the engine control unit.
The engine control unit checks the signals from its own sensors
to ensure that it is possible to increase the throttle setting. If
there is no impediment the engine control unit activates the
speed increase.
The engine control unit then handles the control of the
engine independently for as long as conditions stay the
same.
Vehicle Emissions and Environmental
Impact
Vehicle emissions and environmental impact
• Sulphur Oxides (SOx) from sulphur in fuel, engine
emissions
• Carbon Monoxide (CO) from inefficient combustion
• Carbon dioxoide (CO2) from combustion, green house
gas
• Particulate Matter (PM) from diesel engine emissions
• Nitrogen Oxides (NOx) from diesel engine emissions
• Hydrocarbons (HC) from inefficient combustion
Carbon dioxide and Hydrocarbons
Carbon dioxide contributes to the greenhouse effect, also called
global warming.
Carbon dioxide is generated by burning material that contains
carbon, and is not poisonous. Diesel, the most common fuel for
vehicles, consists of hydrocarbons and during combustion
generates carbon dioxide. Carbon dioxide emissions are directly
related to how much fuel is consumed.
Hydrocarbons are chemical compounds that contain hydrogen
and carbon. Most motor vehicles and engines are powered by
hydrocarbon-based fuels such as gasoline and diesel.
Hydrocarbon pollution results when unburned or partially
burned fuel is emitted from the engine as exhaust, (or from the
crankcase ventilation) and also when fuel evaporates directly
into the atmosphere. Hydrocarbons include many toxic
compounds that cause cancer and other adverse health effects.
Hydrocarbons also react with nitrogen oxides in the presence of
sunlight to form ozone..
Nitrogen oxides
Nitrogen oxides (NOx) is a collective name for nitrogen
monoxide (NO) and nitrogen dioxide (NO2). Nitrogen oxides
contribute to a number of different environmental issues. These
include the formation of tropospheric ozone and the
acidification of land and water. Nitrogen oxides are also
irritating when they are breathed in, and can in high
concentrations cause damage to the respiratory system.
Nitrogen oxides are formed during all combustion where
air is present, as the oxygen and nitrogen in the air react
with each other.
The high degree of efficiency of the diesel engine is achieved
through high pressure, high temperature and excess air during
combustion. This increases the formation of NOx. However,
these characteristics also contribute to low emissions of carbon
dioxide.
Particulate matter
Particulates, alternatively referred to as particulate matter (PM) or
fine particles, are tiny particles of solid or liquid suspended in a gas.
In contrast, aerosol refers to particles and the gas together. Sources
of particulate matter can be man made or natural.
Increased levels of fine particles in the air are linked to health
hazards such as heart disease, altered lung function and lung
cancer.
Particles from a diesel engine consist primarily of soot, various hydrocarbons and
sulphur
Particulate matter is generated by the incomplete combustion of
fuel; however engine lubricating oil is also a factor.

For really good combustion good fuel must be used. Fuel with a
low sulphur content reduces particulate formation.
From January 1, 2005 low sulphur fuel with a sulphur content of
maximum 10 mg/kg (0.1%, 100 ppm) must be available in all
member states of the EU.
The recommended sulphur content for Euro 5 is 50 ppm, (0,05%).
Emisson control, schematic
description of the system
Cooled-EGR
• EGR-valve (3)
• EGR-cooler (B)
• EGR-meter (7)
• VGT turbocharger (D)
After treatment
• Stainless container (E)
• Oxidizing catalytic converter
• Ceramic particulate filter
EGR system
1. EGR valve
2. Rear exhaust pipe
3. EGR cooler
4. Differential pressure sensor
5. Venturi tube
6. EGR temperature sensor
7. EGR pipe
8. Mixing chamber
9. Charge air sensor
I-EGR Function, Medium engine
platform
1. Inlet rocker arm
2. Exhaust rocker arm
3. Slave piston
4. Control valve
5. Low-pressure channel
6. Solenoid valve
7. From engine lubrication system
8. High-pressure circuit
9. Master piston
Main components in the
SCR system
1. Urea tank (AdBlue tank)
2. Pump unit
3. Dosing unit
4. Catalytic converter
Solution principle for the Volvo
SCR system
Exhaust gas cleaning in accordance
with the SCR technology is a system
with only a few components.
Solution principle
1. Urea tank (AdBlue tank)
2. Pump unit
3. Dosing unit
4. Catalytic converter
CCV - CrankCase Ventilation -
Closed
1. Hose connection
2. Connector
3. Turbine
4. Drive shaft
5. Discs
6. Pressure regulator
7. Diaphragm
Selesai