New Generation Volvo Diesel Engine Fundamentals Classroom Training En

March 28, 2018 | Author: Mao LiuGong | Category: Internal Combustion Engine, Diesel Engine, Piston, Cylinder (Engine), Fuel Injection
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Service trainingDiesel Engine Fundamentals Classroom training Trainer booklet Service training Diesel Engine Fundamentals Classroom training Participant booklet Diesel Engine Fundamentals Classroom training Contents Introduction Course content........................................................................................................................... 1 Course objectives....................................................................................................................... 2 Engine history The diesel engine, yesterday and today .................................................................................... 3 First diesel engine ...................................................................................................................... 4 Diesel engines in vehicles.......................................................................................................... 5 Engines for heavier vehicles ...................................................................................................... 6 Diesel engines in Volvo vehicles................................................................................................ 7 Engine range Engine range.............................................................................................................................. 8 General and basic priciples General and basic principles Diesel engine ........................................................................................................................ 9 Internal combustion engine ............................................................................................... 10 Fuel-air mixture .................................................................................................................. 11 Rotating movement............................................................................................................. 12 Power from crankshaft........................................................................................................ 13 Diesel engine - petrol engine ............................................................................................. 14 Diesel engine - another approach ...................................................................................... 15 Sturdy engine components in the diesel engine................................................................. 16 Four strokes for a complete cycle....................................................................................... 17 Four stroke - six cylinder .................................................................................................... 18 Firing order ......................................................................................................................... 19 The diesel engine is miserly with its fuel ............................................................................ 20 Three diesel engine types .................................................................................................. 21 Precombustion indirect-injection engines........................................................................... 22 Swirl-chamber engine ......................................................................................................... 23 Different characteristics Direct injection ............................................................................. 24 Different characteristics Indirect-injection and swirl-chamber ............................................ 25 Diesel engine fundamentals. Test 1 ................................................................................... 26 Engine design ..................................................................................................................... 28 Diesel Engine Fundamentals Classroom training V-engine ............................................................................................................................. 29 Volvo - V8 engines.............................................................................................................. 30 The main engine components ............................................................................................ 31 Cylinder block ..................................................................................................................... 32 Cylinder block - inside ........................................................................................................ 33 Camshaft in cylinder block.................................................................................................. 34 Cylinder liner design ........................................................................................................... 35 Cylinder bore ...................................................................................................................... 36 Cylinder head...................................................................................................................... 37 Diesel engine fundamentals. Test 2 ................................................................................... 38 Cylinder head - Inlet and exhaust ducts ............................................................................. 40 Cylinder head - Copper sleeve ........................................................................................... 41 Cylinder head - Details ....................................................................................................... 42 Cylinder head and cylinder liner seals................................................................................ 43 Cylinder head and cylinder liner seals................................................................................ 44 Cranking mechanism.......................................................................................................... 45 A few facts about loads ...................................................................................................... 46 Crankshaft .......................................................................................................................... 47 Power impulse .................................................................................................................... 48 Crankshaft - Oscillation ...................................................................................................... 49 Damper ............................................................................................................................... 50 The crankshaft is perfectly balanced .................................................................................. 51 Seven main bearings.......................................................................................................... 52 Seven main bearings - connecting rod ............................................................................... 53 V-engine, two connecting rods ........................................................................................... 54 Lubrication ducts ................................................................................................................ 55 What happens in an in-line six cylinder engine .................................................................. 56 Main bearing caps .............................................................................................................. 57 Main bearings screw........................................................................................................... 58 Support bearing .................................................................................................................. 59 Flywheel.............................................................................................................................. 60 Flywheel - other tasks......................................................................................................... 61 Connecting rod ................................................................................................................... 62 Connecting rod - details...................................................................................................... 63 Gudgeon pin ....................................................................................................................... 64 Gudgeon pin hole ............................................................................................................... 65 Gudgeon pin - journal led ................................................................................................... 66 Connecting rod bearing ...................................................................................................... 67 Diesel Engine Fundamentals Classroom training Diesel engine fundamentals. Test 3 ................................................................................... 68 Piston.................................................................................................................................. 70 Piston - Thermal stress and mechanical stress.................................................................. 71 Piston - Materials ................................................................................................................ 72 Articulated piston ............................................................................................................... 73 Piston - Tolerance............................................................................................................... 74 Piston cooling ..................................................................................................................... 75 Piston rings ......................................................................................................................... 76 Piston rings material first ring ............................................................................................. 77 Piston rings material second ring ....................................................................................... 78 Piston rings material oil ring ............................................................................................... 79 Piston rings - Oil ring .......................................................................................................... 80 Diesel engine fundamentals. Test 4 ................................................................................... 81 Valve mechanism ............................................................................................................... 83 Pushrod engine .................................................................................................................. 84 Overhead camshaft ............................................................................................................ 85 Camshaft ............................................................................................................................ 86 Camshaft - Design .............................................................................................................. 87 Engine timing mechanism .................................................................................................. 88 Engine timing mechanism - Sound insulation .................................................................... 89 Crankshaft seal................................................................................................................... 90 Valves, valve guides and valve seats................................................................................. 91 Valves ................................................................................................................................. 92 Valve stem .......................................................................................................................... 93 Valve springs ...................................................................................................................... 94 Valve seals ......................................................................................................................... 95 Pushrod and rocker arm ..................................................................................................... 96 Diesel engine fundamentals. Test 5 ................................................................................... 97 Lubrication system Lubrication system Lubrication system.............................................................................................................. 99 Engine oil quality .............................................................................................................. 100 Splash lubrication - Pressure lubrication .......................................................................... 101 Pressure lubrication .......................................................................................................... 102 Lubrication system - Function........................................................................................... 103 Lubrication system - schematic ........................................................................................ 104 Oil pump - function............................................................................................................ 105 . .................... Test 6 ...................................... 106 Oil filter housing ............................................................................................................................................................................... 110 Diesel engine fundamentals.......................................................... 111 Fuel system Fuel system Fuel injection system .................................................... Test 7C............................................................................................................................................................................ 136 Example of communication ......................................................................................................................................... 122 Injector ..................................... 115 Mechanical regulator or governor.......................................................................................................................................................... 133 Engine control unit .......................................................................................................................................... Test 7A..........................................system function .................................. 120 Injector .....................................................................................................function ............... 124 Fuel systems with unit injectors...........................................parts ..................................................................................................................................................... 140 ............................................................. 130 Injector ..... 135 Other sensors ............. 117 Smoke limiter ................................. 131 Diesel engine fundamentals................................................................................................Diesel Engine Fundamentals Classroom training Oil pump ..................................... 107 Oil flows through the filter ........................................ 118 Fuel filter ............................................................. 116 Supply pump........................ 134 Sensors on the engine..............needle ...................................................................... 127 Diesel engine fundamentals..............................................Engine Management System ........................................... 128 Common rail ....................................................copper sleeve .......................................................................... 123 Diesel engine fundamentals................................................................................................................................................................................................................................................... 109 Oil sump... Test 7D................................................. 132 Engine management system Engine management system EMS .................................................................................................................................................................................................................................................................................. Test 7B.............................. 126 Unit injector ................................................. 108 Oil cooler............................................................................................. 121 Nozzle sleeve ............................................................ 137 Diesel engine fundamentals...... 114 Injection pump ........................................................................................ 138 Intake and exhaust system Intake and exhaust system Intake and exhaust system.............................................................................................................. 119 Pressure pipes..................................... . .......................................................................................... 157 Charge air cooling................................................................................................................................................................................................ 167 Cooling fans in vehicles....................................... Test 8 ......................................... 171 Emissions Emissions Vehicle emissions and environmental impact ................................................................ 149 Turbocharger Turbocharger Turbocharger history....................................................... 163 External components of the cooling system............................ Test 9 ....................................... 154 Turbocharger system........................................ 174 .................................. 153 Wastegate................................................................................................................................................. 162 Cooling system ......................................................... 158 Air to air cooling ................... 168 Cooling fans in bus .............................. 145 Compression brake VEB+ ................................................................................................. 144 Compression brake VEB ................................................................ 170 Diesel engine fundamentals.................................................................................................................................................................. 156 Turbocharger type VGT .................................... 152 Turbocharger bearing .............................................. 166 Radiator ............................... 165 Schematic presentation of the cooling system .................................................... 151 Turbocharging............................................................................................................................................................................................................................. 148 Diesel engine fundamentals................................................................................................................................................................................................ 146 Compression brake JAK................... 147 Engine brake function.................................................................................................................................................................................................................................... 155 Exhaust pressure governor ...........................................................Diesel Engine Fundamentals Classroom training Air filter .................................................................................................................................................................................................. 141 Cyclone filter ................................. 159 Diesel engine fundamentals............................ Test 10 ... 169 Cooling fans in VCE ................................................................................................................................................................................................................................................................................................................................................ 164 Thermostat ........................................................................................................................................................................................... 143 Exhaust pressure governor ........................................................................ 160 Cooling system Cooling system Volvo coolant ........................................ 142 Starter element .............................................................. . ...................... 189 Overview of the exhaust gas processing system ............................................. 178 Diesel engine fundamentals................................. 184 I-EGR Function........................ Test 11C ......................................................................................... 180 EGR EGR Emisson control................... 194 .......... 176 Nitrogen oxides (NOX) .................................................................... schematic description of the system.................................................................................... 188 Solution principle for the Volvo SCR system............................................. Large engine platform............. Medium engine platform ...........................................................CrankCase Ventilation ..........Diesel Engine Fundamentals Classroom training Engine emission ...................................................................... Test 11B.................................................................................................................... 181 EGR system......... Test 11D .......................................... 182 I-EGR................................................................................Selective Catalytic Reduction ............................................................................................................ Test 11A............................................................................................................................................................. 187 Main components in the Volvo SCR system ..... 185 Diesel engine fundamentals....................................................................... Medium engine platform ................................................ 193 Diesel engine fundamentals......................................... 177 Particulate matter................................ 186 SCR SCR SCR ........ 191 CCV CCV CCV ..........................................Closed................................................................. 183 I-EGR....................................... 175 Carbon dioxide and Hydrocarbons ................... 190 Diesel engine fundamentals......................... . 0.01_en Page 1 .Introduction > Course content Notes GT120017A v.1. Also mention practical issues such as breaks. how long they have worked for Volvo and detail any previous experience of other truck workshops they may have. Present the course timetable and give a general idea of what is going to be covered over the days (Course contents and objectives). mobile phones. The use of the student material. say where they come from. Remind the participants that later there will be a written test to complete the course. If this is the first time the participants have been on a Volvo course. Test questions are also included. smoking. Explain briefly what the different subjects will include . etc. will be allowed during the written post test.g. Additional information Course guide Start by welcoming the participants to the course. Trainer notes Page 1 (trainer) . Go through the schedule. e. give their name. tell them a little about the Volvo Company. Morning and afternoon breaks should be adapted to suit local times. company. Mention that some of the tasks from the practical training can be performed as individual tests.give examples.Introduction > Course content Key points  Course content  Practical exercises  Theoretical summary  Course schedule Working procedure Go through Course content (overview). Explain that each practical session will start with theory and after there it will be a practical session. Introduce yourself and let all the participants introduce themselves. including any personal notes the participants may have made. Hand out the student material and inform the participants of the post test that will be held on the last day. Notes Page 2 GT120017A v. belts etc. engine brake system.1. • Carry out jobs in a safe way. fuel systems.g. without causing damage to equipment.0. you should be able to • Select and use appropriate tools and equipment.01_en . • Check and adjust a range of engine components. e. vehicle or person. • Verify proper operation after adjustment. valves. • The purpose of this training is to give you a good knowledge of the Basic Diesel Technology in practical and theoretical. unit injectors. component.Introduction > Course objectives Course objectives After completing the course. Introduction > Course objectives Key points  Course objectives  Check and adjust  Appropriate tools and equipment. Additional information Course guide Trainer notes Page 2 (trainer) .  Damage  Verify proper operation Working procedure Go through Course objectives (overview). The picture on the left shows one of the very earliest engines. Diesel engines today weigh less than half as much as their first ancestors. but soon switched his attention to liquid fuel. Not before 1897 did Diesel manage to produce an engine which functioned anything like he had envisioned. all diesel engines are driven by diesel oil. It suffered a host of problems and did not produce enough power to keep itself running. Today.Engine history > The diesel engine. yesterday and today The diesel engine. Diesel's first engine was completed in 1893. And it's 3 metres tall. considerable effort has been invested in research and development to bring the diesel engine to today's levels of superb efficiency and operational reliability. Rudolf Diesel initially intended powering his new engine with coal dust.1.01_en Page 3 . The engine on the right is a Volvo TAD 1630. GT120017A v. Since then. yesterday and today It all began in 1892 when Rudolf Diesel was granted a patent for a new type of engine. It has a bore of 220 mm and a stroke of 400 mm.0. Roughly 80 years of development separate Rudolf Diesel's first engine from this hyper-modern power unit. and they pump out more than 30 times as much power. It was to be far more efficient than all previously known engine types and it would be powered by a fuel which was cheaper than petrol. 20hp . Be sure that the participants have understood the main purpose of this information. Ask question to be sure that the participants have understand the main purpose of this chapter/slide/information/text.5 ton . yesterday and today Key points  History  Rudolf Diesel  Frenchman  Born 1858  1876 Otto patent 4-stroke engine  1892 patent diesel  Coaldust  First working engine = 4.26% efficiency  1913 suicide on the way to England  The first engines were made for heavier vehicles  First Volvo truck 1928  Volvo truck engine 1946  Turbocharger 1954 Working procedure Go through the text in the student material and also add your own experience/knowledge.Engine history > The diesel engine. Trainer notes Page 3 (trainer) . MAN in Augsburg.01_en .0. It was produced by a German manufacturer. It was used to power industrial machines and was in regular operation until 1930. Notes Page 4 GT120017A v.1.Engine history > First diesel engine First diesel engine The first diesel engines were large and clumsy and they were certainly not designed for installation in moving vehicles. they were intended as powerplants for industry or as prime movers powering generators or pumps. The two-cylinder engine in the picture to the right is from 1898 and it produced 50 hp (37 kW). Rather. Ask question to be sure that the participants have understand the main purpose of this chapter/slide/information/text. Be sure that the participants have understood the main purpose of this information.Engine history > First diesel engine Key points  Large and clumsy  For industry  Powering generators or pumps  1898  50 hp (37 kW)  MAN in Augsburg Working procedure Go through the text in the student material and also add your own experience/knowledge. Trainer notes Page 4 (trainer) . 0. a Benz from 1922. It had two cylinders and produced just 22 kW or 30 horsepower. can be seen here on the right. One of the first. The very first vehicle engines came in the early 1920s.01_en Page 5 .Engine history > Diesel engines in vehicles Diesel engines in vehicles It took considerable research effort and innumerable trials before the diesel engine was ready for installation in moving vehicles. Notes GT120017A v.1. Be sure that the participants have understood the main purpose of this information.Engine history > Diesel engines in vehicles Key points  Installation in moving vehicles  Early 1920s  Benz from 1922  Two cylinders and produced just 22 kW or 30 horsepower Working procedure Go through the text in the student material and also add your own experience/knowledge. Ask question to be sure that the participants have understand the main purpose of this chapter/slide/information/text. Trainer notes Page 5 (trainer) . Volvo Construction Equipment launch diesel engine in 1954. The engine type was called MD1.0. Lightweight series-manufactured diesel engines for passenger cars first made an entry about ten years later.Engine history > Engines for heavier vehicles Engines for heavier vehicles The first engines were made for heavier vehicles such as trucks and tractors. The first such engines bore the Daimler-Benz badge and they had a power output of about 33 kW or 45 horsepower. Volvos busses got a new diesel engine 1945 and one year later it was also introduce in the trucks.1. Notes Page 6 GT120017A v. Rudolf Diesel. long before engines bearing his name became a common sight in moving vehicles. Volvo Penta launch diesel engine in 1958. The engine type was called VDA. died in 1913. The truck pictured here is a Daimler-Benz made in 1923.01_en . the inventor of the diesel engine. died in 1913  Volvo Penta launch diesel engine in 1958.Engine history > Engines for heavier vehicles Key points  Truck Daimler-Benz made in 1923  Lightweight series-manufactured diesel engines  33 kW or 45 horsepower  Rudolf Diesel. Trainer notes Page 6 (trainer) . Ask question to be sure that the participants have understand the main purpose of this chapter/slide/information/text. Be sure that the participants have understood the main purpose of this information. the inventor of the diesel engine. The engine type was called MD1  Volvo Construction Equipment launch diesel engine in 1954  Volvos busses got a new diesel engine 1945  Volvo trucks got a new diesel engine 1946  The engine type was called VDA Working procedure Go through the text in the student material and also add your own experience/knowledge. The VDA produced 71 kW and had a displacement of 6. for example. Volvo's trucks were powered by an engine similar in concept to the diesel engine. Just look at the power outputs. A corresponding engine of today. however. The first engine was a six-cylinder unit producing 71 kilowatts (96 horsepower). The latest generation of engines with which you work are developments of these early units.1. The Hesselman unit is often referred to as a "semi-diesel" engine.0. but featured an electrical ignition system. GT120017A v. this is what it looks like in general terms: there is no other type of engine currently in existence which can compete with the diesel engine in heavy-duty vehicles or as a power source for large generators and pumps. in 1933.12 litres. And the result can be seen if you compare the first VDA engine with a similarly-sized engine of today. It was known as the Hesselman engine and it ran on the same fuel as the diesel engine. Operating reliability is far higher. Fuel consumption is lower. It carried the VDA designation (Volvo Diesel engine type A).01_en Page 7 . So a lot has happened since 1946! But what of the future? Well.Engine history > Diesel engines in Volvo vehicles Diesel engines in Volvo vehicles Diesel engines were first fitted to Volvo trucks in 1946. the D6A (slightly smaller but with a turbocharger and intercooler) produces more then 150 kW! And there's more. More than a decade previously. Durability and service life are longer. Everyone concerned has invested enormous effort and expertise in making the diesel engine better and better. Engine history > Diesel engines in Volvo vehicles Key points  71 kilowatts (96 horsepower)  VDA (Volvo Diesel engine type A)  Hesselman unit is often referred to as a "semi-diesel" engine  VDA produced 71 kW and had a displacement of 6. Trainer notes Page 7 (trainer) . Be sure that the participants have understood the main purpose of this information.12 litres  D7E (slightly smaller but with a turbocharger and intercooler) produces more then 150 kW!  Fuel consumption is lower  Durability and service life are longer  Operating reliability is far higher  Future Working procedure Go through the text in the student material and also add your own experience/knowledge. Ask question to be sure that the participants have understand the main purpose of this chapter/slide/information/text. ... Notes Page 8 GT120017A v.. we have also the D13 engine. 240 horsepower and up to 700 horsepower.. The cylinder volume is between 7 litres and up to 16 litres. This engine was launched in 2005 and the biggest of them all is. _ .01_en .0... launched in 2008.. The smallest engine is the D7E and it was launched in 2006....the D16 and this is also the most powerful of them all. _ ...1.and the D11 engine. Volvo have engines in a range from approx.Engine range > Engine range Engine range We shall look at the diesel engine range on the engine that we have today.the next engine in range is the D9 engine and it was launched in 2001. _ . _ .... Explain why we have overlap for different engines power and torque.Engine range > Engine range Key points  Range  D7E  D9  D11  D13  D16 Working procedure Talk with the participants about the Volvo engine range. This decision is up to the teacher to decide. Her it is possible to run the movie “AN INTRO TO DIESEL ENGINE”. Some markets have tax depending on power other markets set the tax depending on volume. This is like a teaser for the participants. There is overlapping of different engine powers and torques. An another way is to show each chapter where it belongs. Trainer notes Page 8 (trainer) . In the tranier notes under headline "Additional information" the trainer find information when it is time to run each chapter. Additional information Go through the information shown in the additional information. The movie going through the fundamentals estimated time 15 min. That has to do with different taxation in different markets. Electronic Management Systems (EMS) have been used for a number of years.01_en Page 9 . which is basically quite an old invention. They must meet demands for low fuel consumption combined with high performance. The earlier fuel injection system EDC (Electronic Diesel Control). There are few power sources on which so much research and development work is expended as on the diesel engine.General and basic priciples > General and basic principles > Diesel engine Diesel engine High demands are placed on modern engines. and electronics are steadily taking on a more central role in each new generation of engines. Development work has essentially been concentrated on refining existing technology. while at the same time having low levels of noise and exhaust emissions. and Unit Injector have now been developed into a more advanced EMS system that is integrated into the TEA (Truck Electronic Architecture) vehicle electronic system. but a great number of completely new solutions have been developed in recent years. Notes GT120017A v.0.1. do not forget to tell them what is happen if they do not understand the basic when they shall e. fault tracing. Ask question to be sure that the participants have understand the main purpose of this information/text. Trainer notes Page 9 (trainer) . This is like a teaser for the participants. Be sure that the participants have understood the main purpose of this information. Walk around different engines if it is possible and let the participants point out engine main part on the outside.g.General and basic priciples > General and basic principles > Diesel engine Key points  Low fuel consumption combined  High performance  Low levels of noise  Exhaust emissions  Electronic Management Systems (EMS)  Electronic Diesel Control (EDC)  Unit Injector  TEA vehicle electronic system Working procedure Go through the text in the student material and also add your own experience/knowledge. Show the participants the engine parts and explain how they are connected to each other. Additional information Her it is time to run the movie “AN INTRO TO DIESEL ENGINE” chapter "Introduction" and "Basic design". 0.General and basic priciples > General and basic principles > Internal combustion engine The diesel engine is an internal combustion engine  Combustion chamber  Piston  Cylinder · Notes Page 10 GT120017A v.1.01_en . do not forget to tell them what is happen if they do not understand the basic when they shall e. Trainer notes Page 10 (trainer) . Be sure that the participants have understood the main purpose of this information. fault tracing.g. Ask question to be sure that the participants have understand the main purpose of this information/text.General and basic priciples > General and basic principles > Internal combustion engine Key points  Internal combustion engine  Combustion chamber  Piston  Cylinder Working procedure Go through the text in the student material and also add your own experience/knowledge. Show the participants the engine parts and explain how they are connected to each other. 0.01_en Page 11 .1.General and basic priciples > General and basic principles > Fuel-air mixture Fuel-air mixture  Ignited  Pressure  Considerable force  Rotate in a circle Notes GT120017A v. do not forget to tell them what is happen if they do not understand the basic when they shall e. Show the participants the engine parts and explain how they are connected to each other. Be sure that the participants have understood the main purpose of this information. Trainer notes Page 11 (trainer) .g.General and basic priciples > General and basic principles > Fuel-air mixture Key points  Fuel-air mixture  High pressure  Pushes the piston  Force  Rotate in a circle Working procedure Go through the text in the student material and also add your own experience/knowledge. fault tracing. Ask question to be sure that the participants have understand the main purpose of this information/text. 1.0.General and basic priciples > General and basic principles > Rotating movement Rotating movement  Connecting rod  Crankshaft Notes Page 12 GT120017A v.01_en . Trainer notes Page 12 (trainer) . Show the participants the engine parts and explain how they are connected to each other. do not forget to tell them what is happen if they do not understand the basic when they shall e. fault tracing.g.  The force -piston-connecting rod-crankshaft  Propel the vehicle Working procedure Go through the text in the student material and also add your own experience/knowledge.General and basic priciples > General and basic principles > Rotating movement Key points  Movement of the piston  Rotating movement  Connecting rod  Crankshaft. Be sure that the participants have understood the main purpose of this information. Ask question to be sure that the participants have understand the main purpose of this information/text. 01_en Page 13 .1.General and basic priciples > General and basic principles > Power from crankshaft Power from crankshaft  Vehicle  Transmission components  Driven wheels  Driveline Notes GT120017A v.0. Ask question to be sure that the participants have understand the main purpose of this information/text. Show the participants the engine parts and explain how they are connected to each other.General and basic priciples > General and basic principles > Power from crankshaft Key points  Crankshaft-gearbox-rear axle-wheel  Driveline Working procedure Go through the text in the student material and also add your own experience/knowledge. Trainer notes Page 13 (trainer) . fault tracing.g. do not forget to tell them what is happen if they do not understand the basic when they shall e. Be sure that the participants have understood the main purpose of this information. 1.petrol engine Diesel engine .0.General and basic priciples > General and basic principles > Diesel engine .petrol engine  Petrol engine  Ready-mixed blend of petrol and air  Compressed  Ignited  Spark Notes Page 14 GT120017A v.01_en . General and basic priciples > General and basic principles > Diesel engine - petrol engine Key points  Diesel engine  Petrol engine  Differences  Petrol engine.  Electrically generated spark Working procedure Go through the text in the student material and also add your own experience/knowledge. Be sure that the participants have understood the main purpose of this information. Ask question to be sure that the participants have understand the main purpose of this information/text. Show the participants the engine parts and explain how they are connected to each other, do not forget to tell them what is happen if they do not understand the basic when they shall e.g. fault tracing. Trainer notes Page 14 (trainer) General and basic priciples > General and basic principles > Diesel engine - another approach Diesel engine - another approach  Unblended air  Hot air  Compressed  Ignite the diesel fuel  Compression ignition  Peak pressure  Diesel engine 7 and 20 MPa  Petrol engine 3 to 5 MPa Notes GT120017A v.1.0.01_en Page 15 General and basic priciples > General and basic principles > Diesel engine - another approach Key points  Unblended air  Compressed  Hot - ignite the diesel fuel  Fuel  Hot air  Ignited  Compression ignition.  Combustion pressure  Diesel engine 7 to 20 MPa  Petrol engine 3 to 5 MPa  Peak pressure Working procedure Go through the text in the student material and also add your own experience/knowledge. Be sure that the participants have understood the main purpose of this information. Ask question to be sure that the participants have understand the main purpose of this information/text. Show the participants the engine parts and explain how they are connected to each other, do not forget to tell them what is happen if they do not understand the basic when they shall e.g. fault tracing. Trainer notes Page 15 (trainer) General and basic priciples > General and basic principles > Sturdy engine components in the diesel engine Sturdy engine components in the diesel engine  High working pressure  Mechanical stress  More expensive to produce Notes Page 16 GT120017A v.1.0.01_en General and basic priciples > General and basic principles > Sturdy engine components in the diesel engine Key points  Sturdy components  High working pressure  Mechanical stress  More expensive Working procedure Go through the text in the student material and also add your own experience/knowledge. Be sure that the participants have understood the main purpose of this information. Ask question to be sure that the participants have understand the main purpose of this information/text. Show the participants the engine parts and explain how they are connected to each other, do not forget to tell them what is happen if they do not understand the basic when they shall e.g. fault tracing. Trainer notes Page 16 (trainer) General and basic priciples > General and basic principles > Four strokes for a complete cycle Four strokes for a complete cycle  Inlet stroke  Compression stroke  Operating stroke  Exhaust stroke Notes GT120017A v.1.0.01_en Page 17 General and basic priciples > General and basic principles > Four strokes for a complete cycle Key points  Four strokes for a complete cycle  Inlet stroke  Compression stroke  The piston compresses the air  2-3 MPa (20-30 bar)  700-900°C  Fuel injection occurs at the end of the compression stroke  2000-2500°C  Operating stroke  Exhaust stroke Working procedure Go through the text in the student material and also add your own experience/knowledge. Be sure that the participants have understood the main purpose of this information. Ask question to be sure that the participants have understand the main purpose of this information/text. Show the participants the engine parts and explain how they are connected to each other, do not forget to tell them what is happen if they do not understand the basic when they shall e.g. fault tracing. Additional information Her it is time to run the movie “AN INTRO TO DIESEL ENGINE” chapter "4stroke principle". This is like a teaser for the participants. Trainer notes Page 17 (trainer) General and basic priciples > General and basic principles > Four stroke - six cylinder Four stroke - six cylinder Firing order is 1 - 5 - 3 - 6 - 2 - 4 Cylinder 1 The compression stroke has just begun. Cylinder 2 Operating stroke; the pressure is very high right now. Cylinder 3 Exhaust stroke is completed, the inlet stroke begins. Cylinder 4 End of compression stroke, fuel is sprayed in and ignited. Cylinder 5 Inlet stroke has just begun and clean air is fed in. Cylinder 6 The exhaust stroke has just begun. Page 18 GT120017A v.1.0.01_en do not forget to tell them what is happen if they do not understand the basic when they shall e.g. Additional information Her it is time to run the movie “AN INTRO TO DIESEL ENGINE” chapter "Induction stroke". Be sure that the participants have understood the main purpose of this information. fault tracing. After that you have run the four stroke you can also run "Sum up 4-stroke principle" so the participants can see as a sequence. This is like a teaser for the participants. the pressure is very high right now  Cylinder 3 exhaust stroke is completed. "Compression stroke". Trainer notes Page 18 (trainer) . the inlet stroke begins  Cylinder 4 end of compression stroke.5 .6 . 1 . "Working stroke" and "Exhaust stroke".4  Cylinder 1 the compression stroke has just begun  Cylinder 2 operating stroke. Show the participants the engine parts and explain how they are connected to each other. fuel is sprayed in and ignited  Cylinder 5 inlet stroke has just begun and clean air is fed in  Cylinder 6 the exhaust stroke has just begun Working procedure Go through the text in the student material and also add your own experience/knowledge.3 .six cylinder Key points  Four-stroke principle  Firing order. Ask question to be sure that the participants have understand the main purpose of this information/text.2 .General and basic priciples > General and basic principles > Four stroke . 1.01_en Page 19 .General and basic priciples > General and basic principles > Firing order Firing order  Direction the piston is moving  Position of the valves  A six-cylinder engine has a very close firing order  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 Notes GT120017A v.0. g. Ask question to be sure that the participants have understand the main purpose of this information/text. With the engine operating at 2000 rpm. Be sure that the participants have understood the main purpose of this information. there are 6000 combustion strokes per minute or 100 per second. Additional information Operating strokes are coloured red. This is like a teaser for the participants. If the engine is run at that speed. Show the participants the engine parts and explain how they are connected to each other. do not forget to tell them what is happen if they do not understand the basic when they shall e. Her it is time to run the movie “AN INTRO TO DIESEL ENGINE” chapter "Firing order".General and basic priciples > General and basic principles > Firing order Key points  Piston moving  Position of the valves  Each turn of the crankshaft-three operating strokes  Once the crankshaft has rotated twice. Trainer notes Page 19 (trainer) . it takes just three minutes to reach a million combustion strokes. fault tracing. per minute. combustion has taken place in all the cylinders  One combustion stroke does not have time to be completed before the next starts Working procedure Go through the text in the student material and also add your own experience/knowledge. General and basic priciples > General and basic principles > The diesel engine is miserly with its fuel The diesel engine is miserly with its fuel  Cooling losses  Exhaust losses  Friction losses Notes Page 20 GT120017A v.0.01_en .1. Petrol engines have an efficiency rating of about 30%. Passenger-car diesels are somewhat less efficient.  Sankey diagram  Energy 100%. at about 38%.g. 40% (diesel engine) Working procedure Go through the text in the student material and also add your own experience/knowledge.  Cooling losses ca. Trainer notes Page 20 (trainer) . Ask question to be sure that the participants have understand the main purpose of this information/text. 25% (diesel engine)  Friction losses ca. Be sure that the participants have understood the main purpose of this information. 25% (diesel engine)  Exhaust losses ca. The first engines from the end of the previous century had an efficiency rating of a mere 2-5%. Show the participants the engine parts and explain how they are connected to each other.General and basic priciples > General and basic principles > The diesel engine is miserly with its fuel Key points  Fuel-chemical energy  Converts into mechanical effort. 10% (diesel engine)  Efficiency rating ca. up to 43-44% in a truck engine (D13 up to 47%). roughly the same level as twostroke diesel engines for vehicles. do not forget to tell them what is happen if they do not understand the basic when they shall e. fault tracing. Additional information Diesel engines have the highest efficiency rating of all. General and basic priciples > General and basic principles > Three diesel engine types Three diesel engine types  Direct-injection engines  Precombustion indirect-injection engines  Swirl-chamber engines Notes GT120017A v.0.01_en Page 21 .1. General and basic priciples > General and basic principles > Three diesel engine types Key points  Three diesel engine types  Direct-injection engines  Precombustion indirect-injection engines  Swirl-chamber engines  All Volvo diesel engines are direct-injection units Working procedure Go through the text in the student material and also add your own experience/knowledge. Show the participants the engine parts and explain how they are connected to each other. Be sure that the participants have understood the main purpose of this information. do not forget to tell them what is happen if they do not understand the basic when they shall e. fault tracing. Trainer notes Page 21 (trainer) .g. Ask question to be sure that the participants have understand the main purpose of this information/text. 01_en .0.General and basic priciples > General and basic principles > Precombustion indirect-injection engines Precombustion indirect-injection engines  Fuel  Pre-chamber  Combustion  Glowplug Notes Page 22 GT120017A v.1. Be sure that the participants have understood the main purpose of this information. Trainer notes Page 22 (trainer) . do not forget to tell them what is happen if they do not understand the basic when they shall e. is separated into a pre-chamber  Fuel into the pre-chamber  Not sufficient air in the pre-chamber  Mixture is pressed out into the combustion chamber  Heated electrically  VDA diesel engine-indirect-injection engine Working procedure Go through the text in the student material and also add your own experience/knowledge. Ask question to be sure that the participants have understand the main purpose of this information/text.g. fault tracing.General and basic priciples > General and basic principles > Precombustion indirect-injection engines Key points  Precombustion indirect-injection engines  Roughly 25%. Show the participants the engine parts and explain how they are connected to each other. 1.0.General and basic priciples > General and basic principles > Swirl-chamber engine Swirl-chamber engine  Combustion chamber  Swirl-chamber Notes GT120017A v.01_en Page 23 . g. do not forget to tell them what is happen if they do not understand the basic when they shall e. Show the participants the engine parts and explain how they are connected to each other. Trainer notes Page 23 (trainer) . Ask question to be sure that the participants have understand the main purpose of this information/text. fault tracing.General and basic priciples > General and basic principles > Swirl-chamber engine Key points  Swirl-chamber engine  Lrger volume than the indirect-injection engine  Roughly 50% in the swirl-chamber  Same process as in the indirect-injection diesel  Swirl-chamber engines-passenger-car diesels Working procedure Go through the text in the student material and also add your own experience/knowledge. Be sure that the participants have understood the main purpose of this information. 0.General and basic priciples > General and basic principles > Different characteristics Direct injection Different characteristics Direct injection  Small losses  Higher efficiency  Lower fuel consumption  Engine speeds. up to about 4000 rpm Notes Page 24 GT120017A v.01_en .1. Ask question to be sure that the participants have understand the main purpose of this information/text.g. fault tracing. Trainer notes Page 24 (trainer) . Show the participants the engine parts and explain how they are connected to each other. do not forget to tell them what is happen if they do not understand the basic when they shall e.General and basic priciples > General and basic principles > Different characteristics Direct injection Key points  Various engine types have different characteristics  Direct injection-Small losses compared with the others  Direct injection-Higher efficiency rating and lower fuel consumption  Direct injection-Up to about 4000 rpm Working procedure Go through the text in the student material and also add your own experience/knowledge. Be sure that the participants have understood the main purpose of this information. General and basic priciples > General and basic principles > Different characteristics Indirectinjection and swirl-chamber Different characteristics Indirect-injection and swirl-chamber  Combustion is quick  Operate at high speeds.0.  Greater losses  Lower efficiency  High fuel consumption Notes GT120017A v. up to about 6000 rpm.01_en Page 25 .1. do not forget to tell them what is happen if they do not understand the basic when they shall e. up to about 6000 rpm  Greater losses than for direct-injection engines  Lower efficiency rating  Higher fuel consumption Working procedure Go through the text in the student material and also add your own experience/knowledge.General and basic priciples > General and basic principles > Different characteristics Indirectinjection and swirl-chamber Key points  Indirect-injection and swirl-chamber  Combustion is quick  Operate at high speeds. Ask question to be sure that the participants have understand the main purpose of this information/text. Trainer notes Page 25 (trainer) . Be sure that the participants have understood the main purpose of this information. Show the participants the engine parts and explain how they are connected to each other.g. fault tracing. The highest pressure resulting from combustion is known as peak pressure. Test 1 Decide which is correct.01_en .1. Page 26 GT120017A v. In a diesel engine. The air is compressed The fuel is ignited by the hot air Clean air enters into the cylinders Finely atomised fuel is sprayed in Combustion produces high pressure The exhaust gases leave the cylinder State the correct sequence. True False State the correct sequence for the following processes (put the figures in the appropriate boxes 1 -6 ).4 ). finely atomised fuel is sprayed into the combustion chamber. A petrol engine takes in a ready-mixed blend of fuel and air.0.General and basic priciples > General and basic principles > Diesel engine fundamentals. The diesel engine is sometimes equipped with an electrical ignition system. These parts are subjected to greater mechanical stresses in a diesel engine than in a petrol engine. The diesel engine works under higher pressure than a petrol engine. putting the figures in the appropriate boxes ( 1 . Test 1 Diesel engine fundamentals. General and basic priciples > General and basic principles > Diesel engine fundamentals. Inlet stroke 1 Exhaust stroke 4 Operating stroke 3 Compression stroke 2 During one of the strokes in a diesel engine. finely atomised fuel is sprayed into the combustion chamber. Questions that could help to improve the format of the questionnaire in the future may arise. *A petrol engine takes in a ready-mixed blend of fuel and air. *The highest pressure resulting from combustion is known as peak pressure. The diesel engine is sometimes equipped with an electrical ignition system. *In a diesel engine. putting the figures in the appropriate boxes ( 1 . *The diesel engine works under higher pressure than a petrol engine. These parts are subjected to greater mechanical stresses in a diesel engine than in a petrol engine. After that shall the trainer go through the correct answer. The air is compressed 2 The fuel is ignited by the hot air 4 Clean air enters into the cylinders 1 Finely atomised fuel is sprayed in 3 Combustion produces high pressure 5 The exhaust gases leave the cylinder 6 State the correct sequence. Which stroke is this? Inlet stroke Exhaust stroke Compression stroke *Opearating stroke Page 26 (trainer) . Test 1 Key points • Question • Answer Working procedure It is now time to hand out the question to the participants. Additional information Introduction to diesel engines. the piston is on its way down and both valves are shut. Test 1 Key Decide which is correct. *True False State the correct sequence for the following processes (put the figures in the appropriate boxes 1 -6 ). Let each participants work with the question for about 5-10 minutes.4 ). Discuss the answers with the participants if there have been any misunderstandings or linguistic problems. much higher. No.1. the piston is on its way down and both valves are shut.General and basic priciples > General and basic principles > Diesel engine fundamentals.0. Yes. Which stroke is this? Inlet stroke Exhaust stroke Compression stroke Opearating stroke Peak pressure in a diesel engine can approach 20 MPa (200 bar). True False The firing order in a Volvo diesel engine is always: 1-5-4-2-3-6 1-2-3-4-5-6 1-5-3-6-2-4 Which of these engine types has the highest efficiency rating? Petrol engine Direct-injection diesel engine Diesel engine with pre-chamber All Volvo truck diesels as of 1986 are: Pre-combustion chamber engines Direct-injection engines Swirl-chamber engines GT120017A v. How many ignitions are there in a six-cylinder diesel engine for each turn of the crankshaft? Two Three Six How many times does the crankshaft turn for all six cylinders to fire once? One Two Six You have to know both the direction in which the piston is moving and the positions of the valves in order to determine exactly what is happening in a cylinder at any given moment in time. Test 1 nlet stroke Exhaust stroke Operating stroke Compression stroke During one of the strokes in a diesel engine. No.01_en Page 27 . this is true. not so high. this is true.4 Which of these engine types has the highest efficiency rating? Petrol engine *Direct-injection diesel engine Diesel engine with pre-chamber All Volvo truck diesels as of 1986 are: Pre-combustion chamber engines *Direct-injection engines Swirl-chamber engines Trainer notes Page 27 (trainer) .3 . No. How many ignitions are there in a six-cylinder diesel engine for each turn of the crankshaft? Two *Three Six How many times does the crankshaft turn for all six cylinders to fire once? One *Two Six You have to know both the direction in which the piston is moving and the positions of the valves in order to determine exactly what is happening in a cylinder at any given moment in time. much higher.6 . Test 1 Peak pressure in a diesel engine can approach 20 MPa (200 bar). No.5 .2 . not so high.General and basic priciples > General and basic principles > Diesel engine fundamentals. *True False The firing order in a Volvo diesel engine is always: 1-5-4-2-3-6 1-2-3-4-5-6 *1 . *Yes. General and basic priciples > General and basic principles > Engine design Engine design  In-line engine or straight engine  Turbocharged engines  Reliable design  Moving parts  Low engine speeds  Well-balanced  Long service life  Quiet  Simple service  Large crankshaft bearing surface  Seven main bearings  Ideal for turbocharging Notes Page 28 GT120017A v.1.0.01_en . Be sure that the participants have understood the main purpose of this information. smooth operation  Service on this engine is simple  Large crankshaft bearing surface  Crankshaft is journalled in seven main bearings Working procedure Go through the text in the student material and also add your own experience/knowledge. Show the participants the engine parts and explain how they are connected to each other.g. Ask question to be sure that the participants have understand the main purpose of this information/text.General and basic priciples > General and basic principles > Engine design Key points  Designed in different ways  Cylinders are positioned  Straight line-In-line engine or straight engine  Turbocharged engines  Volvo's diesel engines are 6-cylinder in-line engines or "straight-sixes"  Volvo produced 6-cylinder in-line truck engines way back in the 1920s  Semi-diesel  Suitable for large-displacement engines  Simple and it contains a relatively small number of moving parts  Low engine speeds  Well-balanced  Long service life and quiet. fault tracing. Trainer notes Page 28 (trainer) . do not forget to tell them what is happen if they do not understand the basic when they shall e. 1.01_en Page 29 .0.General and basic priciples > General and basic principles > V-engine V-engine  Volvo 8-cylinder engine Notes GT120017A v. Ask question to be sure that the participants have understand the main purpose of this information/text. fault tracing. Trainer notes Page 29 (trainer) . do not forget to tell them what is happen if they do not understand the basic when they shall e.g.General and basic priciples > General and basic principles > V-engine Key points  V-engine  Forties  400 bhp  Military vehicles  Truck  120 bhp Working procedure Go through the text in the student material and also add your own experience/knowledge. Be sure that the participants have understood the main purpose of this information. Show the participants the engine parts and explain how they are connected to each other. 01_en .V8 engines Here are a few reasons why Volvo no longer builds V-engines:  Five main bearings  Two connecting rods .V8 engines Volvo .one crankshaft journal  Service is much more difficult Notes Page 30 GT120017A v.1.General and basic priciples > General and basic principles > Volvo .0. Trainer notes Page 30 (trainer) . do not forget to tell them what is happen if they do not understand the basic when they shall e. fault tracing. Ask question to be sure that the participants have understand the main purpose of this information/text.g. Show the participants the engine parts and explain how they are connected to each other. Be sure that the participants have understood the main purpose of this information.V8 engines Key points  Reasons why Volvo no longer builds V-engines  The crankshaft only has five main bearings  The in-line six has seven main bearings  Two connecting rods  On the same crankshaft journal  The crankshaft bearing surfaces are not very large  Service is much more difficult Working procedure Go through the text in the student material and also add your own experience/knowledge.General and basic priciples > General and basic principles > Volvo . Piston. Connecting rod.0.01_en Page 31 .1.General and basic priciples > General and basic principles > The main engine components The main engine components  Valve cover  Cylinder head  Cylinder head gasket  Cylinder liner  Timing gear casing  Flywheel housing  Cylinder block  Vibration damper  Crankshaft. Flywheel  Stiffening frame (on some engines)  Oil sump Notes GT120017A v. Connecting rod.g. Piston. Show the participants the engine parts and explain how they are connected to each other. Working procedure Go through the text in the student material and also add your own experience/knowledge. Ask question to be sure that the participants have understand the main purpose of this information/text.  Cylinder block with cylinder liners. Be sure that the participants have understood the main purpose of this information. fault tracing. piston rings and gudgeon pins  Crankshaft mechanism with all its relevant parts  Timing mechanism  Valve cover  Cylinder head  Cylinder head gasket  Cylinder liner  Timing gear casing  Flywheel housing  Cylinder block-Engine block  Vibration damper  Crankshaft. Flywheel  Stiffening frame (on some engines)  Oil sump Other components  Inlet manifold  Exhaust manifold  Oil cooler  Oil filter  Coolant pump  Injection equipment. Trainer notes Page 31 (trainer) .General and basic priciples > General and basic principles > The main engine components Key points  Main engine components  Essential for the engine  Work in order for the engine to function safely and reliably. do not forget to tell them what is happen if they do not understand the basic when they shall e. pistons. 0.01_en .1.General and basic priciples > General and basic principles > Cylinder block Cylinder block  Cast in one piece  Cast-iron  Reinforcement ribs Notes Page 32 GT120017A v. Be sure that the participants have understood the main purpose of this information.General and basic priciples > General and basic principles > Cylinder block Key points  Cast in one piece  Cast-iron with a special alloy  Reinforcement ribs on the inside  Vibration in the block  Quiet engine Working procedure Go through the text in the student material and also add your own experience/knowledge. Show the participants the engine parts and explain how they are connected to each other. Trainer notes Page 32 (trainer) . do not forget to tell them what is happen if they do not understand the basic when they shall e. fault tracing. Ask question to be sure that the participants have understand the main purpose of this information/text.g. 01_en Page 33 .inside  Coolant jacket  Cylinder liners  O-rings  Main bearings  Bearings for the camshaft  Lubricating oil ducts  Piston cooling duct Notes GT120017A v.General and basic priciples > General and basic principles > Cylinder block .0.1.inside Cylinder block . fault tracing. Trainer notes Page 33 (trainer) . Ask question to be sure that the participants have understand the main purpose of this information/text.General and basic priciples > General and basic principles > Cylinder block . Be sure that the participants have understood the main purpose of this information. do not forget to tell them what is happen if they do not understand the basic when they shall e.g. Show the participants the engine parts and explain how they are connected to each other.inside Key points  Coolant in the cylinder block  Coolant jacket  Cylinder liner recesses  Grooves for sealing rings  Main bearings  Robust reinforcement ribs leading down to the main bearings  Additional reinforcement around the holes for the cylinder head bolts  Bearings for the camshaft  Machined guides for the valve tappets  Lubricating oil ducts  Main duct (gallery duct)  Piston cooling duct  Piston cooling nozzles-one for each cylinder Working procedure Go through the text in the student material and also add your own experience/knowledge. 1.General and basic priciples > General and basic principles > Camshaft in cylinder block Camshaft in cylinder block  Location  Lifters  Pushrods  Rocker arms  Transmission gears Notes Page 34 GT120017A v.0.01_en . Be sure that the participants have understood the main purpose of this information. Trainer notes Page 34 (trainer) . Ask question to be sure that the participants have understand the main purpose of this information/text. Show the participants the engine parts and explain how they are connected to each other. fault tracing.g.General and basic priciples > General and basic principles > Camshaft in cylinder block Key points  Location  Lifters  Pushrods  Rocker arms  Transmission gears Working procedure Go through the text in the student material and also add your own experience/knowledge. do not forget to tell them what is happen if they do not understand the basic when they shall e. 1.01_en Page 35 .General and basic priciples > General and basic principles > Cylinder liner design Cylinder liner design  Directly in the block  Pressed into recesses in the block  Direct contact with the coolant Notes GT120017A v.0. Be sure that the participants have understood the main purpose of this information. Ask question to be sure that the participants have understand the main purpose of this information/text. do not forget to tell them what is happen if they do not understand the basic when they shall e.g. Show the participants the engine parts and explain how they are connected to each other. Trainer notes Page 35 (trainer) .General and basic priciples > General and basic principles > Cylinder liner design Key points  Cylinder bores directly in the lock  Dry cylinder liners  Wet cylinder liners Working procedure Go through the text in the student material and also add your own experience/knowledge. fault tracing. General and basic priciples > General and basic principles > Cylinder bore Cylinder bore  High degree of precision  Cylinder bore  Milled  Honed  Plateau honing  Checked pattern  Oil pockets  Tapered profile Notes Page 36 GT120017A v.1.0.01_en . g. Be sure that the participants have understood the main purpose of this information.  Milled and honed  Plateau honing  Oil pockets  Constant film of oil  Shorter running-in period  Tapered profile  Prevents carbon on the piston Working procedure Go through the text in the student material and also add your own experience/knowledge.General and basic priciples > General and basic principles > Cylinder bore Key points  High degree of precision  Cylindrical throughout  Smooth surface. do not forget to tell them what is happen if they do not understand the basic when they shall e. fault tracing. Show the participants the engine parts and explain how they are connected to each other. Trainer notes Page 36 (trainer) . Ask question to be sure that the participants have understand the main purpose of this information/text. General and basic priciples > General and basic principles > Cylinder head Cylinder head  Cast-iron alloy  Huge stresses  Combustion process Notes GT120017A v.0.01_en Page 37 .1. Ask question to be sure that the participants have understand the main purpose of this information/text.g. Be sure that the participants have understood the main purpose of this information. Trainer notes Page 37 (trainer) . fault tracing. Show the participants the engine parts and explain how they are connected to each other. do not forget to tell them what is happen if they do not understand the basic when they shall e.General and basic priciples > General and basic principles > Cylinder head Key points  Cylinder head  Cast-iron alloy  Huge stress  High temperature  High pressure Working procedure Go through the text in the student material and also add your own experience/knowledge. Test 2 Place the right figure beside the appropriate name. is cast in one piece is known as the cylinder block is made of silumin features robust reinforcement ridges on the inside is made of a special cast-iron alloy Page 38 GT120017A v.01_en .0. Test 2 Diesel engine fundamentals.General and basic priciples > General and basic principles > Diesel engine fundamentals. Flywheel casing Vibration damper Cylinder head Timing cover Flywheel Cylinder liner Cylinder block Connecting rod Valve cover Crankshaft Oil sump Piston This component in a Volvo diesel engine.1. Additional information Introduction to diesel engines. Test 2 Key Place the right figure beside the appropriate name. After that shall the trainer go through the correct answer. *True False The diesel engine's cylinder head gasket is made of a heat-resistant copper alloy Page 38 (trainer) . *is cast in one piece *is known as the cylinder block is made of silumin *features robust reinforcement ridges on the inside *is made of a special cast-iron alloy *has space for coolant fluid has cylinders drilled directly in it Which of these figures shows a wet cylinder liner? A B *C Plateau honing helps ensure a permanent oil film on the cylinder wall and shortens the running-in period. Questions that could help to improve the format of the questionnaire in the future may arise. Flywheel casing 6 Vibration damper 7 Cylinder head 3 Timing cover 5 Flywheel 11 Cylinder liner 1 Cylinder block 4 Connecting rod 9 Valve cover 2 Crankshaft 8 Oil sump 12 Piston 10 This component in a Volvo diesel engine. Test 2 Key points  Question  Answer Working procedure Discuss the answers with the participants if there have been any misunderstandings or linguistic problems.General and basic priciples > General and basic principles > Diesel engine fundamentals. Let each participants work with the question for about 5-10 minutes. True False The diesel engine's cylinder head gasket is made of a heat-resistant copper alloy an aluminium alloy steel plate a new ceramic material The lower O-rings in the liner seal are made of rubber which hardens and thus provides effective sealing.1. The lower cylinder liner gasket consists of two or three O-rings.General and basic priciples > General and basic principles > Diesel engine fundamentals. The cylinder head gasket can withstand high peak pressures. Test 2 as space for coolant fluid has cylinders drilled directly in it Which of these figures shows a wet cylinder liner? A B C Plateau honing helps ensure a permanent oil film on the cylinder wall and shortens the running-in period. The upper liner seal is a thin O-ring.01_en Page 39 . True False Decide which is/are correct. Notes GT120017A v.0. *The lower cylinder liner gasket consists of two or three O-rings.General and basic priciples > General and basic principles > Diesel engine fundamentals. *The upper liner seal is a thin O-ring. Trainer notes Page 39 (trainer) . Test 2 an aluminium alloy *steel plate a new ceramic material The lower O-rings in the liner seal are made of rubber which hardens and thus provides effective sealing. *The cylinder head gasket can withstand high peak pressures. True *False Decide which is/are correct. Inlet and exhaust ducts  Cooling jacket  Exhaust outlet  Injector sleeve  Inlet and exhaust ducts  Valve seat  Valve guide Notes Page 40 GT120017A v.01_en .0.General and basic priciples > General and basic principles > Cylinder head .1.Inlet and exhaust ducts Cylinder head . Ask question to be sure that the participants have understand the main purpose of this information/text. Trainer notes Page 40 (trainer) . fault tracing.General and basic priciples > General and basic principles > Cylinder head .g.Inlet and exhaust ducts Key points  Direct contact  Large cooling jacket  The hottest areas  Inlet duct  Exhaust duct  Valve seat  Valve guide Working procedure Go through the text in the student material and also add your own experience/knowledge. Be sure that the participants have understood the main purpose of this information. do not forget to tell them what is happen if they do not understand the basic when they shall e. Show the participants the engine parts and explain how they are connected to each other. Copper sleeve Cylinder head .Copper sleeve  Injector  Copper sleeve  Cooling jacket Notes GT120017A v.General and basic priciples > General and basic principles > Cylinder head .0.01_en Page 41 .1. Trainer notes Page 41 (trainer) . do not forget to tell them what is happen if they do not understand the basic when they shall e. fault tracing.g. Ask question to be sure that the participants have understand the main purpose of this information/text.Copper sleeve Key points  Injector  Copper sleeve  Cooling jacket Working procedure Go through the text in the student material and also add your own experience/knowledge.General and basic priciples > General and basic principles > Cylinder head . Show the participants the engine parts and explain how they are connected to each other. Be sure that the participants have understood the main purpose of this information. Details  Cylinder head  Hole for injector  Valve guide  Injector sleeve  Valve seat. exhaust  Valve seat.General and basic priciples > General and basic principles > Cylinder head . inlet Notes Page 42 GT120017A v.Details Cylinder head .01_en .1.0. Be sure that the participants have understood the main purpose of this information.General and basic priciples > General and basic principles > Cylinder head . Ask question to be sure that the participants have understand the main purpose of this information/text. exhaust  Valve seat. inlet Working procedure Go through the text in the student material and also add your own experience/knowledge. Trainer notes Page 42 (trainer) . fault tracing. do not forget to tell them what is happen if they do not understand the basic when they shall e.Details Key points  Cylinder head  Hole for injector  Valve guide  Injector sleeve  Valve seat.g. Show the participants the engine parts and explain how they are connected to each other. 0.01_en Page 43 . which also contains chemical additives  Engine oil.1. which contains chemical additives Notes GT120017A v.General and basic priciples > General and basic principles > Cylinder head and cylinder liner seals Cylinder head and cylinder liner seals  High pressure in the cylinder  Coolant. Ask question to be sure that the participants have understand the main purpose of this information/text. Be sure that the participants have understood the main purpose of this information.General and basic priciples > General and basic principles > Cylinder head and cylinder liner seals Key points  Seals  Cylinder head gasket-highest forces  High pressure  Coolant  Engine oil  Steel plate  O-rings  Ridges or grooves Working procedure Go through the text in the student material and also add your own experience/knowledge.g. do not forget to tell them what is happen if they do not understand the basic when they shall e. Show the participants the engine parts and explain how they are connected to each other. fault tracing. Trainer notes Page 43 (trainer) . General and basic priciples > General and basic principles > Cylinder head and cylinder liner seals Cylinder head and cylinder liner seals  Wet cylinder liner  O-rings  Upper end  Liner collar  Lower seal  Different colours for securing correct mounting Notes Page 44 GT120017A v.0.1.01_en . Trainer notes Page 44 (trainer) . Show the participants the engine parts and explain how they are connected to each other. Ask question to be sure that the participants have understand the main purpose of this information/text. do not forget to tell them what is happen if they do not understand the basic when they shall e.General and basic priciples > General and basic principles > Cylinder head and cylinder liner seals Key points  Rubber O-rings  Upper end-thin O-ring  The silicon sealant-prevent friction  Lower seal-two or three O-rings  Different material  Different colours Working procedure Go through the text in the student material and also add your own experience/knowledge.g. fault tracing. Be sure that the participants have understood the main purpose of this information. 1.0.General and basic priciples > General and basic principles > Cranking mechanism Cranking mechanism  Vibration damper  Gudgeon pin  Piston  Piston rings  Connecting rods  Main bearing  Flywheel  Connecting rod bearing  Thrust washers (axial bearings)  Crankshaft Notes GT120017A v.01_en Page 45 . g.General and basic priciples > General and basic principles > Cranking mechanism Key points  Cranking mechanism  Vibration damper  Gudgeon pin  Piston  Piston rings  Connecting rods  Main bearing  Flywheel  Connecting rod bearing  Thrust washers (axial bearings)  Crankshaft Working procedure Go through the text in the student material and also add your own experience/knowledge. Ask question to be sure that the participants have understand the main purpose of this information/text. Show the participants the engine parts and explain how they are connected to each other. do not forget to tell them what is happen if they do not understand the basic when they shall e. Trainer notes Page 45 (trainer) . Be sure that the participants have understood the main purpose of this information. fault tracing. in other words about 14 tonnes Notes Page 46 GT120017A v.0.1.01_en .130 cm2  140 kN (kilo Newton).General and basic priciples > General and basic principles > A few facts about loads A few facts about loads  High pressure  Immense forces  Peak pressure 11 MPa  Piston surface . Ask question to be sure that the participants have understand the main purpose of this information/text.General and basic priciples > General and basic principles > A few facts about loads Key points  Peak pressure 11 MPa  Piston surface 130 cm2  Force 140 kN (kilo Newton)(14 tonnes)  D13. fault tracing.g. Trainer notes Page 46 (trainer) . Be sure that the participants have understood the main purpose of this information. Show the participants the engine parts and explain how they are connected to each other. do not forget to tell them what is happen if they do not understand the basic when they shall e. the peak pressure is 20 MPa Working procedure Go through the text in the student material and also add your own experience/knowledge. 1.01_en Page 47 .General and basic priciples > General and basic principles > Crankshaft Crankshaft  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  Centrifugal forces  Counterbalances Notes GT120017A v.0. General and basic priciples > General and basic principles > Crankshaft Key points  Crankshaft  Immense stress  Material  Design  Forged of special steel  Special heat treatment  Additional fatigue resistance  Hard bearing surfaces  Centrifugal forces  Connecting rod's lower section  Counterbalances Working procedure Go through the text in the student material and also add your own experience/knowledge.g. Be sure that the participants have understood the main purpose of this information. fault tracing. Trainer notes Page 47 (trainer) . do not forget to tell them what is happen if they do not understand the basic when they shall e. Ask question to be sure that the participants have understand the main purpose of this information/text. Show the participants the engine parts and explain how they are connected to each other. 1.0.General and basic priciples > General and basic principles > Power impulse Power impulse  Power impulse  Torsional tendencies Notes Page 48 GT120017A v.01_en . Ask question to be sure that the participants have understand the main purpose of this information/text. Be sure that the participants have understood the main purpose of this information.g.General and basic priciples > General and basic principles > Power impulse Key points  Power impulse  Torsional tendencies Working procedure Go through the text in the student material and also add your own experience/knowledge. fault tracing. Show the participants the engine parts and explain how they are connected to each other. Trainer notes Page 48 (trainer) . do not forget to tell them what is happen if they do not understand the basic when they shall e. 01_en Page 49 .0.General and basic priciples > General and basic principles > Crankshaft .Oscillation  Rapid oscillation  Vibration damper  Flywheel Notes GT120017A v.Oscillation Crankshaft .1. Ask question to be sure that the participants have understand the main purpose of this information/text. Be sure that the participants have understood the main purpose of this information. Trainer notes Page 49 (trainer) . Show the participants the engine parts and explain how they are connected to each other.Oscillation Key points  Rapid oscillation  Snap the crankshaft  Vibration damper  Flywheel  Pulsationes and vibrations Working procedure Go through the text in the student material and also add your own experience/knowledge. do not forget to tell them what is happen if they do not understand the basic when they shall e.General and basic priciples > General and basic principles > Crankshaft . fault tracing.g. General and basic priciples > General and basic principles > Damper Damper  Fluid-type damper  The flywheel mass (damper ring)  Bushing  Sealed housing  Viscous silicon oil  Steady speed Notes Page 50 GT120017A v.1.0.01_en . Show the participants the engine parts and explain how they are connected to each other. fault tracing. do not forget to tell them what is happen if they do not understand the basic when they shall e.General and basic priciples > General and basic principles > Damper Key points  Fluid-type damper  Very efficient  Damper ring  Bushing  Sealed housing  Viscous silicon oil  Surrounds the flywheel mass Working procedure Go through the text in the student material and also add your own experience/knowledge. Trainer notes Page 50 (trainer) .g. Ask question to be sure that the participants have understand the main purpose of this information/text. Be sure that the participants have understood the main purpose of this information. General and basic priciples > General and basic principles > The crankshaft is perfectly balanced The crankshaft is perfectly balanced  Imbalance  Considerable stress  Vibration in the engine  Precisely balanced Notes GT120017A v.1.0.01_en Page 51 . General and basic priciples > General and basic principles > The crankshaft is perfectly balanced Key points  Imbalance  Considerable stress  Provokes vibration  Precisely balanced  Balanced in a special machine Working procedure Go through the text in the student material and also add your own experience/knowledge. do not forget to tell them what is happen if they do not understand the basic when they shall e. fault tracing. Show the participants the engine parts and explain how they are connected to each other. Be sure that the participants have understood the main purpose of this information.g. Trainer notes Page 51 (trainer) . Ask question to be sure that the participants have understand the main purpose of this information/text. General and basic priciples > General and basic principles > Seven main bearings Seven main bearings  Seven main bearings  Renowned long service life Notes Page 52 GT120017A v.0.1.01_en . General and basic priciples > General and basic principles > Seven main bearings Key points  Seven main bearings  Long service life Working procedure Go through the text in the student material and also add your own experience/knowledge. Trainer notes Page 52 (trainer) . Ask question to be sure that the participants have understand the main purpose of this information/text.g. Show the participants the engine parts and explain how they are connected to each other. do not forget to tell them what is happen if they do not understand the basic when they shall e. fault tracing. Be sure that the participants have understood the main purpose of this information. connecting rod  Sturdy crankshaft bearing  Large bearing surfaces  Long service life  High engine reliability  One crankshaft bearing journal and connecting rod between the main bearings Notes GT120017A v.1.0.01_en Page 53 .connecting rod Seven main bearings .General and basic priciples > General and basic principles > Seven main bearings . do not forget to tell them what is happen if they do not understand the basic when they shall e. Trainer notes Page 53 (trainer) . Be sure that the participants have understood the main purpose of this information. Show the participants the engine parts and explain how they are connected to each other.General and basic priciples > General and basic principles > Seven main bearings .connecting rod Key points  Sturdy crankshaft bearing  Large bearing surfaces  Long service life  High engine reliability  One crankshaft bearing journal and connecting rod between the main bearings Working procedure Go through the text in the student material and also add your own experience/knowledge. fault tracing. Ask question to be sure that the participants have understand the main purpose of this information/text.g. two connecting rods V-engine.01_en .0.two connecting rods Notes Page 54 GT120017A v.1. two connecting rods  Bearing  Vital difference  V-engine .General and basic priciples > General and basic principles > V-engine. Trainer notes Page 54 (trainer) . fault tracing. Ask question to be sure that the participants have understand the main purpose of this information/text.g. two connecting rods Key points  In-line six-V-engine  Two connecting rods-same crankshaft bearing journal  Not be as generously dimensioned Working procedure Go through the text in the student material and also add your own experience/knowledge. Be sure that the participants have understood the main purpose of this information. Show the participants the engine parts and explain how they are connected to each other. do not forget to tell them what is happen if they do not understand the basic when they shall e.General and basic priciples > General and basic principles > V-engine. 1.Lubrication ducts  Pressure-lubricated  Drilled oil ducts in the crankshaft Notes GT120017A v.0.General and basic priciples > General and basic principles > Lubrication ducts Crankshaft .01_en Page 55 . do not forget to tell them what is happen if they do not understand the basic when they shall e.General and basic priciples > General and basic principles > Lubrication ducts Key points  Lubrication ducts-drilled in the cylinder block  Oil under pressure-pressure lubricated  Main bearing journals  Crankshaft bearing journals Working procedure Go through the text in the student material and also add your own experience/knowledge. Ask question to be sure that the participants have understand the main purpose of this information/text. Show the participants the engine parts and explain how they are connected to each other. Be sure that the participants have understood the main purpose of this information. fault tracing.g. Trainer notes Page 55 (trainer) . General and basic priciples > General and basic principles > What happens in an in-line six cylinder engine What happens in an in-line six cylinder engine  Pistons 1 and 6 perform their upward and downward movements simultaneously.  120 crankshaft degrees  Ignition impulses Notes Page 56 GT120017A v.0.1.01_en .  Pistons 3 and 4 move together.  Pistons 2 and 5 move together. fault tracing.  120 crankshaft degrees Working procedure Go through the text in the student material and also add your own experience/knowledge.g. Trainer notes Page 56 (trainer) . Be sure that the participants have understood the main purpose of this information. do not forget to tell them what is happen if they do not understand the basic when they shall e. Ask question to be sure that the participants have understand the main purpose of this information/text.General and basic priciples > General and basic principles > What happens in an in-line six cylinder engine Key points  Pistons 1 and 6  Pistons 2 and 5  Pistons 3 and 4. Show the participants the engine parts and explain how they are connected to each other. 1.01_en Page 57 .General and basic priciples > General and basic principles > Main bearing caps Main bearing caps  Journal led  Main bearing caps  Replaceable  Ready for installation  Bearing shells  Steel core  Bearing-quality metal Notes GT120017A v.0. g. Be sure that the participants have understood the main purpose of this information. do not forget to tell them what is happen if they do not understand the basic when they shall e. Ask question to be sure that the participants have understand the main purpose of this information/text. Trainer notes Page 57 (trainer) .General and basic priciples > General and basic principles > Main bearing caps Key points  Main bearing caps  Replaceable slider bearings  Immense precision  Manufacturer  Bearing shells  Steel core  Bearing-quality metal Working procedure Go through the text in the student material and also add your own experience/knowledge. Show the participants the engine parts and explain how they are connected to each other. fault tracing. General and basic priciples > General and basic principles > Main bearings screw Main bearings screw  Upper bearing shell  Lower shell  Main bearing cap Notes Page 58 GT120017A v.1.0.01_en General and basic priciples > General and basic principles > Main bearings screw Key points  Main bearing screws  Extremely robust  Absorb considerable force during combustion  The upper bearing shell  The lower shell - main bearing cap  Screwed to the cylinder block Working procedure Go through the text in the student material and also add your own experience/knowledge. Be sure that the participants have understood the main purpose of this information. Ask question to be sure that the participants have understand the main purpose of this information/text. Show the participants the engine parts and explain how they are connected to each other, do not forget to tell them what is happen if they do not understand the basic when they shall e.g. fault tracing. Trainer notes Page 58 (trainer) General and basic priciples > General and basic principles > Support bearing Support bearing  Axial position  Acceleration  Retardation  Axial movement  Thrust washers Notes GT120017A v.1.0.01_en Page 59 General and basic priciples > General and basic principles > Support bearing Key points  Support bearing  One main bearing  Specific axial position  Move back when the vehicle is under acceleration  Move forth when the vehicle brakes are applied  Controls the crankshaft's axial movement  Loose thrust washers  Coated with bearing alloy  Precision-machined bearing surfaces Working procedure Go through the text in the student material and also add your own experience/knowledge. Be sure that the participants have understood the main purpose of this information. Ask question to be sure that the participants have understand the main purpose of this information/text. Show the participants the engine parts and explain how they are connected to each other, do not forget to tell them what is happen if they do not understand the basic when they shall e.g. fault tracing. Trainer notes Page 59 (trainer) General and basic priciples > General and basic principles > Flywheel Flywheel  Power impulses Notes Page 60 GT120017A v.1.0.01_en General and basic priciples > General and basic principles > Flywheel Key points  Flywheel  Fairly uneven  Power impulses  Crankshaft's speed increases and slows down every impulse  Even out variations in speed  Balancing Working procedure Go through the text in the student material and also add your own experience/knowledge. Be sure that the participants have understood the main purpose of this information. Ask question to be sure that the participants have understand the main purpose of this information/text. Show the participants the engine parts and explain how they are connected to each other, do not forget to tell them what is happen if they do not understand the basic when they shall e.g. fault tracing. Trainer notes Page 60 (trainer) General and basic priciples > General and basic principles > Flywheel - other tasks Flywheel - other tasks  Starter ring  Indication grooves Notes GT120017A v.1.0.01_en Page 61 General and basic priciples > General and basic principles > Flywheel - other tasks Key points  Starter ring  Starter motor gear  Electronic fuel injection control  Indication grooves Working procedure Go through the text in the student material and also add your own experience/knowledge. Be sure that the participants have understood the main purpose of this information. Ask question to be sure that the participants have understand the main purpose of this information/text. Show the participants the engine parts and explain how they are connected to each other, do not forget to tell them what is happen if they do not understand the basic when they shall e.g. fault tracing. Trainer notes Page 61 (trainer) General and basic priciples > General and basic principles > Connecting rod Connecting rod  Forged  High-alloy steel  Chrome-molybdenum steel  Chrome manganese silicon steel  Extremely durable  Strong and lightweight  I-shaped profile  Flexing  Big end  Small end  Bronze bushing Notes Page 62 GT120017A v.01_en .0.1. General and basic priciples > General and basic principles > Connecting rod Key points  Connecting rod  Forged from high-alloy steel  Chrome-molybdenum steel  Chrome manganese silicon steel  Extremely durable  Strong and lightweight  I-shaped profile  Tendency to flexing  Big end  Small end  Gudgeon pin Working procedure Go through the text in the student material and also add your own experience/knowledge. do not forget to tell them what is happen if they do not understand the basic when they shall e. Trainer notes Page 62 (trainer) .g. fault tracing. Show the participants the engine parts and explain how they are connected to each other. Be sure that the participants have understood the main purpose of this information. Ask question to be sure that the participants have understand the main purpose of this information/text. General and basic priciples > General and basic principles > Connecting rod .1.details Connecting rod .01_en Page 63 .0.details  Classified  Marked  Front marking  Trapezoidal  Lubricated via ducts  Splash lubrication  Diagonally split Notes GT120017A v. do not forget to tell them what is happen if they do not understand the basic when they shall e.details Key points  Classified by weight  Marked with number or letters  Marking facing to the front  Trapezoidal  Piston more ridgit  Lubricated via ducts  Splash lubrication  Gudgeon pin  Diagonally split  Serrations  Split Working procedure Go through the text in the student material and also add your own experience/knowledge.g.General and basic priciples > General and basic principles > Connecting rod . fault tracing. Ask question to be sure that the participants have understand the main purpose of this information/text. Show the participants the engine parts and explain how they are connected to each other. Be sure that the participants have understood the main purpose of this information. Trainer notes Page 63 (trainer) . 0.1.General and basic priciples > General and basic principles > Gudgeon pin Gudgeon pin  Crankshaft mechanism  High-quality material  Chrome-manganese steel  Chrome-molybdenum steel alloys  Minimise weight  Surface-hardened  Finely-ground Notes Page 64 GT120017A v.01_en . Ask question to be sure that the participants have understand the main purpose of this information/text. fault tracing. Be sure that the participants have understood the main purpose of this information. do not forget to tell them what is happen if they do not understand the basic when they shall e. Trainer notes Page 64 (trainer) .General and basic priciples > General and basic principles > Gudgeon pin Key points  Gudgeon pin  Crankshaft mechanism  Considerable stress and load  High-quality material  Chrome-manganese steel  Chrome-molybdenum steel alloys  Tubular  Surface-hardened  Finely-ground  Fine tolerances Working procedure Go through the text in the student material and also add your own experience/knowledge.g. Show the participants the engine parts and explain how they are connected to each other. General and basic priciples > General and basic principles > Gudgeon pin hole Gudgeon pin hole  Larger diameter  Changes shape  High load Notes GT120017A v.1.01_en Page 65 .0. do not forget to tell them what is happen if they do not understand the basic when they shall e. Ask question to be sure that the participants have understand the main purpose of this information/text. Show the participants the engine parts and explain how they are connected to each other. Additional information Gudgeon pin hole The gudgeon pin hole has a larger diameter at the recess. providing space for the gudgeon pin when it changes shape under high load. Trainer notes Page 65 (trainer) . Be sure that the participants have understood the main purpose of this information.General and basic priciples > General and basic principles > Gudgeon pin hole Key points  Larger diameter at the recess  Changes shape under high load Working procedure Go through the text in the student material and also add your own experience/knowledge. fault tracing.g. 0.journal led  Journal led  Floating fit  Locking rings Notes Page 66 GT120017A v.1.journal led Gudgeon pin .General and basic priciples > General and basic principles > Gudgeon pin .01_en . g. Show the participants the engine parts and explain how they are connected to each other. do not forget to tell them what is happen if they do not understand the basic when they shall e.journal led Key points  Journal led  Floating fit  Locking rings Working procedure Go through the text in the student material and also add your own experience/knowledge. Be sure that the participants have understood the main purpose of this information. Ask question to be sure that the participants have understand the main purpose of this information/text.General and basic priciples > General and basic principles > Gudgeon pin . Trainer notes Page 66 (trainer) . fault tracing. General and basic priciples > General and basic principles > Connecting rod bearing Connecting rod bearing  Two bearing shells  Machined big end  Guide lugs  Pressure-lubricated Notes GT120017A v.1.01_en Page 67 .0. General and basic priciples > General and basic principles > Connecting rod bearing Key points  Connecting rod bearing  Machined big end  Guide lugs  Fit properly  Pressure-lubricated Working procedure Go through the text in the student material and also add your own experience/knowledge. Be sure that the participants have understood the main purpose of this information.g. Trainer notes Page 67 (trainer) . Show the participants the engine parts and explain how they are connected to each other. do not forget to tell them what is happen if they do not understand the basic when they shall e. Ask question to be sure that the participants have understand the main purpose of this information/text. fault tracing. True False Page 68 GT120017A v. Volvo diesel engines have fluid-type vibration dampers. Crank bearing Vibration damper Crankshaft Thrust washers Piston Connecting rods Flywheel Main bearing Piston rings Gudgeon pin Decide which is correct. Imbalance in the crankshaft affects the main bearings but does not cause vibration in the engine or particularly heavy load on the crankshaft. The crankshaft is balanced in a special machine. Test 3 Place the right number beside the appropriate name. The crankshafts in Volvo diesel engines are forged from special steel.General and basic priciples > General and basic principles > Diesel engine fundamentals. The ducts in the crankshaft's counterbalances are part of the lubrication system.01_en .0.1. Test 3 Diesel engine fundamentals. General and basic priciples > General and basic principles > Diesel engine fundamentals. Let each participants work with the question for about 5-10 minutes. Additional information Introduction to diesel engines. *The crankshaft is balanced in a special machine. Test 3 Key Place the right number beside the appropriate name. The crankshafts in Volvo diesel engines are forged from special steel. Page 68 (trainer) . *True False Nitro-carburisation is a heat-treatment method for crankshafts. After that shall the trainer go through the correct answer. *True False The term "seven-bearing crankshaft" means that the crankshaft has as many main bearing pins as crankshaft pins. *True False A bearing shell is made of a steel shell lined with bearing metal. Imbalance in the crankshaft affects the main bearings but does not cause vibration in the engine or particularly heavy load on the crankshaft. *Volvo diesel engines have fluid-type vibration dampers. True *False This illustration shows the crank weight positions in relation to each other. Test 3 Key points  Question  Answer Working procedure Discuss the answers with the participants if there have been any misunderstandings or linguistic problems. Questions that could help to improve the format of the questionnaire in the future may arise. Crank bearing 8 Vibration damper 4 Crankshaft 5 Thrust washers 6 Piston 2 Connecting rods 10 Flywheel 9 Main bearing 7 Piston rings 1 Gudgeon pin 3 Decide which is correct. The ducts in the crankshaft's counterbalances are part of the lubrication system. True False The term "seven-bearing crankshaft" means that the crankshaft has as many main bearing pins as crankshaft pins.General and basic priciples > General and basic principles > Diesel engine fundamentals. Pistons 1 and 6 make their vertical movements at the same time.1.01_en Page 69 .0. keeps the crankshaft in a pre-determined axial position. True False Notes GT120017A v. Pistons 2 and 5 make their vertical movements at the same time. Test 3 itro-carburisation is a heat-treatment method for crankshafts. the fourth main bearing. The connecting rod's big-end is split diagonally. Pistons 1 and 3 make their vertical movements at the same time. Pistons 3 and 6 make their vertical movements at the same time. True False This illustration shows the crank weight positions in relation to each other. True False The support bearing. The starter ring gear is on the flywheel. True False A bearing shell is made of a steel shell lined with bearing metal. There are 120 crankshaft degrees between ignition points. The main bearings and crankshaft bearings are slider bearings. True False Decide what is correct. There are 120:2 crankshaft degrees between ignition points. The clutch acts on the flywheel's surface-ground face. The flywheel evens out variations in rpm. Pistons 3 and 4 make their vertical movements at the same time. General and basic priciples > General and basic principles > Diesel engine fundamentals. *The flywheel evens out variations in rpm. *True False The support bearing. The connecting rod's big-end is split diagonally. *There are 120 crankshaft degrees between ignition points. *Pistons 1 and 6 make their vertical movements at the same time. Test 3 Pistons 1 and 3 make their vertical movements at the same time. *The starter ring gear is on the flywheel. *Pistons 2 and 5 make their vertical movements at the same time. *The clutch acts on the flywheel's surface-ground face. *Pistons 3 and 4 make their vertical movements at the same time. The main bearings and crankshaft bearings are slider bearings. the fourth main bearing. Pistons 3 and 6 make their vertical movements at the same time. *True False Decide what is correct. *True False Trainer notes Page 69 (trainer) . keeps the crankshaft in a pre-determined axial position. There are 120:2 crankshaft degrees between ignition points. 1.General and basic priciples > General and basic principles > Piston Piston  Absorb combustion pressure  Transfer considerable force  Gudgeon pin  Connecting rod  Crankshaft  Piston roof  Perfect fit  Combustion pressure  Loss of engine power  Piston ring  Piston ring groove Notes Page 70 GT120017A v.0.01_en . g.crankshaft  Piston roof  Guide surface  Combustion pressure leakage  Piston and cylinder wall  Piston rings  Piston ring groove Working procedure Go through the text in the student material and also add your own experience/knowledge.General and basic priciples > General and basic principles > Piston Key points  Piston  Immense load  Crankshaft mechanism  Transfer considerable force  Gudgeon pin . Be sure that the participants have understood the main purpose of this information. do not forget to tell them what is happen if they do not understand the basic when they shall e.connecting rod . Show the participants the engine parts and explain how they are connected to each other. Ask question to be sure that the participants have understand the main purpose of this information/text. fault tracing. Trainer notes Page 70 (trainer) . General and basic priciples > General and basic principles > Piston .1.Thermal stress and mechanical stress  Thermal stress  Mechanical stress  Combustion pressure load  Wear against the cylinder wall  Wear of the ring groove owing to piston ring movement  Wear of the gudgeon pin bearing Notes GT120017A v.Thermal stress and mechanical stress Piston .01_en Page 71 .0. Ask question to be sure that the participants have understand the main purpose of this information/text. Trainer notes Page 71 (trainer) . do not forget to tell them what is happen if they do not understand the basic when they shall e. Be sure that the participants have understood the main purpose of this information. fault tracing.General and basic priciples > General and basic principles > Piston .g.Thermal stress and mechanical stress Key points  Thermal stress  Mechanical stress  Combustion pressure load  Wear against the cylinder wall  Wear of the ring groove  Wear of the gudgeon pin bearing Working procedure Go through the text in the student material and also add your own experience/knowledge. Show the participants the engine parts and explain how they are connected to each other. Materials Piston .01_en .General and basic priciples > General and basic principles > Piston .1.0.Materials  Aluminium alloy  Silicon  Iron  Nickel  Manganese  Copper  Magnesium  Extremely durable  Thermal expansion Notes Page 72 GT120017A v. Show the participants the engine parts and explain how they are connected to each other. Trainer notes Page 72 (trainer) .g.General and basic priciples > General and basic principles > Piston . do not forget to tell them what is happen if they do not understand the basic when they shall e. Be sure that the participants have understood the main purpose of this information. Ask question to be sure that the participants have understand the main purpose of this information/text.Materials Key points  Aluminium alloy  Steel  Diameter Working procedure Go through the text in the student material and also add your own experience/knowledge. fault tracing. steel  Bottom section .General and basic priciples > General and basic principles > Articulated piston Articulated piston  Articulated pistons .1.aluminium Notes GT120017A v.split pistons  Separately journal led  Gudgeon pin  Top section .01_en Page 73 .0. Trainer notes Page 73 (trainer) .General and basic priciples > General and basic principles > Articulated piston Key points  Articulated pistons (split pistons)  Separately journal led  Top section . Ask question to be sure that the participants have understand the main purpose of this information/text. do not forget to tell them what is happen if they do not understand the basic when they shall e.aluminium  Small gap prevent heat transference  Higher temperature  Higher co-efficient of efficiency Working procedure Go through the text in the student material and also add your own experience/knowledge. fault tracing. Be sure that the participants have understood the main purpose of this information. Show the participants the engine parts and explain how they are connected to each other.steel  Bottom section .g. 1.01_en .0.General and basic priciples > General and basic principles > Piston .Tolerance Piston .Tolerance  Dimensional tolerances  Cylinder liner kits  Piston heat  Piston ring  Piston ring carrier Notes Page 74 GT120017A v. g.complete kits  Heat is transferred  Vulnerable to wear  Piston ring carrier made of cast-iron Working procedure Go through the text in the student material and also add your own experience/knowledge. Trainer notes Page 74 (trainer) . Be sure that the participants have understood the main purpose of this information. do not forget to tell them what is happen if they do not understand the basic when they shall e.General and basic priciples > General and basic principles > Piston .08 mm  Pistons and liners . Show the participants the engine parts and explain how they are connected to each other. Ask question to be sure that the participants have understand the main purpose of this information/text.07-0. fault tracing.Tolerance Key points  Tight dimensional tolerances  Differences 0. 0.General and basic priciples > General and basic principles > Piston cooling 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 Notes GT120017A v.01_en Page 75 .1. Ask question to be sure that the participants have understand the main purpose of this information/text.General and basic priciples > General and basic principles > Piston cooling Key points  Internal piston cooling  Piston crown. do not forget to tell them what is happen if they do not understand the basic when they shall e.channel  Very efficient cooling Working procedure Go through the text in the student material and also add your own experience/knowledge. fault tracing. Be sure that the participants have understood the main purpose of this information. Trainer notes Page 75 (trainer) .g. Show the participants the engine parts and explain how they are connected to each other. 0.General and basic priciples > General and basic principles > Piston rings Piston rings  Two types  Compression ring  Compression pressure  Combustion pressure  High pressure  High temperature  Oil scraper ring Notes Page 76 GT120017A v.01_en .1. Ask question to be sure that the participants have understand the main purpose of this information/text.back to the sump Working procedure Go through the text in the student material and also add your own experience/knowledge.General and basic priciples > General and basic principles > Piston rings Key points  Piston ring  Ring grooves  Compression rings  Compression pressure  Combustion pressure  High pressure  High temperature  Wear  Forces stemming  Oil scraper rings  Oil on the cylinder walls  Oil . Show the participants the engine parts and explain how they are connected to each other. do not forget to tell them what is happen if they do not understand the basic when they shall e. fault tracing. Be sure that the participants have understood the main purpose of this information. Trainer notes Page 76 (trainer) .g. 01_en Page 77 .0.1.General and basic priciples > General and basic principles > Piston rings material first ring Piston rings material first ring  Cast-iron  Surface-treated  Two compression rings  One oil scraper ring  Keystone ring  Chrome-plated  Molybdenum Notes GT120017A v. Ask question to be sure that the participants have understand the main purpose of this information/text. do not forget to tell them what is happen if they do not understand the basic when they shall e.General and basic priciples > General and basic principles > Piston rings material first ring Key points  Cast-iron  Surface-treated  Two compression rings  One oil scraper ring  Different versions  Trapezoidal cross-section . fault tracing. Be sure that the participants have understood the main purpose of this information.Keystone ring  Ability to keep clean  Chrome-plated  Molybdenum Working procedure Go through the text in the student material and also add your own experience/knowledge. Show the participants the engine parts and explain how they are connected to each other.g. Trainer notes Page 77 (trainer) . 0.1.General and basic priciples > General and basic principles > Piston rings material second ring Piston rings material second ring  Chrome-plated  Internal ridge  Twistrings Notes Page 78 GT120017A v.01_en . General and basic priciples > General and basic principles > Piston rings material second ring Key points  Chrome-plated  Internal ridge  Twist  "Twistrings" Working procedure Go through the text in the student material and also add your own experience/knowledge. Show the participants the engine parts and explain how they are connected to each other. Ask question to be sure that the participants have understand the main purpose of this information/text. fault tracing. Trainer notes Page 78 (trainer) .g. do not forget to tell them what is happen if they do not understand the basic when they shall e. Be sure that the participants have understood the main purpose of this information. 01_en Page 79 .1.0.General and basic priciples > General and basic principles > Piston rings material oil ring Piston rings material oil ring  Chrome-plated  Expanding spring Notes GT120017A v. General and basic priciples > General and basic principles > Piston rings material oil ring Key points  Chrome-plated  Two scraper edges  Spring Working procedure Go through the text in the student material and also add your own experience/knowledge. do not forget to tell them what is happen if they do not understand the basic when they shall e. Be sure that the participants have understood the main purpose of this information.g. Show the participants the engine parts and explain how they are connected to each other. Trainer notes Page 79 (trainer) . fault tracing. Ask question to be sure that the participants have understand the main purpose of this information/text. Oil ring  Oil  Return holes Notes Page 80 GT120017A v.0.01_en .1.General and basic priciples > General and basic principles > Piston rings .Oil ring Piston rings . g. Show the participants the engine parts and explain how they are connected to each other. Trainer notes Page 80 (trainer) .General and basic priciples > General and basic principles > Piston rings . Ask question to be sure that the participants have understand the main purpose of this information/text. fault tracing. do not forget to tell them what is happen if they do not understand the basic when they shall e. Be sure that the participants have understood the main purpose of this information.Oil ring Key points  Oil  Led back  Crankcase  Oil sump  Return holes Working procedure Go through the text in the student material and also add your own experience/knowledge. 0. Test 4 The gudgeon pin is prevented from moving towards the cylinder wall by.01_en Page 81 . Piston and liner are matched together as per the classification letter. a screw which locks the pin to the connecting rod. Put the numbers in the appropriate boxes. GT120017A v. Piston rings Piston crown Piston ring groove Piston shirt Combustion chamber Lock ring Decide what is correct. lock-rings in the piston. Pistons and cylinder liners are classified according to diameter. a decive which locks it to the small-end. Test 4 Diesel engine fundamentals.General and basic priciples > General and basic principles > Diesel engine fundamentals.1. Questions that could help to improve the format of the questionnaire in the future may arise. Piston rings 3 Piston crown 2 Piston ring groove 5 Piston shirt 6 Combustion chamber 1 Lock ring 4 Decide what is correct. *True False A Keystone ring has the ability to keep clean because the chamfered surfaces work against the ring carrier's surfaces. After that shall the trainer go through the correct answer. a screw which locks the pin to the connecting rod. 2. *lock-rings in the piston. Put the numbers in the appropriate boxes. Let each participants work with the question for about 5-10 minutes. thus scraping the oil as the piston moves downwards. *True False The Keystone ring has a trapezoidal cross-section. Additional information Introduction to diesel engines. a decive which locks it to the small-end. *Piston and liner are matched together as per the classification letter.General and basic priciples > General and basic principles > Diesel engine fundamentals. A twist-ring twists in the ring groove. 3 etc. *Pistons and cylinder liners are classified according to diameter. *True Page 81 (trainer) . Pistons are marked with classification figures 1. Test 4 Key points  Question  Answer Working procedure Discuss the answers with the participants if there have been any misunderstandings or linguistic problems. *True False The oil scraper ring has two chrome-plated scraper edges which are pressed against the cylinder wall. Test 4 Key The gudgeon pin is prevented from moving towards the cylinder wall by. Test 4 istons are marked with classification figures 1. 3 etc.0.1.01_en . A twist-ring twists in the ring groove. True False Notes Page 82 GT120017A v. True False The Keystone ring has a trapezoidal cross-section.General and basic priciples > General and basic principles > Diesel engine fundamentals. thus scraping the oil as the piston moves downwards. True False A Keystone ring has the ability to keep clean because the chamfered surfaces work against the ring carrier's surfaces. True False The oil scraper ring has two chrome-plated scraper edges which are pressed against the cylinder wall. 2. Test 4 False Trainer notes Page 82 (trainer) .General and basic priciples > General and basic principles > Diesel engine fundamentals. General and basic priciples > General and basic principles > Valve mechanism Valve mechanism  Overhead valve  Valve  Rocker arm  Pushrod  Camshaft Valve tappet  Valve lifter (even called valve lifters)  Robustly dimensioned  Considerable loads  Spherical  Surface-hardened  The jacket  Rotates Notes GT120017A v.1.01_en Page 83 .0. cam  Spherical  Surface-hardened Working procedure Go through the text in the student material and also add your own experience/knowledge. Ask question to be sure that the participants have understand the main purpose of this information/text. This is like a teaser for the participants. do not forget to tell them what is happen if they do not understand the basic when they shall e.General and basic priciples > General and basic principles > Valve mechanism Key points  Valve mechanism  Overhead valve engines  Valve  Rocker arm  Pushrod  Camshaft  Open and shut the valves  Valve tappet  Convert the camshaft's rotating  Tappets (even called valve lifters)  Bottom of the tappet  The contact surface . Trainer notes Page 83 (trainer) . Additional information Her it is time to run the movie “AN INTRO TO DIESEL ENGINE” chapter "Valve mechanism".g. Be sure that the participants have understood the main purpose of this information. fault tracing. Show the participants the engine parts and explain how they are connected to each other. 0.1.01_en .General and basic priciples > General and basic principles > Pushrod engine Pushrod engine  Pushrod act  Rocker arm  Valve yoke Notes Page 84 GT120017A v. fault tracing. Trainer notes Page 84 (trainer) . Be sure that the participants have understood the main purpose of this information.General and basic priciples > General and basic principles > Pushrod engine Key points  Pushrod engine  Pushrod  Rocker arm  Valves  Valve yoke Working procedure Go through the text in the student material and also add your own experience/knowledge. Ask question to be sure that the participants have understand the main purpose of this information/text. Show the participants the engine parts and explain how they are connected to each other. do not forget to tell them what is happen if they do not understand the basic when they shall e.g. 0.01_en Page 85 .1.General and basic priciples > General and basic principles > Overhead camshaft Overhead camshaft  Rocker arm  Directly  Cam Notes GT120017A v. Trainer notes Page 85 (trainer) . Be sure that the participants have understood the main purpose of this information. Show the participants the engine parts and explain how they are connected to each other. Ask question to be sure that the participants have understand the main purpose of this information/text.General and basic priciples > General and basic principles > Overhead camshaft Key points  Overhead camshaft  Acted directly by the cam  NO pushrods  Few parts  Valve mechanism Working procedure Go through the text in the student material and also add your own experience/knowledge. fault tracing.g. do not forget to tell them what is happen if they do not understand the basic when they shall e. Thrust washer Notes Page 86 GT120017A v.01_en .0.General and basic priciples > General and basic principles > Camshaft Camshaft  Forging  Casting  Steel alloy  Special cast-iron alloy  One cam for each valve  Camshaft bearings  Surface-hardened  Pressure-lubricated  Axial bearing .1. Ask question to be sure that the participants have understand the main purpose of this information/text. Trainer notes Page 86 (trainer) . Be sure that the participants have understood the main purpose of this information.g. do not forget to tell them what is happen if they do not understand the basic when they shall e. fault tracing.General and basic priciples > General and basic principles > Camshaft Key points  Camshaft  Forging or casting  Steel alloy  Special cast-iron alloy  One cam for each valve  Seven bearing  Surface-hardened  Pressure-lubricated  Two cams between  Robust design  Immense forces  Axial bearing  Axial bearing . Show the participants the engine parts and explain how they are connected to each other.thrust washer Working procedure Go through the text in the student material and also add your own experience/knowledge. 0.General and basic priciples > General and basic principles > Camshaft .1.Timing gears  A = the total camheight  B = called the basic circle  C = the camlift Notes GT120017A v.Design Camshaft .01_en Page 87 .Design  Valves open and shut at exactly the right time  Driven by the crankshaft  Engine timing mechanism . General and basic priciples > General and basic principles > Camshaft . fault tracing."Timing gears" A .Design Key points  Precisely designed  Valves open and shut  Exactly the right time  Engine's torque  Exhaust gas values  Opening and closing timing  Driven by the crankshaft  "Engine timing mechanism" . do not forget to tell them what is happen if they do not understand the basic when they shall e. Show the participants the engine parts and explain how they are connected to each other.B = C  A = the total camheight  B = called the basic circle  C = the camlift Working procedure Go through the text in the student material and also add your own experience/knowledge.g. Ask question to be sure that the participants have understand the main purpose of this information/text. Trainer notes Page 87 (trainer) . Be sure that the participants have understood the main purpose of this information. power steering and feed pump  Drive gear. air compressor  Drive gear. double  Gear for power take off (extra equipment)  Idler wheel. adjustable  Camshaft gear  Drive gear.0.General and basic priciples > General and basic principles > Engine timing mechanism Engine timing mechanism  Timing gear plate  Crankshaft gear  Idler gear.01_en . power steering and fuel feed pump  Intermediary gear.1. lubrication oil pump  Flywheel damper with teeth for the inductive camshaft sensor Notes Page 88 GT120017A v. power steering and feed pump  10. Timing gear plate  2. Trainer notes Page 88 (trainer) . Intermediary gear. do not forget to tell them what is happen if they do not understand the basic when they shall e. power steering and fuel feed pump  9. Idler gear. Camshaft gear  7. Idler wheel. Gear for power take off (extra equipment)  5. Crankshaft gear  3. Ask question to be sure that the participants have understand the main purpose of this information/text. lubrication oil pump  11.General and basic priciples > General and basic principles > Engine timing mechanism Key points  Engine timing mechanism  Drives the camshaft  Fuel pump  Other ancillaries  1.crankshaft gear  The gears are marked  Helical teeth  Quietly  Less wear Working procedure Go through the text in the student material and also add your own experience/knowledge. air compressor  8. double  4.g. This is like a teaser for the participants. adjustable  6. fault tracing.positioned . Be sure that the participants have understood the main purpose of this information. Drive gear. Additional information Her it is time to run the movie “AN INTRO TO DIESEL ENGINE” chapter "Engine timing gear". Drive gear. Flywheel damper with teeth for the inductive camshaft sensor  Camshaft gear . Drive gear. Show the participants the engine parts and explain how they are connected to each other. Sound insulation Engine timing mechanism .General and basic priciples > General and basic principles > Engine timing mechanism .Sound insulation  Timing gear plate  Timing gear casings  Sound insulation  Laminated steel Notes GT120017A v.01_en Page 89 .0.1. fault tracing.General and basic priciples > General and basic principles > Engine timing mechanism .Sound insulation Key points  Timing gear plate  timing gear casings  Sound insulation  Laminated steel layers with an intermediate plastic layer in between Working procedure Go through the text in the student material and also add your own experience/knowledge.g. Be sure that the participants have understood the main purpose of this information. Ask question to be sure that the participants have understand the main purpose of this information/text. Show the participants the engine parts and explain how they are connected to each other. do not forget to tell them what is happen if they do not understand the basic when they shall e. Trainer notes Page 89 (trainer) . 1.General and basic priciples > General and basic principles > Crankshaft seal Crankshaft seal  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 Notes Page 90 GT120017A v.01_en .0. radial sealing ring  Two rubber lips  Outer lip prevents dust  Inner rubber lip is spring-loaded  The second type is a Teflon overlap  Two lips  The outer lip prevents dust from  The inner rubber lip is a Teflon seal  This seal is not spring-loaded Working procedure Go through the text in the student material and also add your own experience/knowledge.General and basic priciples > General and basic principles > Crankshaft seal Key points  Two different types  Rubber overlap seal . Ask question to be sure that the participants have understand the main purpose of this information/text. Show the participants the engine parts and explain how they are connected to each other. Be sure that the participants have understood the main purpose of this information. do not forget to tell them what is happen if they do not understand the basic when they shall e. Trainer notes Page 90 (trainer) .g. fault tracing. General and basic priciples > General and basic principles > Valves. valve guides and valve seats  The job of the valve  One or two valve springs  Journal led  Valve guide  Valve's sealing  Valve seat Notes GT120017A v. valve guides and valve seats Valves.01_en Page 91 .0.1. Trainer notes Page 91 (trainer) . Ask question to be sure that the participants have understand the main purpose of this information/text. Be sure that the participants have understood the main purpose of this information.General and basic priciples > General and basic principles > Valves. do not forget to tell them what is happen if they do not understand the basic when they shall e. valve guides and valve seats Key points  Valves  Valve guides  Valve seats  Open for precisely calculated periods  Shut during the remaining time  One or two valve springs  Valve's sealing surface  Valve leaks  Different angle for inlet and exhaust Working procedure Go through the text in the student material and also add your own experience/knowledge. fault tracing. Show the participants the engine parts and explain how they are connected to each other.g. 1.0.General and basic priciples > General and basic principles > Valves Valves  Considerable stress  High temperatures  800°C  Cooled by the air which flow  Force of the valve spring  Nickel chromium steel  Stellite  Friction-welded  Nimonic 80  Chrome-plated Notes Page 92 GT120017A v.01_en . Show the participants the engine parts and explain how they are connected to each other.General and basic priciples > General and basic principles > Valves Key points  Considerable stress  Direct contact with the combustion process  High temperature  The exhaust valve  800°C  The inlet valve cooled by the air  Valve spring  Valve disc  30 kilo Newton  Nickel chromium steel  Stellite  Nimonic 80  Chrome-plated valve stems Working procedure Go through the text in the student material and also add your own experience/knowledge. Ask question to be sure that the participants have understand the main purpose of this information/text. Be sure that the participants have understood the main purpose of this information. Trainer notes Page 92 (trainer) .g. do not forget to tell them what is happen if they do not understand the basic when they shall e. fault tracing. 1.General and basic priciples > General and basic principles > Valve stem Valve stem  Journal led  Cast-iron  Replaceable  Seals  Valve seat rings Notes GT120017A v.0.01_en Page 93 . General and basic priciples > General and basic principles > Valve stem Key points  Valve guide  Cast-iron  Replaceable  The valve disc  The valve seats  Valve seat rings  Heat-resist  Durable material Working procedure Go through the text in the student material and also add your own experience/knowledge. Trainer notes Page 93 (trainer) . Ask question to be sure that the participants have understand the main purpose of this information/text. fault tracing. Be sure that the participants have understood the main purpose of this information.g. do not forget to tell them what is happen if they do not understand the basic when they shall e. Show the participants the engine parts and explain how they are connected to each other. 1.General and basic priciples > General and basic principles > Valve springs Valve springs  Valve spring washer  Valve locks  Two halves  Valve springs  Guide washer Notes Page 94 GT120017A v.0.01_en . Show the participants the engine parts and explain how they are connected to each other. Be sure that the participants have understood the main purpose of this information. fault tracing. Trainer notes Page 94 (trainer) .General and basic priciples > General and basic principles > Valve springs Key points  Valve spring  Valve spring washer  Two valve locks  Valve stem grooves  Single valve springs  Double valve springs  Oscillation of the springs Working procedure Go through the text in the student material and also add your own experience/knowledge. do not forget to tell them what is happen if they do not understand the basic when they shall e. Ask question to be sure that the participants have understand the main purpose of this information/text.g. 01_en Page 95 .General and basic priciples > General and basic principles > Valve seals Valve seals  Lubrication  High oil consumption  Rubber seals Notes GT120017A v.0.1. do not forget to tell them what is happen if they do not understand the basic when they shall e.g. Trainer notes Page 95 (trainer) . Be sure that the participants have understood the main purpose of this information. Ask question to be sure that the participants have understand the main purpose of this information/text.General and basic priciples > General and basic principles > Valve seals Key points  Seals  Lubrication  High oil consumption  Inlet duct  Combustion chamber  Rubber seals  Valve guide Working procedure Go through the text in the student material and also add your own experience/knowledge. fault tracing. Show the participants the engine parts and explain how they are connected to each other. 01_en .0.1.General and basic priciples > General and basic principles > Pushrod and rocker arm Pushrod and rocker arm  Strong  Lightweight  Tubular  Pressed-in end-pieces  Oil channel  Adjustment screw  Valve clearance  Thermal expansion  Journal led  Bronze bushings  Pressure-lubricated  Valve covers Notes Page 96 GT120017A v. General and basic priciples > General and basic principles > Pushrod and rocker arm Key points  Pushrod  Rocker arm  Strong  Lightweight  Tubular  Pressed-in end-pieces  The adjustment screw  Valve clearance  Increases in length  The rocker arm shaft  Bronze bushings  Pressure-lubricated  Valve covers Working procedure Go through the text in the student material and also add your own experience/knowledge. piston and connecting rod.g. Oil sump. fault tracing. Using the correct information from Impact for removing the cylinder head. Be sure that the participants have understood the main purpose of this information. Show the participants the engine parts and explain how they are connected to each other. Trainer notes Page 96 (trainer) . Ask question to be sure that the participants have understand the main purpose of this information/text. do not forget to tell them what is happen if they do not understand the basic when they shall e. 0.. oil pump turbocharger coolant pump compressed air compressor power steering servo pump GT120017A v. Test 5 Diesel engine fundamentals. It can also drive the..1.01_en Page 97 . Camshaft Valve lifter Cam Pushrod Rocker arm shaft Rocker arm Lock-nut Valve Adjuster screw Valve spring Rocker arm bushing The engine timing mechanism consists of a gear which drives the camshaft and injection pump.General and basic priciples > General and basic principles > Diesel engine fundamentals. Test 5 Place the right number beside the appropriate name. Camshaft 7 Valve lifter 6 Cam 8 Pushrod 5 Rocker arm shaft 11 Rocker arm 1 Lock-nut 3 Valve 9 Adjuster screw 4 Valve spring 10 Rocker arm bushing 2 The engine timing mechanism consists of a gear which drives the camshaft and injection pump. *The exhaust valve is much hotter than the inlet valve *The valve's sealing surface can be coated with stellite *Some valves are made in two pieces The valve stem is made of Nimonic *The valve stems in Volvo engines are chrome-plated Page 97 (trainer) .General and basic priciples > General and basic principles > Diesel engine fundamentals. It can also drive the. After that shall the trainer go through the correct answer. Questions that could help to improve the format of the questionnaire in the future may arise.. Test 5 Key points  Question  Answer Working procedure Discuss the answers with the participants if there have been any misunderstandings or linguistic problems. Additional information Introduction to diesel engines.. Test 5 Key Place the right number beside the appropriate name. Let each participants work with the question for about 5-10 minutes. *oil pump turbocharger *coolant pump *compressed air compressor *power steering servo pump The valve lifter is found to one side of the cam's centre line so that the lifter can be made lighter the production process is simpler *lifter wear is more evenly distributed Decide which is/are correct. 1.0. True False Notes Page 98 GT120017A v. The exhaust valve is much hotter than the inlet valve The valve's sealing surface can be coated with stellite Some valves are made in two pieces The valve stem is made of Nimonic The valve stems in Volvo engines are chrome-plated The valve seats are replaceable valve seat rings which are shrunk into place. Duct Valve Sealing surface Valve guide Valve lock Valve spring Valve spring washer Valve seat Guide washer If the camshaft gear incorrectly set by a single tooth.General and basic priciples > General and basic principles > Diesel engine fundamentals. the valves will strike the piston. Test 5 The valve lifter is found to one side of the cam's centre line so that the lifter can be made lighter the production process is simpler lifter wear is more evenly distributed Decide which is/are correct. True False A certain degree of valve clearance is essential since the valve increases in length when it heats up during operation. True False Place the figures in the appropriate boxes.01_en . the valves will strike the piston.General and basic priciples > General and basic principles > Diesel engine fundamentals. Test 5 The valve seats are replaceable valve seat rings which are shrunk into place. *True False A certain degree of valve clearance is essential since the valve increases in length when it heats up during operation. *True False Place the figures in the appropriate boxes. Duct 3 Valve 4 Sealing surface 1 Valve guide 5 Valve lock 9 Valve spring 6 Valve spring washer 8 Valve seat 2 Guide washer 7 If the camshaft gear incorrectly set by a single tooth. *True False Trainer notes Page 98 (trainer) . these components must be lubricated. and lubricated with clean oil and the right sort of oil! Notes GT120017A v. the answer would almost certainly be something like "Surely you must understand that the engine has to be lubricated!".1.01_en Page 99 . And of course it is true that engine components which rub against each other must be separated by a thin film of oil. In other words.Lubrication system > Lubrication system > Lubrication system Lubrication system If you were to ask anyone why there must be oil in an engine.0. Additional information Her it is time to run the movie “AN INTRO TO DIESEL ENGINE” chapter "Lubrication system". Ask question to be sure that the participants have understand the main purpose of this information/text. do not forget to tell them what is happen if they do not understand the basic when they shall e. Show the participants the engine parts and explain how they are connected to each other. This is like a teaser for the participants. Be sure that the participants have understood the main purpose of this information. Trainer notes Page 99 (trainer) .g.Lubrication system > Lubrication system > Lubrication system Key points  Lubrication system  Thin film of oil  Clean oil  Right sort of oil  Lubricate all moving engine parts  Wear and friction should be as little as possible  Conduct heat away  Sealing agent  Plateau honing  Clean  Sludge  Corrosion  Oils require a very complex compound  Base oil (refined mineral oil)  Additives  Synthetic oil Working procedure Go through the text in the student material and also add your own experience/knowledge. fault tracing. 0.1.01_en .Lubrication system > Lubrication system > Engine oil quality Engine oil quality  Oil change  Engine oil quality  The contents of sulphur in the fuel Notes Page 100 GT120017A v. Be sure that the participants have understood the main purpose of this information. Trainer notes Page 100 (trainer) .Lubrication system > Lubrication system > Engine oil quality Key points  Specify oil  Viscosity  Different temperatures  Impact  Service schedule  Oil grade  Oil filter  Oil change  Engine oil quality  VDS  Sulphur Working procedure Go through the text in the student material and also add your own experience/knowledge. Show the participants the engine parts and explain how they are connected to each other. fault tracing. do not forget to tell them what is happen if they do not understand the basic when they shall e.g. Ask question to be sure that the participants have understand the main purpose of this information/text. Pressure lubrication Splash lubrication .0.01_en Page 101 .Lubrication system > Lubrication system > Splash lubrication .1.Pressure lubrication  Splash-lubrication  Crankshaft's rotating motion  Pressure lubrication  Oil pump  Lubrication points  Cylinder walls  Timing gears Notes GT120017A v. Ask question to be sure that the participants have understand the main purpose of this information/text.Lubrication system > Lubrication system > Splash lubrication . Trainer notes Page 101 (trainer) .g. do not forget to tell them what is happen if they do not understand the basic when they shall e.Pressure lubrication Key points  Required points  Splash-lubrication  Crankshaft's rotating motion  Not sufficient for modern high-powered engines  Pressure lubrication  Oil pump  Lubrication points  Cylinder walls and timing gears are splash-lubricated Working procedure Go through the text in the student material and also add your own experience/knowledge. fault tracing. Be sure that the participants have understood the main purpose of this information. Show the participants the engine parts and explain how they are connected to each other. 01_en .1.Lubrication system > Lubrication system > Pressure lubrication Pressure lubrication  Oil sump  Oil pump  Oil cooler  Oil filter  Oil ducts  Lubricates  Cools  Cleans  Seals  Oil gallery Notes Page 102 GT120017A v.0. do not forget to tell them what is happen if they do not understand the basic when they shall e.g. Show the participants the engine parts and explain how they are connected to each other. Ask question to be sure that the participants have understand the main purpose of this information/text. fault tracing. Trainer notes Page 102 (trainer) .Lubrication system > Lubrication system > Pressure lubrication Key points  Pressure-lubrication system  Circulating in a sealed system  Block diagram  Oil grade  Oil sump  Oil pump  Oil cooler  Oil filter  Oil ducts  Lubrication points  Back to the oil sump  100 litres a minute  Gear pump  Driven by the engine crankshaft  Two longitudinal oil channels  Main lubrication channel (oil gallery)  Piston cooling oil gallery  Timing gears  VCB  Valve  Rocker arm shaft  Camshaft bearings  Rocker arm bearings  Oil filter housing  Full flow filter  Bypass filter Working procedure Go through the text in the student material and also add your own experience/knowledge. Be sure that the participants have understood the main purpose of this information. 0.Function The lubrication system shown on these two pages comes from a 13-litre engine. pump and oil filter housing.  Reduction valve  Safety valve  Thermostat valve for oil cooler  By-pass valve for full flow filter  Opening valve for piston cooling  Control valve for piston cooling Notes GT120017A v.Lubrication system > Lubrication system > Lubrication system .01_en Page 103 .Function Lubrication system . The oil flow through the engine is regulated by six valves located inside the engine block.1. Lubrication system > Lubrication system > Lubrication system . Ask question to be sure that the participants have understand the main purpose of this information/text. do not forget to tell them what is happen if they do not understand the basic when they shall e. Trainer notes Page 103 (trainer) .g. Be sure that the participants have understood the main purpose of this information. Show the participants the engine parts and explain how they are connected to each other. fault tracing.Function Key points  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 Working procedure Go through the text in the student material and also add your own experience/knowledge. 01_en .schematic Lubrication system .1.Lubrication system > Lubrication system > Lubrication system .schematic  Strainer  Plastic tube  Oil pump  Pressure pipe  Oil cooler  Filter housing  Full flow filters  Main lubrication gallery  Separator turbine  VCB valve  Air compressor  Turbocharger  Bypass filter  Nozzles Notes Page 104 GT120017A v.0. Lubrication system > Lubrication system > Lubrication system . do not forget to tell them what is happen if they do not understand the basic when they shall e.schematic Key points  Strainer (1)  Plastic tube (2)  Oil pump (3)  Pressure pipe (4)  Oil cooler (5)  Filter housing (6)  Full flow filters (7)  Main lubrication gallery (8)  Separator turbine (9)  VCB valve (10)  Air compressor (11)  Turbocharger (12)  Bypass filter (13)  Nozzles (14) Working procedure Go through the text in the student material and also add your own experience/knowledge.g. fault tracing. Ask question to be sure that the participants have understand the main purpose of this information/text. Trainer notes Page 104 (trainer) . Show the participants the engine parts and explain how they are connected to each other. Be sure that the participants have understood the main purpose of this information. 01_en Page 105 .0.function Oil pump .1.Lubrication system > Lubrication system > Oil pump .function  Gear-driven pump  Pump housing  Negative pressure  Gaps between the gear teeth  Lubrication ducts  Rotor pump Notes GT120017A v. fault tracing.Lubrication system > Lubrication system > Oil pump .function Key points  Oil pump  Gear-driven pump  Two gear wheels  Pump housing  Negative pressure  Gaps between the gear teeth  Lubrication ducts  Rotor pump  100-200 kPa (1-2 bar)  300-500 kPa Working procedure Go through the text in the student material and also add your own experience/knowledge. Ask question to be sure that the participants have understand the main purpose of this information/text. do not forget to tell them what is happen if they do not understand the basic when they shall e. Trainer notes Page 105 (trainer) . Show the participants the engine parts and explain how they are connected to each other. Be sure that the participants have understood the main purpose of this information.g. 01_en .0.parts Oil pump .Lubrication system > Lubrication system > Oil pump .parts  Idler gear  Bearing sleeve  Attachment bracket and pumping housing  Bushing  Driveshaft  Drive gear  Driven shaft  Driving pump gear  Driven pump gear Notes Page 106 GT120017A v.1. parts Key points  Dimensioned  Driven by the engine timing mechanism  Idler gear  Bearing sleeve  Attachment bracket and pumping housing  Bushing  Driveshaft  Drive gear  Driven shaft  Driving pump gear  Driven pump gear Working procedure Go through the text in the student material and also add your own experience/knowledge. do not forget to tell them what is happen if they do not understand the basic when they shall e. fault tracing. Trainer notes Page 106 (trainer) . Be sure that the participants have understood the main purpose of this information. Ask question to be sure that the participants have understand the main purpose of this information/text.g. Show the participants the engine parts and explain how they are connected to each other.Lubrication system > Lubrication system > Oil pump . 01_en Page 107 .0.1.regulate oil flow  Spin-on type  10 bar without leaking  Burst test  Pressure up to 16 bar  75.000 times from 0 to 8 bar Notes GT120017A v.Lubrication system > Lubrication system > Oil filter housing Oil filter housing  Number of valves . Trainer notes Page 107 (trainer) .  75. fault tracing. do not forget to tell them what is happen if they do not understand the basic when they shall e. Be sure that the participants have understood the main purpose of this information. Show the participants the engine parts and explain how they are connected to each other.000 times from 0 to 8 bar Working procedure Go through the text in the student material and also add your own experience/knowledge.g. Ask question to be sure that the participants have understand the main purpose of this information/text.Lubrication system > Lubrication system > Oil filter housing Key points  Oil filter housing  Valves  Spin-on type  Rubber rings  10 bar without leaking. Lubrication system > Lubrication system > Oil flows through the filter Oil flows through the filter  Filter insert  Filter paper  Particles down to approx.0. 7 litres/minute  Oil filter replacement  Clogged oil filters Notes Page 108 GT120017A v. 40 thousandths of a millimetre (40 µm)  Bypass filter .10 µm  Oil flow rate is approx.01_en .1. Show the participants the engine parts and explain how they are connected to each other.Lubrication system > Lubrication system > Oil flows through the filter Key points  The oil flow  Filter paper  Particles down to approx.g. do not forget to tell them what is happen if they do not understand the basic when they shall e. Ask question to be sure that the participants have understand the main purpose of this information/text.  Particles down to approx. fault tracing. Be sure that the participants have understood the main purpose of this information. 40 thousandths of a millimetre (40 µm). 10 µm  7 litres/minute Working procedure Go through the text in the student material and also add your own experience/knowledge. Trainer notes Page 108 (trainer) . 1.01_en Page 109 .0.Lubrication system > Lubrication system > Oil cooler Oil cooler  10-15% heat  130°C  100°C  Common type Notes GT120017A v. do not forget to tell them what is happen if they do not understand the basic when they shall e. Trainer notes Page 109 (trainer) . Show the participants the engine parts and explain how they are connected to each other.g. Ask question to be sure that the participants have understand the main purpose of this information/text. Be sure that the participants have understood the main purpose of this information.Lubrication system > Lubrication system > Oil cooler Key points  Oil cooler  10-15%  130°C  100°C  Flat oil cooler Working procedure Go through the text in the student material and also add your own experience/knowledge. fault tracing. 0.1.01_en .Lubrication system > Lubrication system > Oil sump Oil sump  Moulded plastic (composite)  Reducing engine noise levels  Pressed steel variant  Aluminum  Sealing strip  Dry sump Notes Page 110 GT120017A v. Point out main parts/valves and system layout in vehicle. Show the participants the engine parts and explain how they are connected to each other. Be sure that the participants have understood the main purpose of this information.g.Lubrication system > Lubrication system > Oil sump Key points  Oil sump  Moulded plastic (composite)  Noise level  Steel  Aluminum  Sealing strip  Dry sump  Lubricating oil tank Working procedure Go through the text in the student material and also add your own experience/knowledge. fault tracing. Additional information If their is time you can also using VTT to read out oil pressure. Trainer notes Page 110 (trainer) . Ask question to be sure that the participants have understand the main purpose of this information/text. Open an old oil pump. do not forget to tell them what is happen if they do not understand the basic when they shall e. 01_en Page 111 .Lubrication system > Lubrication system > Diesel engine fundamentals. True False A high sulphur content in the fuel has no effect on the engine oil change frequency. that is true No.1. piston cooling features its own oil duct in the cylinder block. namely to: lubricate by forming a thin film of oil between the moving parts cool by leading away the heat act as a seal between the pistons and cylinders reduce coolant temperature by cooling the fluid keep the engine clean by leding away soot particles and dirt act as a noise-dampening material at the shaft seals Volvo's VDS oil grade can withstand more operational hours than a simpler oil quality. not so much Yes. much more In Volvo engines. Test 6 Diesel engine fundamentals. GT120017A v. No. Test 6 Oil has several vital functions. True False Oil flow through the engine can be 100 litres/minute in a large engine.0. *True False The reduction valve prevents oil pressure from rising too high. Let each participants work with the question for about 5-10 minutes. that is true No. Additional information Introduction to diesel engines. After that shall the trainer go through the correct answer. Test 6 Key points  Question  Answer Working procedure Discuss the answers with the participants if there have been any misunderstandings or linguistic problems. No. True *False Oil flow through the engine can be 100 litres/minute in a large engine. not so much *Yes. Test 6 Key Oil has several vital functions. *True False The oil cooler is a type of heat exchanger. *True False The piston cooling valve opens when oil pressure reaches a preset value. *True False A high sulphur content in the fuel has no effect on the engine oil change frequency. piston cooling features its own oil duct in the cylinder block. namely to: *lubricate by forming a thin film of oil between the moving parts *cool by leading away the heat *act as a seal between the pistons and cylinders reduce coolant temperature by cooling the fluid *keep the engine clean by leding away soot particles and dirt act as a noise-dampening material at the shaft seals Volvo's VDS oil grade can withstand more operational hours than a simpler oil quality.Lubrication system > Lubrication system > Diesel engine fundamentals. Page 111 (trainer) . much more In Volvo engines. Questions that could help to improve the format of the questionnaire in the future may arise. 1. I check in the maintenance instructions. the filters become clogged. True False All Volvo diesel engines have full-flow filters. As a result. True False The oil cooler is a type of heat exchanger.0. How do you find out the replacement interval? I replacement them now and again. no oil will get to the lubrication points inside the engine. True False Which is the pump's inlet and which is the outlet? Inlet Outlet The pump in question 9 is a Disc-type pump Rotor pump Crecent pump Internal gear wheel pump Gear wheel pump Eccentric pump What is this? Piston lubrication Piston cooling Oil reduction Return pipe for turbocharger oil Is the following statement correct? If the driver does not replace the oil filters. Test 6 True False The reduction valve prevents oil pressure from rising too high.01_en . Page 112 GT120017A v. I ask a friend. True False The piston cooling valve opens when oil pressure reaches a preset value. True False Oil filters must be replaced after a certain number of operational kilometers.Lubrication system > Lubrication system > Diesel engine fundamentals. *True False What is the name of the oil cooler type which Volvo uses in almost all its diesel engines? Central radiator Cyclone radiator Page 112 (trainer) .000 times from 0 to 8 bar.Lubrication system > Lubrication system > Diesel engine fundamentals. *I check in the maintenance instructions. no oil will get to the lubrication points inside the engine. Considerable amounts of heat must be directed away from the engine's interior. True *False All Volvo diesel engines have full-flow filters. As a result. How do you find out the replacement interval? I replacement them now and again. the filters become clogged. I ask a friend. What proportion does the oil manage to lead away? Less than 5% *10-15% More than 25% In one of the tests on a Volvo oil filter. *True False Oil filters must be replaced after a certain number of operational kilometers. Test 6 *True False Which is the pump's inlet and which is the outlet? Inlet~2 Outlet~1 The pump in question 9 is a Disc-type pump Rotor pump Crecent pump Internal gear wheel pump *Gear wheel pump Eccentric pump What is this? Piston lubrication *Piston cooling Oil reduction Return pipe for turbocharger oil Is the following statement correct? If the driver does not replace the oil filters. the pressure in the filter rises 75. the oil temperature can reach 130°C. True False What is the name of the oil cooler type which Volvo uses in almost all its diesel engines? Central radiator Cyclone radiator Flat radiator With the engine under high operating load.0. the pressure in the filter rises 75. What proportion does the oil manage to lead away? Less than 5% 10-15% More than 25% In one of the tests on a Volvo oil filter.1. True False Notes GT120017A v.01_en Page 113 . Test 6 onsiderable amounts of heat must be directed away from the engine's interior.000 times from 0 to 8 bar.Lubrication system > Lubrication system > Diesel engine fundamentals. Lubrication system > Lubrication system > Diesel engine fundamentals. the oil temperature can reach 130°C. Test 6 *Flat radiator With the engine under high operating load. *True False Trainer notes Page 113 (trainer) . Fuel system > Fuel system > Fuel injection system Fuel Injection system  Injection pump  Unit Injector system  Common Rail system  Injected at the right moment  Tank  Supply pump  Fuel filters  Pipe  Overflow valve  Return pipe  High pressure pipe  Injectors Notes Page 114 GT120017A v.1.01_en .0. Additional information Her it is time to run the movie “AN INTRO TO DIESEL ENGINE” chapter "Fuel system". Be sure that the participants have understood the main purpose of this information. do not forget to tell them what is happen if they do not understand the basic when they shall e.5 bar)  Fuel filters  Injection pump  Overflow valve  Return pipe  High pressure  Pressure pipe  Injectors  Atomised and sprayed into the combustion chamber Working procedure Go through the text in the student material and also add your own experience/knowledge. Ask question to be sure that the participants have understand the main purpose of this information/text.Fuel system > Fuel system > Fuel injection system Key points  Fuel Injection system  Different systems  Injection pump  Radial type  In line type  Unit Injector system  Common Rail system  Fuel quantity  Milligrams of fuel  Engine speeds  Engine loads  Incorrect fuel quantities  Interference  Impairing  The right moment  Top dead centre  Injection sequence  Extremely precise tolerances  Tank  Supply pump  150 kPa (1. fault tracing. This is like a teaser for the participants. Show the participants the engine parts and explain how they are connected to each other. Page 114 (trainer) .g. 0.01_en Page 115 .Fuel system > Fuel system > Injection pump Injection pump  Older fuel system  One pump element for each cylinder  Pump-camshaft  Pressure-valve  Injector's pressure pipe  Control rod Notes GT120017A v.1. fault tracing. Trainer notes Page 115 (trainer) . do not forget to tell them what is happen if they do not understand the basic when they shall e. Show the participants the engine parts and explain how they are connected to each other. Ask question to be sure that the participants have understand the main purpose of this information/text. Be sure that the participants have understood the main purpose of this information.g.Fuel system > Fuel system > Injection pump Key points  The injection pump  Older fuel system  Engine timing mechanism  Six pump elements  Piston  Cam on the pump-camshaft  Pressure-valve  Injector's pressure pipe Working procedure Go through the text in the student material and also add your own experience/knowledge. Fuel system > Fuel system > Mechanical regulator or governor Mechanical regulator or governor  Mechanical regulator or governor  Electronic regulators  Linkage system  Accelerator pedal Notes Page 116 GT120017A v.1.01_en .0. do not forget to tell them what is happen if they do not understand the basic when they shall e. fault tracing.g.Fuel system > Fuel system > Mechanical regulator or governor Key points  Mechanical regulator or governor  Electronic regulators  Control rod's position  Two spring-loaded weights  Linkage system  Accelerator pedal  Throttle arm Working procedure Go through the text in the student material and also add your own experience/knowledge. Trainer notes Page 116 (trainer) . Be sure that the participants have understood the main purpose of this information. Ask question to be sure that the participants have understand the main purpose of this information/text. Show the participants the engine parts and explain how they are connected to each other. Fuel system > Fuel system > Supply pump Supply pump  Piston pump  Pump camshaft  Hand-pump Notes GT120017A v.01_en Page 117 .0.1. do not forget to tell them what is happen if they do not understand the basic when they shall e. fault tracing.Fuel system > Fuel system > Supply pump Key points  Supply pump  Specific pressure  Piston pump  Hand-pump Working procedure Go through the text in the student material and also add your own experience/knowledge. Be sure that the participants have understood the main purpose of this information. Ask question to be sure that the participants have understand the main purpose of this information/text. Trainer notes Page 117 (trainer) . Show the participants the engine parts and explain how they are connected to each other.g. 0.Fuel system > Fuel system > Smoke limiter Smoke limiter  Black smoke  Legal limits  Inlet manifold  Turbocharger pressure Notes Page 118 GT120017A v.01_en .1. Ask question to be sure that the participants have understand the main purpose of this information/text. Show the participants the engine parts and explain how they are connected to each other. do not forget to tell them what is happen if they do not understand the basic when they shall e. fault tracing. Be sure that the participants have understood the main purpose of this information.g.Fuel system > Fuel system > Smoke limiter Key points  Smoke limiter  Fuel  Black smoke  Legal limits  Inlet manifold  Turbo pressure  Less fuel means less smoke Working procedure Go through the text in the student material and also add your own experience/knowledge. Trainer notes Page 118 (trainer) . fine filter  Special paper Notes GT120017A v.002 mm  Hair .0.Fuel system > Fuel system > Fuel filter Fuel filter  Clearance .0.1.001 to 0.20 times thicker  Filter insert  Filter housing  Spin-on filter  Box filter  Fuel filter .01_en Page 119 . fault tracing. Trainer notes Page 119 (trainer) .g.  Hair is about 20 times thicker  Several different filters  Filter insert  Filter housing  Spin-on or box filter  Special type of paper  Creased and coiled Working procedure Go through the text in the student material and also add your own experience/knowledge.002 mm. do not forget to tell them what is happen if they do not understand the basic when they shall e. Be sure that the participants have understood the main purpose of this information.Fuel system > Fuel system > Fuel filter Key points  Fuel filter  Dirt particle  Damage  0.001 to 0. Show the participants the engine parts and explain how they are connected to each other. Ask question to be sure that the participants have understand the main purpose of this information/text. Fuel system > Fuel system > Pressure pipes Pressure pipes  The pressure pipes .high-pressure leads  Steel  High pressures  Clamps· Notes Page 120 GT120017A v.1.01_en .0. Trainer notes Page 120 (trainer) . fault tracing. Show the participants the engine parts and explain how they are connected to each other. Be sure that the participants have understood the main purpose of this information.g.Fuel system > Fuel system > Pressure pipes Key points  Pressure pipes (high-pressure leads)  Steel  High pressures  Thick. do not forget to tell them what is happen if they do not understand the basic when they shall e. Ask question to be sure that the participants have understand the main purpose of this information/text. rigid walls  Inner diameter  Cylinder head's by clamps Working procedure Go through the text in the student material and also add your own experience/knowledge. copper sleeve Injector .Fuel system > Fuel system > Injector .1.0.copper sleeve  Cylinder head  Copper sleeve  Considerable heat  Efficient heat dissipation Notes GT120017A v.01_en Page 121 . Additional information The injector's job is to inject finely atomised fuel into the combustion chamber. Be sure that the participants have understood the main purpose of this information. do not forget to tell them what is happen if they do not understand the basic when they shall e.g. The fuel is atomised by being sprayed in under high pressure Trainer notes Page 121 (trainer) . fault tracing.copper sleeve Key points  Injector  Inject  Atomised fuel  Combustion chamber  High pressure  Copper sleeve  Heat Working procedure Go through the text in the student material and also add your own experience/knowledge.Fuel system > Fuel system > Injector . Show the participants the engine parts and explain how they are connected to each other. Ask question to be sure that the participants have understand the main purpose of this information/text. 01_en .0.1.needle Nozzle sleeve .needle  Shaped differently in different configurations  The type of engine  Shape of the combustion chamber  Nozzle sleeve  Ground needle  Tapered sealing  0.002-0.004 mm  Lubricates  Cools Notes Page 122 GT120017A v.Fuel system > Fuel system > Nozzle sleeve . Ask question to be sure that the participants have understand the main purpose of this information/text.002-0. fault tracing. do not forget to tell them what is happen if they do not understand the basic when they shall e.Fuel system > Fuel system > Nozzle sleeve .004 mm  Lubricates  Cools Working procedure Go through the text in the student material and also add your own experience/knowledge.g. Be sure that the participants have understood the main purpose of this information. Show the participants the engine parts and explain how they are connected to each other.needle Key points  Injector  Nozzle  Configurations  Type of engine and the shape of the combustion chamber  Nozzle sleeve  Needle  Tapered sealing surface  Seat in the sleeve  0. Trainer notes Page 122 (trainer) . function  Nozzle holder  Pressure pipe  Return fuel pipe  Spring  Pressure pin  Needle  Pressure chamber  Sleeve  Adjusted Notes GT120017A v.Fuel system > Fuel system > Injector .01_en Page 123 .0.function Injector .1. Trainer notes Page 123 (trainer) . do not forget to tell them what is happen if they do not understand the basic when they shall e.Fuel system > Fuel system > Injector . Be sure that the participants have understood the main purpose of this information. Read out feed pressure by using VTT.function Key points  Nozzle holder  Coupling  Pressure pipe  Return fuel pipe  Force from the spring  Pressure pin  Needle  Opening pressure  Adjustment washers  Adjustment screw  Pressure chamber  Increases sufficiently  Four or five holes in the sleeve Working procedure Go through the text in the student material and also add your own experience/knowledge. fault tracing. Ask question to be sure that the participants have understand the main purpose of this information/text. Show the participants the engine parts and explain how they are connected to each other.g. Point out main parts/valves and system layout in vehicle. Fuel system > Fuel system > Diesel engine fundamentals.0. Test 7B The injection pump ensures that the correct amount of fuel is injected into the engine ensures that the fuel is injected into the inlet manifold injects fuel at the correct point in time is made to extremely high tolerance levels The injection pump in Volvo engines is lubricated from the engine's lubrication system has a pump element which supplies fuel to all the injectors has a regulator which meters the amount of fuel is driven by a belt from the timing mechanism varies the amount of fuel depending on the position of the control rod The smoke limiter reduces the grey and white smoke regulates the amount of fuel so that black smoke stays within legal limits is affected by turbo pressure The injector Page 124 GT120017A v.1. Test 7B Diesel engine fundamentals.01_en . reduces the grey and white smoke *regulates the amount of fuel so that black smoke stays within legal limits *is affected by turbo pressure The injector *has the job of injecting finely atomised fuel into the combustion chamber *gets very hot and this heat is led away via the copper sleeve has a lower section shaped like a pressure valve *is connected to the injection pump via the pressure pipes The fuel filter must have an overflow valve *is made such that fuel flows through a paper filter insert *is of a type known as a spin-on or box filter The diesel engine's exhaust gases Page 124 (trainer) . Questions that could help to improve the format of the questionnaire in the future may arise. Additional information Introduction to diesel engines. Let each participants work with the question for about 5-10 minutes. After that shall the trainer go through the correct answer. Test 7B Key The injection pump *ensures that the correct amount of fuel is injected into the engine ensures that the fuel is injected into the inlet manifold *injects fuel at the correct point in time *is made to extremely high tolerance levels The injection pump in Volvo engines *is lubricated from the engine's lubrication system has a pump element which supplies fuel to all the injectors *has a regulator which meters the amount of fuel is driven by a belt from the timing mechanism *varies the amount of fuel depending on the position of the control rod The smoke limiter. Test 7B Key points  Question  Answer Working procedure Discuss the answers with the participants if there have been any misunderstandings or linguistic problems.Fuel system > Fuel system > Diesel engine fundamentals. Fuel system > Fuel system > Diesel engine fundamentals.0.01_en Page 125 . Test 7B as the job of injecting finely atomised fuel into the combustion chamber gets very hot and this heat is led away via the copper sleeve has a lower section shaped like a pressure valve is connected to the injection pump via the pressure pipes The fuel filter must have an overflow valve is made such that fuel flows through a paper filter insert is of a type known as a spin-on or box filter The diesel engine's exhaust gases have a lower carbon monoxide content than in a petrol engine contains no lead compounds has a higher carbon monoxide content than in a petrol engine contains nitrogen oxides. just like petrol engine exhaust gases Notes GT120017A v.1. Fuel system > Fuel system > Diesel engine fundamentals. Test 7B *have a lower carbon monoxide content than in a petrol engine *contains no lead compounds has a higher carbon monoxide content than in a petrol engine *contains nitrogen oxides. just like petrol engine exhaust gases Trainer notes Page 125 (trainer) . Notes Page 126 GT120017A v.  A valve section with a fuel valve which is acted on by a solenoid valve.  An injector section corresponding to the injector jets in a normal injector.01_en .Fuel system > Fuel system > Fuel systems with unit injectors Fuel systems with unit injectors The unit injector system consists of:  A pump section corresponding to the pump element in an in-line injection pump.1.0. g. Be sure that the participants have understood the main purpose of this information. do not forget to tell them what is happen if they do not understand the basic when they shall e. Trainer notes Page 126 (trainer) . Show the participants the engine parts and explain how they are connected to each other. Ask question to be sure that the participants have understand the main purpose of this information/text.Fuel system > Fuel system > Fuel systems with unit injectors Key points  Unit injectors  Pump element and injector are combined  Electronic control  Injection timing and fuel volume can be controlled for each injection by the control unit  Control pulses  Solenoid valve  Mounted in the same place  Overhead camshaft or high level camshaft  A pump section corresponding to the pump element in an in-line injection pump  A valve section with a fuel valve which is acted on by a solenoid valve  An injector section corresponding to the injector jets in a normal injector Working procedure Go through the text in the student material and also add your own experience/knowledge. fault tracing. Fuel system > Fuel system > Unit injector .system function  High pressure  150-220 MPa (1500-2200bar)  Fewer harmful exhaust emissions  The feed section  Control unit  Cooled  Galleries in the cylinder head Notes GT120017A v.system function Unit Injector .01_en Page 127 .0.1. Fuel system > Fuel system > Unit injector - system function Key points  Injection pressure is very high  150-220 MPa (1500-2200bar)  Achieve atomisation of the fuel and better combustion  Fewer harmful exhaust emissions  The feed section (low pressure section)  Gear pump  Hand pump  Control unit  Cooled by the fuel  Galleries in the cylinder head  Overflow valve  Supply pressure  Vents small amounts of air from the system  Bleed screw for venting the fuel system  Starting characteristics  Reduce exhaust emissions  Raises the temperature in the cylinder and combustion chamber  Maximum is four revolutions at -20 ˚C Working procedure Go through the text in the student material and also add your own experience/knowledge. Be sure that the participants have understood the main purpose of this information. Ask question to be sure that the participants have understand the main purpose of this information/text. Show the participants the engine parts and explain how they are connected to each other, do not forget to tell them what is happen if they do not understand the basic when they shall e.g. fault tracing. Trainer notes Page 127 (trainer) Fuel system > Fuel system > Diesel engine fundamentals. Test 7C Diesel engine fundamentals. Test 7C The start of an injection is controlled by …. The fuel feed pressure By the spill valve closing point By the cam shaft lobe profile The injected fuel quantity is determined by …. The pumping element stroke The return spring closing force Electrical activation time, which is the length of time the spill valve remains closed The unit injector is supplied via External pressure pipes Integral ducts machined directly into the cylinder head. Channels in the camshaft bearing brackets Each unit injector has its own pumping element False True The EUI pumping element is activated by…. The camshaft lobe via a rocker Page 128 GT120017A v.1.0.01_en Fuel system > Fuel system > Diesel engine fundamentals. Test 7C Key points  Question  Answer Working procedure Discuss the answers with the participants if there have been any misunderstandings or linguistic problems. Questions that could help to improve the format of the questionnaire in the future may arise. Let each participants work with the question for about 5-10 minutes. After that shall the trainer go through the correct answer. Additional information Diesel engine fundamentals. Test 7C Key 1. The start of an injection is controlled by …. The fuel feed pressure *By the spill valve closing point By the cam shaft lobe profile 2. The injected fuel quantity is determined by …. The pumping element stroke The return spring closing force *Electrical activation time, which is the length of time the spill valve remains closed 3. The unit injector is supplied via External pressure pipes *Integral ducts machined directly into the cylinder head. Channels in the camshaft bearing brackets 4. False *True Each unit injector has its own pumping element 5. The EUI pumping element is activated by…. *The camshaft lobe via a rocker Push rods Connecting rods Trainer notes Page 128 (trainer) Fuel system > Fuel system > Diesel engine fundamentals. Test 7C Push rods Connecting rods Notes GT120017A v.1.0.01_en Page 129 Fuel system > Fuel system > Diesel engine fundamentals. Test 7C Trainer notes Page 129 (trainer) Fuel system > Fuel system > Common rail 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 Notes Page 130 GT120017A v.1.0.01_en Fuel system > Fuel system > Common rail Key points  EMS2  Common rail  Injectors  High pressure  1600 bar  Engine control unit (EECU)  Sensors  Low pressure side (orange)  High pressure side (red)  Feed pump (1)  Fuel tank (2)  Pre-filter (3)  Fuel distributor (4)  Fuel filter housing (5)  Unit pumps (6)  Common rail (7)  Injectors (8)  Longitudinal channel (9) Return line Working procedure Go through the text in the student material and also add your own experience/knowledge. Be sure that the participants have understood the main purpose of this information. Ask question to be sure that the participants have understand the main purpose of this information/text. Show the participants the engine parts and explain how they are connected to each other, do not forget to tell them what is happen if they do not understand the basic when they shall e.g. fault tracing. Trainer notes Page 130 (trainer) Fuel system > Fuel system > Injector Injector  Injector body  Nozzle holder  Solenoid valve  Preinjection  Main injection  Post-injection · Notes GT120017A v.1.0.01_en Page 131 g. do not forget to tell them what is happen if they do not understand the basic when they shall e. Trainer notes Page 131 (trainer) . Be sure that the participants have understood the main purpose of this information. fault tracing. Ask question to be sure that the participants have understand the main purpose of this information/text.Fuel system > Fuel system > Injector Key points  Injector body  Nozzle holder  Solenoid valve  Preinjection  Main injection  Post-injection Working procedure Go through the text in the student material and also add your own experience/knowledge. Show the participants the engine parts and explain how they are connected to each other. 0.01_en . There are two high pressure pumps for each cylinder The injectors are mechanically activated by the engine timing gear The injector needle is always subject to high pressure Notes Page 132 GT120017A v.1. Test 7D What is the part of the fuel system called the “common rail”? A thick walled metal tube that serves as an accumulator that stores fuel at high pressure The return line common for all injectors for returning leak-off fuel back to tank The part of the electrical cable harness used for activating all injector solenoids simultaneously In a common rail system….Fuel system > Fuel system > Diesel engine fundamentals. Test 7D Diesel engine fundamentals. In a common rail system…. Questions that could help to improve the format of the questionnaire in the future may arise.Fuel system > Fuel system > Diesel engine fundamentals. Test 7D Key points  Question  Answer  Working procedure Discuss the answers with the participants if there have been any misunderstandings or linguistic problems. What is the part of the fuel system called the “common rail”? *A thick walled metal tube that serves as an accumulator that stores fuel at high pressure The return line common for all injectors for returning leak-off fuel back to tank The part of the electrical cable harness used for activating all injector solenoids simultaneously 2. Let each participants work with the question for about 5-10 minutes. Additional information Diesel engine fundamentals. After that shall the trainer go through the correct answer. There are two high pressure pumps for each cylinder The injectors are mechanically activated by the engine timing gear *The injector needle is always subject to high pressure Trainer notes Page 132 (trainer) . Test 7D Key 1. 0.1.01_en Page 133 .Engine management system > Engine management system > EMS .Engine Management System EMS (Engine Management System)  Low fuel consumption  Noise  Exhaust emissions  EMS (Engine Management System)  EDC (Electronic Diesel Control)  Unit Injectors  TEA (Truck Electronic Architecture)  Electronic fuel injection  Diagnostics  Fault tracing  Engine control unit  Fault code  Information link  Display  Stored Notes GT120017A v. Be sure that the participants have understood the main purpose of this information.Engine management system > Engine management system > EMS . Show the participants the engine parts and explain how they are connected to each other. do not forget to tell them what is happen if they do not understand the basic when they shall e. Trainer notes Page 133 (trainer) .g. fault tracing. Ask question to be sure that the participants have understand the main purpose of this information/text.Engine Management System Key points  EMS (Engine Management System)  EDC (Electronic Diesel Control)  Unit Injectors  TEA (Truck Electronic Architecture) Working procedure Go through the text in the student material and also add your own experience/knowledge. 1.0.01_en .Engine management system > Engine management system > Engine control unit Engine control unit  Truck electronic architecture  Data links  Vehicle electronic control unit  Sensors  Cooled  Starter element  Unit injectors  Exhaust pressure governor (EPG)  Compression brake Notes Page 134 GT120017A v. Compression brake Working procedure Go through the text in the student material and also add your own experience/knowledge. Show the participants the engine parts and explain how they are connected to each other. Trainer notes Page 134 (trainer) . Be sure that the participants have understood the main purpose of this information. fault tracing. Starter element  2. Ask question to be sure that the participants have understand the main purpose of this information/text.g.Engine management system > Engine management system > Engine control unit Key points  1. do not forget to tell them what is happen if they do not understand the basic when they shall e. Unit injectors  3. Exhaust pressure governor (EPG)  4. 0.Engine management system > Engine management system > Sensors on the engine Sensors on the engine The engine control unit includes an atmospheric pressure sensor.01_en Page 135 . 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 Notes GT120017A v.1. Oil temperature and oil pressure Working procedure Go through the text in the student material and also add your own experience/knowledge. Camshaft position  4. fault tracing. Show the participants the engine parts and explain how they are connected to each other. Engine coolant temperature  7.Engine management system > Engine management system > Sensors on the engine Key points  1. Additional information The following is a list of engine sensors that provide input to the EMS: Ambient Air Temperature Sensor Ambient Pressure sensor Boost Air Pressure (BAP) Sensor Camshaft Position (Engine Position) Sensor Crankshaft Position (Engine Speed) Sensor Differential Pressure DPF Sensor EGR Differential Pressure Sensor EGR Temperature Sensor Engine Coolant Level (ECL) Sensor Engine Coolant Temperature (ECT) Sensor Engine Oil Pressure (EOP) Sensor Engine Oil Level (EOL) Sensor Engine Oil Temperature (EOT) Sensor Exhaust Temperature Sensor (DPF Sensors) Fuel Pressure Sensor Intake Air Temperature And Humidity (IATH) Sensor Intake Manifold (Boost) Temperature Sensor Throttle Position (TP) Sensor Turbo Speed Sensor Variable Geometry Turbocharger (VGT) Position Sensor Trainer notes Page 135 (trainer) . Engine coolant level  5. do not forget to tell them what is happen if they do not understand the basic when they shall e. Charge air temperature and charge pressure  3. Fuel pressure  2.g. Air temperature and air pressure  6. Ask question to be sure that the participants have understand the main purpose of this information/text. Be sure that the participants have understood the main purpose of this information. Crankshaft position and engine speed  8. clutch and accelerator pedal  Parking brake  Engine brake Notes Page 136 GT120017A v.01_en .1.Engine management system > Engine management system > Other sensors Other sensors  Vehicle speed (through sensors in the gearbox)  Cruise control  Retarder  ABS system  Brake.0. Retarder  6. Brake. fault tracing. Cruise control  5. Vehicle speed (through sensors in the gearbox)  4. do not forget to tell them what is happen if they do not understand the basic when they shall e. Ask question to be sure that the participants have understand the main purpose of this information/text. Be sure that the participants have understood the main purpose of this information. Engine brake Working procedure Go through the text in the student material and also add your own experience/knowledge. Show the participants the engine parts and explain how they are connected to each other.Engine management system > Engine management system > Other sensors Key points  3. clutch and accelerator pedal  8. Additional information The following is a list of engine sensors that provide input to the EMS: Ambient Air Temperature Sensor Ambient Pressure sensor Boost Air Pressure (BAP) Sensor Camshaft Position (Engine Position) Sensor Crankshaft Position (Engine Speed) Sensor Differential Pressure DPF Sensor EGR Differential Pressure Sensor EGR Temperature Sensor Engine Coolant Level (ECL) Sensor Engine Coolant Temperature (ECT) Sensor Engine Oil Pressure (EOP) Sensor Engine Oil Level (EOL) Sensor Engine Oil Temperature (EOT) Sensor Exhaust Temperature Sensor (DPF Sensors) Fuel Pressure Sensor Intake Air Temperature And Humidity (IATH) Sensor Intake Manifold (Boost) Temperature Sensor Throttle Position (TP) Sensor Turbo Speed Sensor Variable Geometry Turbocharger (VGT) Position Sensor Trainer notes Page 136 (trainer) . ABS system  7. Parking brake  9.g. 01_en Page 137 . The engine control unit then handles the control of the engine independently for as long as conditions stay the same.Engine management system > Engine management system > Example of communication Example of communication When the driver. The engine control unit checks the signals from its own sensors to ensure that it is possible to increase the throttle setting.0.1. a signal is transmitted from the accelerator pedal to the vehicle electronic control unit. If there is no impediment the engine control unit activates the speed increase. for example. wants to increase speed and depresses the accelerator pedal. Notes GT120017A v. This signal is transmitted over the data link to the engine control unit. do not forget to tell them what is happen if they do not understand the basic when they shall e. Trainer notes Page 137 (trainer) . Ask question to be sure that the participants have understand the main purpose of this information/text. Run sensor test in VCADS Pro. Show the participants the engine parts and explain how they are connected to each other. Be sure that the participants have understood the main purpose of this information. fault tracing.g.Engine management system > Engine management system > Example of communication Key points  Communication  Increase speed  Accelerator pedal  Signal  Vehicle electronic control unit  Data link  Engine control unit  Sensors  Throttle setting Working procedure Go through the text in the student material and also add your own experience/knowledge. Point out the engine sensors. Test 7A Which component is the EMS connected to Unit injector Sensors Fuel filter Oil pump Can you use the EMS system for diagnostic and fault tracing Yes No The engine control unit regulates different systems and components.01_en .1. Which one below is correct? Starter element Unit injectors Exhaust pressure governor (EPG) Compression brake Point out the following sensor on the engine/picture Fuel pressure Page 138 GT120017A v.Engine management system > Engine management system > Diesel engine fundamentals.0. Test 7A Diesel engine fundamentals. Air temperature and air pressure 6. Engine coolant level 5. Oil temperature and oil pressure Trainer notes Page 138 (trainer) . After that shall the trainer go through the correct answer. Camshaft position 4.Engine management system > Engine management system > Diesel engine fundamentals. Questions that could help to improve the format of the questionnaire in the future may arise. Additional information Introduction to diesel engines. Charge air temperature and charge pressure 3. Fuel pressure 2. Crankshaft position and engine speed 8. Test 7A Key points  Question  Answer Working procedure Discuss the answers with the participants if there have been any misunderstandings or linguistic problems. Test 7A Key Which component is the EMS connected to *Unit injector *Sensors Fuel filter Oil pump Can you use the EMS system for diagnostic and fault tracing *Yes No The engine control unit regulates different systems and components. Which one below is correct? *Starter element *Unit injectors *Exhaust pressure governor (EPG) *Compression brake Point out the following sensor on the engine/picture 1. Let each participants work with the question for about 5-10 minutes. Engine coolant temperature 7. Test 7A 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 Notes GT120017A v.0.1.01_en Page 139 .Engine management system > Engine management system > Diesel engine fundamentals. Test 7A Trainer notes Page 139 (trainer) .Engine management system > Engine management system > Diesel engine fundamentals. 1.cast in aluminium  O-rings .0.01_en .silicon-sealant  Air filter  Turbocharger  Charge air cooler  The exhaust manifold .Intake and exhaust system > Intake and exhaust system > Intake and exhaust system Intake and exhaust system  Separated from the fuel system  Clean air through the intake system  Inlet manifold .heat-resistant material with high nickel content  Two -or three piece unit  Sealing rings  Exhaust pipe  Silencer  All Volvo engines are boosted with a turbocharger Notes Page 140 GT120017A v. Ask question to be sure that the participants have understand the main purpose of this information/text. do not forget to tell them what is happen if they do not understand the basic when they shall e. fault tracing.g.Intake and exhaust system > Intake and exhaust system > Intake and exhaust system Key points  Intake and exhaust system  Separated from the fuel system  Clean air through the intake system  Fuel from a separate fuel system  Intake manifold .cast in aluminium  Sealing  Rubber O-rings  Silicon-sealant  Air filter  Turbocharger  Charge air cooler  Air resistance  A large through-flow area is of prime importance  Exhaust manifold  Considerable stress  Heat-resistant material with high nickel content  Two -or three piece unit  Sealed with sealing rings or a special sealing compound Working procedure Go through the text in the student material and also add your own experience/knowledge. Show the participants the engine parts and explain how they are connected to each other. Trainer notes Page 140 (trainer) . Be sure that the participants have understood the main purpose of this information. 01_en Page 141 .1.0.Intake and exhaust system > Intake and exhaust system > Air filter Air filter  Reliability and life length  Clean  Pollutants  20 cubic metres per minute  Large through-flow area  10 square metres  Paper filter  Air filter housing Notes GT120017A v. fault tracing.g. Show the participants the engine parts and explain how they are connected to each other.Intake and exhaust system > Intake and exhaust system > Air filter Key points          Air filter Reliability and life length Clean Pollutants 20 cubic metres per minute Large through-flow area 10 square metres Paper filter Air filter housing Working procedure Go through the text in the student material and also add your own experience/knowledge. do not forget to tell them what is happen if they do not understand the basic when they shall e. Ask question to be sure that the participants have understand the main purpose of this information/text. Trainer notes Page 141 (trainer) . Be sure that the participants have understood the main purpose of this information. Intake and exhaust system > Intake and exhaust system > Cyclone filter Cyclone filter  Difficult conditions  Desert climate  Option  Cyclone tubes  Air rotates  Centrifugal force  Dust particles  Rubber valve Notes Page 142 GT120017A v.1.0.01_en . g. Show the participants the engine parts and explain how they are connected to each other. Trainer notes Page 142 (trainer) . fault tracing. Be sure that the participants have understood the main purpose of this information. do not forget to tell them what is happen if they do not understand the basic when they shall e. Ask question to be sure that the participants have understand the main purpose of this information/text.Intake and exhaust system > Intake and exhaust system > Cyclone filter Key points  Difficult conditions  Desert climate  Cyclone filter  Cyclone tubes  Air intake  Air rotates  Dust particles  Centrifugal force  Rubber valve Working procedure Go through the text in the student material and also add your own experience/knowledge. 0.Intake and exhaust system > Intake and exhaust system > Starter element Starter element  Intake manifold  Warm the air  Helps the engine start  White smoke  Cold starts  Starter element  Electrically heated Notes GT120017A v.1.01_en Page 143 . Ask question to be sure that the participants have understand the main purpose of this information/text. do not forget to tell them what is happen if they do not understand the basic when they shall e. Be sure that the participants have understood the main purpose of this information.Intake and exhaust system > Intake and exhaust system > Starter element Key points  Starter element  Intake manifold  Warm the air  White smoke  Electrically heated  Two or three heater coils Working procedure Go through the text in the student material and also add your own experience/knowledge. Trainer notes Page 143 (trainer) . fault tracing.g. Show the participants the engine parts and explain how they are connected to each other. 1.Intake and exhaust system > Intake and exhaust system > Exhaust pressure governor Exhaust pressure governor  Exhaust pressure governor (EPG)  Compressed air  Restricts the flow  Back pressure  Braking effect  Compression brake · Notes Page 144 GT120017A v.0.01_en . do not forget to tell them what is happen if they do not understand the basic when they shall e.Intake and exhaust system > Intake and exhaust system > Exhaust pressure governor Key points  Engine brake  Exhaust pressure governor (EPG)  Compressed air  VEB . Be sure that the participants have understood the main purpose of this information. Ask question to be sure that the participants have understand the main purpose of this information/text. Trainer notes Page 144 (trainer) .g. fault tracing.Volvo Engine Brake  Compression brake Working procedure Go through the text in the student material and also add your own experience/knowledge. Show the participants the engine parts and explain how they are connected to each other. VEB  Compression brake  Camshaft  Rocker arms  Hydraulic piston  Lubrication system  Hydraulic valve  Rocker arm pistons Notes GT120017A v.0.1.Intake and exhaust system > Intake and exhaust system > Compression brake VEB Compression brake .01_en Page 145 . fault tracing. Trainer notes Page 145 (trainer) .g. do not forget to tell them what is happen if they do not understand the basic when they shall e. Be sure that the participants have understood the main purpose of this information. Show the participants the engine parts and explain how they are connected to each other.Intake and exhaust system > Intake and exhaust system > Compression brake VEB Key points  Compression brake  Camshaft  Rocker arms  Hydraulic piston  Lubrication system  Hydraulic valve  Rocker arm pistons Working procedure Go through the text in the student material and also add your own experience/knowledge. Ask question to be sure that the participants have understand the main purpose of this information/text. VEB+ function Notes Page 146 GT120017A v.01_en .1.VEB+  VEB+ Volvo Engine Brake  Camshaft with four cam lobes  Brake cam .0.Intake and exhaust system > Intake and exhaust system > Compression brake VEB+ Compression brake . Show the participants the engine parts and explain how they are connected to each other.g. Ask question to be sure that the participants have understand the main purpose of this information/text. Trainer notes Page 146 (trainer) .Intake and exhaust system > Intake and exhaust system > Compression brake VEB+ Key points  VEB+  EPG (Exhaust Pressure Governor). fault tracing. Be sure that the participants have understood the main purpose of this information.VEB+ function  VCB  Engine braking control in position 2  Engine speed above 900 rpm  Vehicle speed above 5 km/h  Clutch pedal released completely  Engine oil temperature above 55°C  Turbocharging pressure below 0.  D16E EPG .butterfly type  VEB+ Volvo Engine Brake  Camshaft with four cam lobes  Inlet cam  Injector cam  Exhaust cam  Brake cam . do not forget to tell them what is happen if they do not understand the basic when they shall e.5 bar  Accelerator pedal released completely Working procedure Go through the text in the student material and also add your own experience/knowledge. 01_en Page 147 .0.1.Intake and exhaust system > Intake and exhaust system > Compression brake JAK Compression brake JAK  Energy-absorbing air compressor  Mounted above the rocker arm bridge  Operate on the exhaust valves  Always in combination with the exhaust brake · _  Solenoid valve  Control valve  Pressure piston Notes GT120017A v. Trainer notes Page 147 (trainer) .Adjustment screw.Jake brake  1.Pressure piston  3. do not forget to tell them what is happen if they do not understand the basic when they shall e. Be sure that the participants have understood the main purpose of this information. fault tracing.Intake and exhaust system > Intake and exhaust system > Compression brake JAK Key points  Compression brake .g. Show the participants the engine parts and explain how they are connected to each other.Solenoid valve  4.Control valve  2. pressure piston  Energy-absorbing air compressor  Reducing the load on the service brakes  Mounted above the rocker arm bridge  Operate on the exhaust valves  Always in combination with the exhaust brake Working procedure Go through the text in the student material and also add your own experience/knowledge. Ask question to be sure that the participants have understand the main purpose of this information/text. 1.Intake and exhaust system > Intake and exhaust system > Engine brake function Engine brake function  Engine brake function  Compression stroke  Power stroke  Exhaust stroke Notes Page 148 GT120017A v.01_en .0. Ask question to be sure that the participants have understand the main purpose of this information/text. Be sure that the participants have understood the main purpose of this information. fault tracing Trainer notes Page 148 (trainer) .Intake and exhaust system > Intake and exhaust system > Engine brake function Key points  Engine brake function  Compression stroke  Power stroke  Exhaust stroke Working procedure Go through the text in the student material and also add your own experience/knowledge. do not forget to tell them what is happen if they do not understand the basic when they shall e. Show the participants the engine parts and explain how they are connected to each other.g. 0. Test 8 Diesel engine fundamentals.Intake and exhaust system > Intake and exhaust system > Diesel engine fundamentals. Test 8 The inlet system of a diesel engine is entirely separated from the fuel system. True False The quantity of air to be cleaned in a large engine is: approx. approx. approx.1. 20 m3/min. 10 m3/min.01_en Page 149 . 5 m3/min. An engine which has to work in surroundings where the air is strongly polluted has an extra air filter known as a centrifugal filter cyclone filter sand separator What is this? GT120017A v. approx.Intake and exhaust system > Intake and exhaust system > Diesel engine fundamentals. Test 8 Key points  Question  Answer Working procedure Discuss the answers with the participants if there have been any misunderstandings or linguistic problems. *approx. *True False The quantity of air to be cleaned in a large engine is: approx. After that shall the trainer go through the correct answer. An engine which has to work in surroundings where the air is strongly polluted has an extra air filter known as a centrifugal filter *cyclone filter sand separator What is this? a magnetic air filter a cyclone filter *a starter element a filter cleaner Page 149 (trainer) . 5 m3/min. Questions that could help to improve the format of the questionnaire in the future may arise. Let each participants work with the question for about 5-10 minutes. Additional information Introduction to diesel engines. Test 8 Key The inlet system of a diesel engine is entirely separated from the fuel system. 20 m3/min. 10 m3/min. 1. True False Notes Page 150 GT120017A v. It is therefore made of a material with a high nickel content.Intake and exhaust system > Intake and exhaust system > Diesel engine fundamentals. Test 8 a magnetic air filter a cyclone filter a starter element a filter cleaner The exhaust manifold is subjected to considerable thermal stress.01_en .0. Test 8 The exhaust manifold is subjected to considerable thermal stress. It is therefore made of a material with a high nickel content.Intake and exhaust system > Intake and exhaust system > Diesel engine fundamentals. *True False Trainer notes Page 150 (trainer) . Turbocharger > Turbocharger > Turbocharger history Turbocharger history Notes GT120017A v.01_en Page 151 .1.0. The movie explains the development of the turbocharged engine through the years.Turbocharger > Turbocharger > Turbocharger history Key points Turbo charger history Working procedure Her it is time to run the movie “THE VOLVO TURBO HERITAGE 1954-2004”. This is like a teaser for the participants. Trainer notes Page 151 (trainer) . 1.Turbocharger > Turbocharger > Turbocharging Turbocharging  More air into the cylinder  Not steal power  Volvo turbo engines .5 bar)  Speed .2200 rps (130.000-100.000 rpm)  Top speed .150 kPa (1.000 rpm) Notes Page 152 GT120017A v.01_en .1954  40 to 50% higher output  Cleaner exhaust gases  Lower fuel consumption  Quieter engine operation  Turbocharger function  Boost pressure .1250-1670 rps (75.0. do not forget to tell them what is happen if they do not understand the basic when they shall e.g. Trainer notes Page 152 (trainer) . Show the participants the engine parts and explain how they are connected to each other.000 rpm)  2200 rps (130.000 rpm) Working procedure Go through the text in the student material and also add your own experience/knowledge. fault tracing. Be sure that the participants have understood the main purpose of this information. Ask question to be sure that the participants have understand the main purpose of this information/text.Turbocharger > Turbocharger > Turbocharging Key points  Turbo charging  Compressor air  Turbocharger  Powered by the flow  1954  Extending the engine's power  40 to 50%  Cleaner exhaust gases  Lower fuel consumption  Quieter engine  Turbine housing  Exhaust system  Turbine wheel  Compressor wheel  Shaft  Compressor housing  Air filter  Inlet manifold  150 kPa (1.000-100.5 bar)  1250-1670 rps (75. Turbocharger > Turbocharger > Turbocharger bearing Turbocharger bearing  Rotor shaft  Bearing  High speed  Lubrication  Cooled  Clean oil Notes GT120017A v.01_en Page 153 .1.0. Show the participants the engine parts and explain how they are connected to each other. do not forget to tell them what is happen if they do not understand the basic when they shall e. Ask question to be sure that the participants have understand the main purpose of this information/text. Be sure that the participants have understood the main purpose of this information. Trainer notes Page 153 (trainer) .g. fault tracing.Turbocharger > Turbocharger > Turbocharger bearing Key points  Rotor shaft  Slider bearings  Reliable lubrication  Lubricated and cooled by engine oil  Clean oil Working procedure Go through the text in the student material and also add your own experience/knowledge. 0.01_en .Turbocharger > Turbocharger > Wastegate Wastegate  Engine torque requirements at low engine speeds  Temperatures  Emissions  Boost pressure  Bypass  Overspeed  Pneumatic actuator · Notes Page 154 GT120017A v.1. Trainer notes Page 154 (trainer) . Show the participants the engine parts and explain how they are connected to each other. fault tracing. do not forget to tell them what is happen if they do not understand the basic when they shall e.g. Ask question to be sure that the participants have understand the main purpose of this information/text. Be sure that the participants have understood the main purpose of this information.Turbocharger > Turbocharger > Wastegate Key points  Wastegate  Requirements at low engine speeds  Producing good air flow  Reduces exhaust temperatures  Reduces emissions  Boost pressure  Bypass into the exhaust system  Overspeed  Pneumatic actuator  Valve.bypass flap Working procedure Go through the text in the student material and also add your own experience/knowledge. 01_en Page 155 .0.1.Turbocharger > Turbocharger > Turbocharger system Turbocharger system  Intake system  Exhaust system  Turbocharger  Starter element  Exhaust pressure governor EPG  Blue exhaust smoke Notes GT120017A v. Turbocharger > Turbocharger > Turbocharger system Key points  Intake  Exhaust  Turbocharger  Starter element  Exhaust pressure governor . Be sure that the participants have understood the main purpose of this information. Show the participants the engine parts and explain how they are connected to each other. do not forget to tell them what is happen if they do not understand the basic when they shall e.g. Trainer notes Page 155 (trainer) .EPG  Reducing white and blue exhaust smoke Working procedure Go through the text in the student material and also add your own experience/knowledge. fault tracing. Ask question to be sure that the participants have understand the main purpose of this information/text. 0.Turbocharger > Turbocharger > Exhaust pressure governor Exhaust pressure governor  Exhaust pressure governor EPG  Turbocharger  Two functions  Pneumatic cylinder  Vehicle's pneumatic system  Solenoid  Butterfly Notes Page 156 GT120017A v.01_en .1. Additional information Butterfly. see D16E. Be sure that the participants have understood the main purpose of this information.Turbocharger > Turbocharger > Exhaust pressure governor Key points  Exhaust pressure governor .g. do not forget to tell them what is happen if they do not understand the basic when they shall e. Ask question to be sure that the participants have understand the main purpose of this information/text. design and function. Trainer notes Page 156 (trainer) . Show the participants the engine parts and explain how they are connected to each other. fault tracing.EPG  Below the turbocharger  Two functions  Counterpressure  Kept warm  White exhaust smoke  Shutter housing  Shutter  Pneumatic cylinder  Compressed air  Solenoid Working procedure Go through the text in the student material and also add your own experience/knowledge. Exhaust Gas Recirculation  EMS  Movable sleeve  Lever  Actuator  Gear ratio  Electric motor Notes GT120017A v.01_en Page 157 .0.1.Turbocharger > Turbocharger > Turbocharger type VGT Turbocharger type VGT  Variable Geometry Turbine. VGT  EGR. Variable Geometry Turbine  EGR system  Gas flow  EGR-meter  EMS system  EGR-valve  Axial movable sleeve (1)  Lever (2)  Actuator (3)  Gear ratio (4)  Electric motor (5) Working procedure Go through the text in the student material and also add your own experience/knowledge. do not forget to tell them what is happen if they do not understand the basic when they shall e.Turbocharger > Turbocharger > Turbocharger type VGT Key points  VGT . fault tracing.g. Trainer notes Page 157 (trainer) . Be sure that the participants have understood the main purpose of this information. Ask question to be sure that the participants have understand the main purpose of this information/text. Show the participants the engine parts and explain how they are connected to each other. 0.Turbocharger > Turbocharger > Charge air cooling Charge air cooling There are two types of charge air cooler:  Air to air cooling  Fluid to air cooling The charge air cooler principle  Compressor  Turbine  Charge air cooler (Intercooler) Notes Page 158 GT120017A v.1.01_en . Show the participants the engine parts and explain how they are connected to each other.g.Turbocharger > Turbocharger > Charge air cooling Key points  Charge air cooling  Air to air cooling  Fluid to air cooling  Compressor  Turbine  Charge air cooler (Intercooler) Working procedure Go through the text in the student material and also add your own experience/knowledge. Be sure that the participants have understood the main purpose of this information. Ask question to be sure that the participants have understand the main purpose of this information/text. Trainer notes Page 158 (trainer) . do not forget to tell them what is happen if they do not understand the basic when they shall e. fault tracing. 1.Turbocharger > Turbocharger > Air to air cooling Air to air cooling  Common type  Charge air cooler (intercooler)  Reduces the air temperature  Raising engine power output  Higher torque  Lower fuel consumption  Positioned in front of the engine cooling radiator · Notes GT120017A v.01_en Page 159 .0. do not forget to tell them what is happen if they do not understand the basic when they shall e. fault tracing.Turbocharger > Turbocharger > Air to air cooling Key points  Air to air cooling  Reduces the air temperature by roughly 100°C  Raising engine power output by about 10%  Torque is also higher  Fuel consumption drops  In front of the engine cooling radiator Working procedure Go through the text in the student material and also add your own experience/knowledge. Show the participants the engine parts and explain how they are connected to each other. Be sure that the participants have understood the main purpose of this information. Trainer notes Page 159 (trainer) . Ask question to be sure that the participants have understand the main purpose of this information/text.g. Page 160 GT120017A v. Test 9 Put the numbers in the appropriate boxes.Turbocharger > Turbocharger > Diesel engine fundamentals.1.0. Turbo pipe Gasket Sealing rings Inlet duct Exhaust manifold Engine turbocharging means that the air intake is positioned above the engine the incoming air is pressed in from below more air is pressed into the engine There are several additional benefits to using a turbocharger.01_en . Test 9 Diesel engine fundamentals. Exhaust gases are cleaner Fuel consumption is lower Inlet noise is lower Engine power increases Exhaust noise is lower Pipe routing is simpler An exhaust pressure governor reduces the white and blue smoke in the exhaust gases. *Exhaust gases are cleaner *Fuel consumption is lower *Inlet noise is lower *Engine power increases *Exhaust noise is lower Pipe routing is simpler An exhaust pressure governor reduces the white and blue smoke in the exhaust gases. Let each participants work with the question for about 5-10 minutes. Test 9 Key points  Question  Answer Working procedure Discuss the answers with the participants if there have been any misunderstandings or linguistic problems. *True False A diesel engine with a turbocharger and intercooler has the best possible efficiency rating. Questions that could help to improve the format of the questionnaire in the future may arise. *True False "Intercooler" is another name for charge air cooler.Turbocharger > Turbocharger > Diesel engine fundamentals. Additional information Introduction to diesel engines. Turbo pipe 4 Gasket 3 Sealing rings 1 Inlet duct 5 Exhaust manifold 2 Engine turbocharging means that the air intake is positioned above the engine the incoming air is pressed in from below *more air is pressed into the engine There are several additional benefits to using a turbocharger. Page 160 (trainer) . After that shall the trainer go through the correct answer. Test 9 Key Put the numbers in the appropriate boxes. 01_en Page 161 . True False Notes GT120017A v. True False "Intercooler" is another name for charge air cooler.Turbocharger > Turbocharger > Diesel engine fundamentals. Test 9 rue False A diesel engine with a turbocharger and intercooler has the best possible efficiency rating.0.1. Test 9 *True False Trainer notes Page 161 (trainer) .Turbocharger > Turbocharger > Diesel engine fundamentals. 0.1.Cooling system > Cooling system > Volvo coolant Volvo coolant  Over heating  Circulates the coolant  Absorbs heat  Radiator  Fluid cooled  Liquid coolant  Glycol  Water Notes Page 162 GT120017A v.01_en . Cooling system > Cooling system > Volvo coolant Key points  Over heating  Circulates the coolant  Absorbs heat  Radiator  Fluid cooled  Liquid coolant  Glycol Water Working procedure Go through the text in the student material and also add your own experience/knowledge. Be sure that the participants have understood the main purpose of this information. do not forget to tell them what is happen if they do not understand the basic when they shall e. fault tracing. Ask question to be sure that the participants have understand the main purpose of this information/text.g. Trainer notes Page 162 (trainer) . Show the participants the engine parts and explain how they are connected to each other. In such cases. Notes GT120017A v.1. Volvo anticorrosion fluid is added in the ratio of 1:30 (1 litre of fluid to 30 litres of water). no anti-freeze is needed but corrosion protection is still essential to prevent engine damage. All these fluids which circulate inside the cooling system are known as coolants. On markets where the ambient temperature never drops below 0°C. the coolant should consist of a mixture of water and anti-freeze. Referring to them as "water" is incorrect since there is always something added to the water.0.01_en Page 163 .Cooling system > Cooling system > Cooling system Cooling system  Heat  Cylinder block  Cylinder head _ Coolant When the ambient temperature is below 0°C. cooling system  Heat from the cylinder block and cylinder heads  Cooling jacket  Cylinders and combustion chambers have the same temperature  Combustion to be as efficient and clean as possible  Correct operational temperature  Light or heavy load  Low flow resistance  Thermo-siphon principle  Pump circulation  Coolant pump  Coolant  0°C  Mixture of water and anti-freeze  Anti-corrosion fluid  "water" Working procedure Go through the text in the student material and also add your own experience/knowledge. Additional information Her it is time to run the movie “AN INTRO TO DIESEL ENGINE” chapter "Cooling system".lubricating oil  Radiated from the sides of the engine itself  20-30% . This is like a teaser for the participants. Trainer notes Page 163 (trainer) . Show the participants the engine parts and explain how they are connected to each other. fault tracing.Cooling system > Cooling system > Cooling system Key points  Cooling system  10-15% . Ask question to be sure that the participants have understand the main purpose of this information/text. do not forget to tell them what is happen if they do not understand the basic when they shall e. Be sure that the participants have understood the main purpose of this information.g.  Filling cap.Cooling system > Cooling system > External components of the cooling system External components of the cooling system  Coolant filter  Oil cooler  Coolant pump  Air compressor.0.  Thermostat  Radiator Notes Page 164 GT120017A v.01_en .1.  Heating cell package in cab  Expansion tank  Level indicator. Trainer notes Page 164 (trainer) . Be sure that the participants have understood the main purpose of this information. Ask question to be sure that the participants have understand the main purpose of this information/text. do not forget to tell them what is happen if they do not understand the basic when they shall e. fault tracing.Cooling system > Cooling system > External components of the cooling system Key points  External components  Coolant filter  Oil cooler  Coolant pump  Air compressor  Heating cell  Expansion tank  Level indicator. Show the participants the engine parts and explain how they are connected to each other.  Warning lamp  Filling cap .g.over pressure valves  Thermostat  Return pipe  Radiator Working procedure Go through the text in the student material and also add your own experience/knowledge. 1. (cold engine) Coolant can only flow through the lower pipe.0. Notes GT120017A v.Cooling system > Cooling system > Thermostat Thermostat Shut. Open. (warm engine) Coolant can only flow through the upper pipe.01_en Page 165 . . Trainer notes Page 165 (trainer) . Ask question to be sure that the participants have understand the main purpose of this information/text. fault tracing.g. (cold engine)  Open. Show the participants the engine parts and explain how they are connected to each other. Be sure that the participants have understood the main purpose of this information. (warm engine) Working procedure Go through the text in the student material and also add your own experience/knowledge. do not forget to tell them what is happen if they do not understand the basic when they shall e.Cooling system > Cooling system > Thermostat Key points  Thermostat regulates  Shut. 01_en .Cooling system > Cooling system > Schematic presentation of the cooling system Schematic presentation of the cooling system.  Inner circuit  Outer circuit Notes Page 166 GT120017A v.0.1. fault tracing.g.Cooling system > Cooling system > Schematic presentation of the cooling system Key points  Schematic  Inner circuit  Outer circuit Working procedure Go through the text in the student material and also add your own experience/knowledge. Show the participants the engine parts and explain how they are connected to each other. do not forget to tell them what is happen if they do not understand the basic when they shall e. Ask question to be sure that the participants have understand the main purpose of this information/text. Be sure that the participants have understood the main purpose of this information. Trainer notes Page 166 (trainer) . 0.Cooling system > Cooling system > Radiator Radiator  Heat exchanger  Copper  Brass  Aluminium  Plastic  Upper tank  Lower tank  Honeycomb  Pipes  Thin steel fins Notes GT120017A v.01_en Page 167 .1. do not forget to tell them what is happen if they do not understand the basic when they shall e. fault tracing. Be sure that the participants have understood the main purpose of this information.Cooling system > Cooling system > Radiator Key points  Radiator  Heat exchanger  Copper  Brass  Aluminium  Two containers  Upper tank  Lower tank  Plastic  Honeycomb  Pipes  Two up to four rows  Steel Working procedure Go through the text in the student material and also add your own experience/knowledge. Ask question to be sure that the participants have understand the main purpose of this information/text. Trainer notes Page 167 (trainer) . Show the participants the engine parts and explain how they are connected to each other.g. 0.Cooling system > Cooling system > Cooling fans in vehicles Cooling fans in vehicles  Visco clutch  Fan axle  Fan  Drive belt  Automatic belt tensioners Notes Page 168 GT120017A v.1.01_en . Ask question to be sure that the participants have understand the main purpose of this information/text. Show the participants the engine parts and explain how they are connected to each other. Be sure that the participants have understood the main purpose of this information. do not forget to tell them what is happen if they do not understand the basic when they shall e.g. out through the radiator. Fixed fans are designed to provide an ambient temperature of +50° Trainer notes Page 168 (trainer) .  Low temperature 25% of full speed  60°C . In a generator set.  Maximum flow  Thermostat-regulated fan  Fluid coupling which senses the temperature of the air which has flowed through the radiator.95% of full speed  5% slipping of the fluid coupling  Reduces fuel consumption  Less noise  Working procedure Go through the text in the student material and also add your own experience/knowledge. Additional information Cooling fans in industrial engines These engines feature fixed fans which are either pressure or suction fans. The former means that the fan provides a thrust of air from behind the engine.Cooling system > Cooling system > Cooling fans in vehicles Key points  Cooling fan  10 kW (14 bhp). this flow of air cools both the generator and the engine. fault tracing. Cooling system > Cooling system > Cooling fans in bus Cooling fans in bus  Electro-hydraulic system  Coolant temperature sensor  PWM-signal  Stepless regulation  Rotational speed induction sensor Notes GT120017A v.01_en Page 169 .0.1. Cooling system > Cooling system > Cooling fans in bus Key points  Electro-hydraulic system  Coolant temperature sensor  PWM-signal  Stepless regulation  Rotational speed induction sensor Working procedure Go through the text in the student material and also add your own experience/knowledge. Ask question to be sure that the participants have understand the main purpose of this information/text. Show the participants the engine parts and explain how they are connected to each other. do not forget to tell them what is happen if they do not understand the basic when they shall e. Trainer notes Page 169 (trainer) . Be sure that the participants have understood the main purpose of this information. fault tracing.g. 0.Cooling system > Cooling system > Cooling fans in VCE Cooling fans in VCE  Articulated Haulers  Wheel loaders  Driven by hydraulic oil  Hydraulic pump  Hydraulic fan motor  Vehicle ECU  Sensors  Valve  Reversible fan Notes Page 170 GT120017A v.01_en .1. Be sure that the participants have understood the main purpose of this information. Point out main parts and system layout in vehicle Trainer notes Page 170 (trainer) .g.Cooling system > Cooling system > Cooling fans in VCE Key points  Articulated Haulers  Wheel loaders  Driven by hydraulic oil  Hydraulic pump  Hydraulic fan motor  Vehicle ECU  Sensors  Valve  Reversible fan Working procedure Go through the text in the student material and also add your own experience/knowledge. do not forget to tell them what is happen if they do not understand the basic when they shall e. Show the participants the engine parts and explain how they are connected to each other. fault tracing. Ask question to be sure that the participants have understand the main purpose of this information/text. True False Put the numbers in the appropriate boxes.0. GT120017A v.01_en Page 171 . Test 10 Diesel engine fundamentals. Test 10 Roughly 25% of the energy supplied to the engine is led away by the cooling system. the operational temperature can be higher than 100°C without any risk of the system boiling over.1. True False It is the thermostat which provides the cooling system's over-pressure. True False How many degrees (roughly) does the coolant temperature drop on its way through the radiator? 10°C 20°C 30°C Since there is an over-pressure in the cooling system.Cooling system > Cooling system > Diesel engine fundamentals. Cooling system > Cooling system > Diesel engine fundamentals. Test 10 Key points  Question  Answer Working procedure Discuss the answers with the participants if there have been any misunderstandings or linguistic problems. Questions that could help to improve the format of the questionnaire in the future may arise. Let each participants work with the question for about 5-10 minutes. After that shall the trainer go through the correct answer. Additional information Introduction to diesel engines. Test 10 Key Roughly 25% of the energy supplied to the engine is led away by the cooling system. *True False How many degrees (roughly) does the coolant temperature drop on its way through the radiator? *10°C 20°C 30°C Since there is an over-pressure in the cooling system, the operational temperature can be higher than 100°C without any risk of the system boiling over. *True False It is the thermostat which provides the cooling system's over-pressure. True *False Put the numbers in the appropriate boxes. Filling cap 10 Coolant pump 5 Air compressor 6 Expansion tank 8 Cab heating element 7 Coolant filter 3 Level indicator 9 Return pipe, Cylinder head 2 Thermostat 1 Oil cooler 4 Page 171 (trainer) Cooling system > Cooling system > Diesel engine fundamentals. Test 10 illing cap Coolant pump Air compressor Expansion tank Cab heating element Coolant filter Level indicator Return pipe, Cylinder head Thermostat Oil cooler The cooling mantle is in the cylinder block and cylinder head. True False The thermostat keeps the pipe leading to the radiator shut until the engine is sufficiently heated. True False The coolant pump is a centrifugal pump. It can pump considerable quantities of fluid at low pressure. True False Decide what is correct as regards the coolant pump. The pump is usually driven by the timing gear Two rubber lip seals ensure pump shaft sealing There is a ceramic slider ring in Volvo pumps Pump shaft sealing consists of a slider ring seal If the ambient temperature never drops below 0°C, there is no need for glycol, but corrosion protection is necessary. True False The piston thermostat has a low flow resistance. True False A coolant filter contains anti-corrosion agent. True False It is an advantage if the radiator fan does not work at all when the vehicle is running at a low road speed or is at a standstill with the engine operating when the ambient air is cold and provides good cooling when the engine is running under high load Page 172 GT120017A v.1.0.01_en Cooling system > Cooling system > Diesel engine fundamentals. Test 10 The cooling mantle is in the cylinder block and cylinder head. *True False The thermostat keeps the pipe leading to the radiator shut until the engine is sufficiently heated. *True False The coolant pump is a centrifugal pump. It can pump considerable quantities of fluid at low pressure. *True False Decide what is correct as regards the coolant pump. *The pump is usually driven by the timing gear Two rubber lip seals ensure pump shaft sealing *There is a ceramic slider ring in Volvo pumps *Pump shaft sealing consists of a slider ring seal If the ambient temperature never drops below 0°C, there is no need for glycol, but corrosion protection is necessary. *True False The piston thermostat has a low flow resistance. *True False A coolant filter contains anti-corrosion agent. *True False It is an advantage if the radiator fan does not work at all when the vehicle is running at a low road speed or is at a standstill with the engine operating *when the ambient air is cold and provides good cooling when the engine is running under high load when the ambient air is hot A thermostat fan reduces the engine's fuel consumption since it only steals a little power from the engine when it spins at low speed. *True Page 172 (trainer) Cooling system > Cooling system > Diesel engine fundamentals. Test 10 hen the ambient air is hot A thermostat fan reduces the engine's fuel consumption since it only steals a little power from the engine when it spins at low speed. True False Notes GT120017A v.1.0.01_en Page 173 Cooling system > Cooling system > Diesel engine fundamentals. Test 10 False Trainer notes Page 173 (trainer) Emissions > Emissions > 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 Notes Page 174 GT120017A v.1.0.01_en Emissions > Emissions > Vehicle emissions and environmental impact Key points The most important air pollutants include: - 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 Working procedure Go through the text in the student material and also add your own experience/knowledge. Be sure that the participants have understood the main purpose of this information. Ask question to be sure that the participants have understand the main purpose of this information/text. Show the participants the engine parts and explain how they are connected to each other, do not forget to tell them what is happen if they do not understand the basic when they shall e.g. fault tracing. Trainer notes Page 174 (trainer) Emissions > Emissions > Engine emission Engine emission The diagram above shows the dramatic decrease in NOx and PM necessary to meet the Euro 4 and especially Euro 5 legislations. Stricter emission legislation has caused an increased need for exhaust aftertreatment, in order to remove harmful pollutants, such as NOx and particulates. The NOx emissions from a diesel engine are lowered by adding a reducing agent to the exhaust gas flow, such as urea or diesel fuel. The particulates are typically removed by collecting in a filter device, with continuous or periodic regeneration of the filter.  1st October 2006 - Euro 4  1st October 2009 - Euro 5  Nitrogen oxides (NOx)  Particulate (PM) Notes GT120017A v.1.0.01_en Page 175 buses and coaches will be required to be fitted with onboard diagnostics which will monitor the performance of both SCR and EGR systems to ensure emission compliance during use. Important to do the correct adjustment to get the correct emission. Additional information Go through the information shown below. Enforcement authorities will be able to download faults recorded on the vehicle ECU. http://violin.net/volvotechnology/corporate/en/business_functions/business_key_technology _areas Trainer notes Page 175 (trainer) .Emissions > Emissions > Engine emission Key points  Emission  EGR  SCR Working procedure Talk with the participants about the Volvo engine emission. There is more information about emissions on the violin link below. From 1st October 2007 all new trucks.volvo. which may take the form of gases. Hydrocarbons also react with nitrogen oxides in the presence of sunlight to form ozone. In typical urban areas. Compared with the petrol engine. Carbon dioxide is generated by burning material that contains carbon. This is expected to lead to climate change. or droplets. buses.0. the most common fuel for vehicles. Hydrocarbons include many toxic compounds that cause cancer and other adverse health effects. Carbon dioxide emissions are directly related to how much fuel is consumed. also called global warming. come from a great variety of industrial and natural processes. Hydrocarbons.1. The greenhouse effect is a natural phenomenon which means that the earth is heated when radiated heat is captured by greenhouse gases in the atmosphere.Emissions > Emissions > Carbon dioxide and Hydrocarbons Carbon dioxide and Hydrocarbons Carbon dioxide contributes to the greenhouse effect. a very significant fraction comes from cars. Carbon dioxide is one of the most important greenhouse gases. Diesel. and non-road mobile sources such as construction vehicles and boats. trucks.01_en . and is not poisonous. keeping down emissions of carbon dioxide. the diesel engine has a considerably greater degree of efficiency. (or from the crankcase ventilation) and also when fuel evaporates directly into the atmosphere. This means that the energy content of the fuel is utilised better. Since the industrial revolution human beings have added to the greenhouse effect through increased greenhouse gas emissions. 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. tiny particles. Hydrocarbon pollution results when unburned or partially burned fuel is emitted from the engine as exhaust. Page 176 GT120017A v. consists of hydrocarbons and during combustion generates carbon dioxide. not poisonous  Diesel  Hydrocarbon  Fuelconsumption Working procedure Go through the text in the student material and also add your own experience/knowledge. Show the participants the engine parts and explain how they are connected to each other. Trainer notes Page 176 (trainer) .Emissions > Emissions > Carbon dioxide and Hydrocarbons Key points  Carbon dioxide  Greenhouse effect . Be sure that the participants have understood the main purpose of this information.g.global warming  Greenhouse gases  Industrial revolution  Climate change  Carbon . do not forget to tell them what is happen if they do not understand the basic when they shall e. fault tracing. Ask question to be sure that the participants have understand the main purpose of this information/text. 1.01_en Page 177 . The high degree of efficiency of the diesel engine is achieved through high pressure.. and can in high concentrations cause damage to the respiratory system. creating various oxides of nitrogen. However.Emissions > Emissions > Nitrogen oxides (NOX) Nitrogen oxides Nitrogen oxides (NOx) is a collective name for nitrogen monoxide (NO) and nitrogen dioxide (NO2). These include the formation of tropospheric ozone and the acidification of land and water. This increases the formation of NOx. Nitrogen oxides are formed during all combustion where air is present. as the oxygen and nitrogen in the air react with each other. Nitrogen oxides are also irritating when they are breathed in. high temperature and excess air during combustion. the oxygen and nitrogen gases in air will not react with each other. At ambient temperatures. In an internal combustion engine. Nitrogen oxides contribute to a number of different environmental issues. In areas of high motor vehicle traffic. the amount of nitrogen oxides emitted into the atmosphere can be quite significant. such as in large cities. GT120017A v. these characteristics also contribute to low emissions of carbon dioxide. Developments in engine technology have lead to considerable reductions in NOx emissions from diesel engines. combustion of a mixture of air and fuel produces combustion temperatures high enough to drive endothermic reactions between atmospheric nitrogen and oxygen in the flame.0. fault tracing.Emissions > Emissions > Nitrogen oxides (NOX) Key points  Nitrogen oxides . Be sure that the participants have understood the main purpose of this information. Show the participants the engine parts and explain how they are connected to each other. Trainer notes Page 177 (trainer) .g. Ask question to be sure that the participants have understand the main purpose of this information/text. do not forget to tell them what is happen if they do not understand the basic when they shall e.NOX  Nitrogen monoxide (NO)  Nitrogen dioxide (NO2)  Tropospheric ozone  Irritating  Respiratory system Working procedure Go through the text in the student material and also add your own experience/knowledge. Fuel with a low sulphur content reduces particulate formation. Particulate matter also contributes to poor visibility and soot deposition. When they are breathed in the particles are transported into the lungs carrying with them harmful substances.01_en . Increased levels of fine particles in the air are linked to health hazards such as heart disease. particulate filters. and sea spray. aerosol refers to particles and the gas together.g. e. Various technical measures have reduced particulate formation in modern diesel engines. Low sulphur fuel does not only produce lower emissions of particulates and oxides of sulphur. Particles from a diesel engine consist primarily of soot. dust storms. Particles can exacerbate existing respiratory problems and high concentrations can probably lead to reduced pulmonary function. various hydrocarbons and sulphur. Particulate matter is generated by the incomplete combustion of fuel. altered lung function and lung cancer. The USA is also introduced requirements for greater access to low sulphur vehicle fuel from 2006.1. are tiny particles of solid or liquid suspended in a gas. power plants and various industrial processes also generate significant amounts of aerosols. originating from volcanoes. 2005 low sulphur fuel with a sulphur content of maximum 10 mg/kg (0. Sources of particulate matter can be man made or natural. alternatively referred to as particulate matter (PM) or fine particles. forest and grassland fires. In contrast. such as the burning of fossil fuels in vehicles. anthropogenic aerosols -those made by human activities -currently account for about 10 percent of the total amount of aerosols in our atmosphere. Human activities. For really good combustion good fuel must be used.Emissions > Emissions > Particulate matter Particulate matter Particulates. Averaged over the globe. Some particulates occur naturally. living vegetation. 100 ppm) must be available in all member states of the EU. Good fuel quality also provides greater opportunity for the use of aftertreatment equipment. From January 1. but is also a prerequisite for certain types of exhaust after-treatment. however engine lubricating oil is also a factor. Page 178 GT120017A v.1%.0. Trainer notes Page 178 (trainer) .g. fault tracing. Show the participants the engine parts and explain how they are connected to each other. Be sure that the participants have understood the main purpose of this information. Ask question to be sure that the participants have understand the main purpose of this information/text.Emissions > Emissions > Particulate matter Key points  Particles  Soot  Hydrocarbons  Sulphur  Harmful substances  Respiratory problems  Reduced pulmonary function  Poor visibility  Soot deposition  Incomplete combustion of fuel  Engine lubricating oil  Good fuel  Low sulphur Working procedure Go through the text in the student material and also add your own experience/knowledge. do not forget to tell them what is happen if they do not understand the basic when they shall e. 05%). (0.0.Emissions > Emissions > Particulate matter The recommended sulphur content for Euro 5 is 50 ppm.1. Notes GT120017A v.01_en Page 179 . Emissions > Emissions > Particulate matter Trainer notes Page 179 (trainer) . Nitrogen oxides (NOx) Particulate (PM) Carbon monoxide (CO) Carbon dioxide (CO2) Sulphur oxide (SOx) The recommended sulphur content for Euro 5 is 50 ppm. Test 11A Diesel engine fundamentals. (0.05%) 30 ppm. (0.0. (0.03%) 500 ppm.005%) Notes Page 180 GT120017A v.1. (0.50%) 5 ppm.01_en . Test 11A Which pollutants is lower in Euro 5 comparing to Euro 4.Emissions > Emissions > Diesel engine fundamentals. (0.50%) 5 ppm. (0. After that shall the trainer go through the correct answer.03%) 500 ppm. Additional information Introduction to diesel engines. *Nitrogen oxides (NOx) *Particulate (PM) Carbon monoxide (CO) Carbon dioxide (CO2) Sulphur oxide (SOx) The recommended sulphur content for Euro 5 is *50 ppm. (0.05%) 30 ppm. (0.Emissions > Emissions > Diesel engine fundamentals. Test 11A Key points  Question  Answer Working procedure Discuss the answers with the participants if there have been any misunderstandings or linguistic problems. Let each participants work with the question for about 5-10 minutes. Test 11A Key Which pollutants is lower in Euro 5 comparing to Euro 4. Questions that could help to improve the format of the questionnaire in the future may arise.005%) Trainer notes Page 180 (trainer) . schematic description of the system Emisson control.EGR > EGR > Emisson control. schematic description of the system  Emisson control  Cooled-EGR  EGR-valve  EGR-cooler  EGR-meter  VGT turbocharger  After treatment  Stainless container  Oxidizing catalytic converter  Ceramic particulate filter Notes GT120017A v.0.1.01_en Page 181 . EGR > EGR > Emisson control. do not forget to tell them what is happen if they do not understand the basic when they shall e. Ask question to be sure that the participants have understand the main purpose of this information/text. Be sure that the participants have understood the main purpose of this information. fault tracing. Trainer notes Page 181 (trainer) . Show the participants the engine parts and explain how they are connected to each other. schematic description of the system Key points  Emisson control  Schematic  Cooled-EGR  Reducing of the nitrogen oxide  EGR-valve (A)  EGR-cooler (B)  EGR-meter (C)  VGT turbocharger (D)  Good driveability  Turbine geometry  EMS system  After treatment  Muffler (E)  Stainless container  Oxidizing catalytic converter  Ceramic particulate filter Working procedure Go through the text in the student material and also add your own experience/knowledge.g. EGR > EGR > EGR system EGR system  EGR valve  Rear exhaust pipe  EGR cooler  Differential pressure sensor  Venturi tube  EGR temperature sensor  EGR pipe  Mixing chamber  Charge air sensor Notes Page 182 GT120017A v.1.01_en .0. EGR > EGR > EGR system Key points  EGR system  EGR valve  Rear exhaust pipe  EGR cooler  Differential pressure sensor  Venturi tube  EGR temperature sensor  EGR pipe  Mixing chamber  Charge air sensor  EGR = Exhaust Gas Recirculation  Nitrous oxide (NO x)  Combustion temperature  Cooled exhaust  Maximum EGR Working procedure Go through the text in the student material and also add your own experience/knowledge. Ask question to be sure that the participants have understand the main purpose of this information/text. do not forget to tell them what is happen if they do not understand the basic when they shall e. Be sure that the participants have understood the main purpose of this information.g. Trainer notes Page 182 (trainer) . fault tracing. Show the participants the engine parts and explain how they are connected to each other. Large engine platform  Internal exhaust Gas Recirculation .I-EGR  Reduce nitrogen oxide emissions . Large engine platform I-EGR.NOx  Specially designed exhaust rocker .01_en Page 183 .double rocker arm  Controlled by the engine ECU · Notes GT120017A v.1.EGR > EGR > I-EGR.0. Trainer notes Page 183 (trainer) . Large engine platform Key points  Internal exhaust Gas Recirculation . Show the participants the engine parts and explain how they are connected to each other.EGR > EGR > I-EGR.NOx  High temperature  Peak combustion temperature  Specially designed exhaust rocker .I-EGR  Added to the air-fuel mixture  Reduce nitrogen oxide emissions . Be sure that the participants have understood the main purpose of this information.double rocker arm  Exhaust valve lift during the inlet stroke  PWM controlled solenoid Controlled by the engine ECU Working procedure Go through the text in the student material and also add your own experience/knowledge. fault tracing. Ask question to be sure that the participants have understand the main purpose of this information/text. do not forget to tell them what is happen if they do not understand the basic when they shall e.g. EGR > EGR > I-EGR.0.1.01_en . Medium engine platform I-EGR. Medium engine platform  Medium range engines  Construction equipment  Mounted on top Notes Page 184 GT120017A v. fault tracing Trainer notes Page 184 (trainer) . Show the participants the engine parts and explain how they are connected to each other. Be sure that the participants have understood the main purpose of this information.g.EGR > EGR > I-EGR. Medium engine platform Key points  Medium range engines  Construction equipment  Mounted on top Working procedure Go through the text in the student material and also add your own experience/knowledge. Ask question to be sure that the participants have understand the main purpose of this information/text. do not forget to tell them what is happen if they do not understand the basic when they shall e. 0. Medium engine platform  Inlet rocker arm  Exhaust rocker arm  Slave piston  Control valve  Low-pressure channel  Solenoid valve  From engine lubrication system  High-pressure circuit  Master piston Notes GT120017A v.1.01_en Page 185 . Medium engine platform I-EGR Function.EGR > EGR > I-EGR Function. Show the participants the engine parts and explain how they are connected to each other. fault tracing Trainer notes Page 185 (trainer) . Be sure that the participants have understood the main purpose of this information. From engine lubrication system  8. Inlet rocker arm  2. Solenoid valve  7. Ask question to be sure that the participants have understand the main purpose of this information/text. Medium engine platform Key points  When the I-EGR is to be turned on/off is controlled by the engine ECU  1. Master piston Working procedure Go through the text in the student material and also add your own experience/knowledge.g. High-pressure circuit  9.EGR > EGR > I-EGR Function. Control valve  5. Low-pressure channel  6. do not forget to tell them what is happen if they do not understand the basic when they shall e. Slave piston  4. Exhaust rocker arm  3. Test 11B Diesel engine fundamentals.1.EGR > EGR > Diesel engine fundamentals.01_en .0. Test 11B Put the numbers in the appropriate boxes. EGR valve Rear exhaust pipe EGR cooler Differential pressure sensor Venturi tube EGR temperature sensor EGR pipe Mixing chamber Charge air sensor Notes Page 186 GT120017A v. Differential pressure sensor 5. Test 11B Key points  Question  Answer Working procedure Discuss the answers with the participants if there have been any misunderstandings or linguistic problems. EGR valve 2. Let each participants work with the question for about 5-10 minutes.EGR > EGR > Diesel engine fundamentals. 1. EGR temperature sensor 7. Venturi tube 6. Questions that could help to improve the format of the questionnaire in the future may arise. Mixing chamber 9. EGR cooler 4. EGR pipe 8. After that shall the trainer go through the correct answer. Test 11B Key Put the numbers in the appropriate boxes. Rear exhaust pipe 3. Additional information Introduction to diesel engines. Charge air sensor Trainer notes Page 186 (trainer) . SCR > SCR > SCR .Selective Catalytic Reduction SCR .3-4% AdBlue  Euro 5 .Selective Catalytic Reduction  SCR (Selective Catalytic Reduction) .1.01_en Page 187 .catalytic exhaust gas cleaning  Euro 4 .1 October 2006  Difference between Euro 4 and Euro 3  Nitrogen oxides (NO x) reduced by 30%  Particle emissions reduced 80%  AdBlue  Exhaust gases  Catalytic converter  Nitrous oxides .0.4-5% AdBlue Notes GT120017A v.nitrogen gas and steam  Euro 4 . nitrogen gas and steam  Euro 4 .catalytic exhaust gas cleaning  Euro 4 . Be sure that the participants have understood the main purpose of this information.1 October 2006  Difference between Euro 4 and Euro 3  Nitrogen oxides (NO x) reduced by 30%  Particle emissions reduced 80%  AdBlue  Exhaust gases  Catalytic converter  Nitrous oxides . Trainer notes Page 187 (trainer) .3-4% AdBlue  Euro 5 .Selective Catalytic Reduction Key points  SCR (Selective Catalytic Reduction) .SCR > SCR > SCR . Ask question to be sure that the participants have understand the main purpose of this information/text. fault tracing.4-5% AdBlue Working procedure Go through the text in the student material and also add your own experience/knowledge. do not forget to tell them what is happen if they do not understand the basic when they shall e.g. Show the participants the engine parts and explain how they are connected to each other. 1.0.SCR > SCR > Main components in the Volvo SCR system Main components in the Volvo SCR system  Urea tank (AdBlue tank)  Pump unit  Dosing unit  Catalytic converter Notes Page 188 GT120017A v.01_en . Ask question to be sure that the participants have understand the main purpose of this information/text. Trainer notes Page 188 (trainer) . fault tracing.SCR > SCR > Main components in the Volvo SCR system Key points  EU emission  Reductions  Emissions  Particulates (PM)  Nitrous oxides (NOx) Working procedure Go through the text in the student material and also add your own experience/knowledge. Be sure that the participants have understood the main purpose of this information.g. Show the participants the engine parts and explain how they are connected to each other. do not forget to tell them what is happen if they do not understand the basic when they shall e. SCR > SCR > Solution principle for the Volvo SCR system Solution principle for the Volvo SCR system Exhaust gas cleaning in accordance with the SCR technology is a system with only a few components.1.0.  Solution principle Notes GT120017A v.01_en Page 189 . Trainer notes Page 189 (trainer) . fault tracing. Ask question to be sure that the participants have understand the main purpose of this information/text. Be sure that the participants have understood the main purpose of this information. Show the participants the engine parts and explain how they are connected to each other. do not forget to tell them what is happen if they do not understand the basic when they shall e.SCR > SCR > Solution principle for the Volvo SCR system Key points  Main component  SCR system  Urea tank (1)  Pump unit (2)  Dosing unit (3)  Silencer (4)  SCR catalytic converter  Solution principle  Sprayed into the exhaust gases  Atomised form  Before the catalytic converter (5)  Spraying is controlled by the EMS (Engine Management System)  Optimal reduction of emissions  Urea into ammonia and carbon dioxide  Nitrous oxides (NO x) converted into harmless nitrogen gas and steam  200°C Working procedure Go through the text in the student material and also add your own experience/knowledge.g. urea dosing system  Filter  Flow direction valve  Cooling control valve  Non-return valve  Dosing unit  Exhaust temperature sensor  Catalytic converter  NOx sensor (only used for OBD .1.0.On Board Diagnostics) Notes Page 190 GT120017A v.SCR > SCR > Overview of the exhaust gas processing system Overview of the exhaust gas processing system  Urea tank (AdBlue tank)  Urea tank level sensor  Urea tank temperature sensor  Urea solution pump  Urea solution filter  Urea solution pressure sensor  Urea solution temperature sensor  MID233 control unit.01_en . Non-return valve  13. urea dosing system  9. Urea solution temperature sensor  8. Trainer notes Page 190 (trainer) . Exhaust temperature sensor  15.Engine Electronic Control Unit)  Normal operation  10°C  15°C Diesel Oxidation Catalyst. Urea tank temperature sensor  4. Urea solution filter  6. Be sure that the participants have understood the main purpose of this information. Ask question to be sure that the participants have understand the main purpose of this information/text. Urea solution pressure sensor  7. Dosing unit  14. Urea tank (AdBlue tank)  2. Catalytic converter  16.g. do not forget to tell them what is happen if they do not understand the basic when they shall e. Flow direction valve  11. Show the participants the engine parts and explain how they are connected to each other. NOx sensor (only used for OBD . Urea tank level sensor  3. Pressure sensor (3) Temperature sensor (4) Working procedure Go through the text in the student material and also add your own experience/knowledge.On Board Diagnostics)  MID128 (EECU . Cooling control valve  12. DPF (2) Muffler Stainless steel Carbon monoxide (CO) and Hydrocarbons (HC) Carbon dioxide (CO2) and water Nitrogen oxide (NO) Nitrogen dioxide (NO2) 250 and 450 degrees. Filter  10. Urea solution pump  5. MID233 control unit. DOC (1) Diesel Particulate Filter. fault tracing.SCR > SCR > Overview of the exhaust gas processing system Key points  Principles diagram  1. Test 11C Diesel engine fundamentals. Urea tank/AdBlue tank Pump unit Dosing/metering unit Catalytic converter Where in the exhaust system is the Adblue sprayed Just before catalytic converter Just before the turbocharger Just before the outlet from the catalytic converter Put the numbers in the appropriate boxes. Urea tank level sensor Urea tank temperature sensor Urea solution pump Urea solution filter Urea solution pressure sensor GT120017A v.1.01_en Page 191 . Test 11C Put the numbers in the appropriate boxes.0.SCR > SCR > Diesel engine fundamentals. Urea tank/AdBlue tank 2. 2. NOx sensor (only used for OBD . Exhaust temperature sensor 16. Urea solution temperature sensor 8. Filter 10.On Board Diagnostics) Page 191 (trainer) . Urea tank level sensor 3. Non-return valve 14. Flow direction valve 11. Let each participants work with the question for about 5-10 minutes. Test 11C Key Put the numbers in the appropriate boxes.SCR > SCR > Diesel engine fundamentals. Questions that could help to improve the format of the questionnaire in the future may arise. After that shall the trainer go through the correct answer. Urea solution pump 5. Urea tank temperature sensor 4. 1. Additional information Introduction to diesel engines. urea dosing system 9. Dosing/metering unit 4. Catalytic converter Where in the exhaust system is the Adblue sprayed *Just before catalytic converter Just before the turbocharger Just before the outlet from the catalytic converter Put the numbers in the appropriate boxes. Urea solution filter 6. Test 11C Key points  Question  Answer Working procedure Discuss the answers with the participants if there have been any misunderstandings or linguistic problems. MID233 control unit. Cooling control valve 12. Urea solution pressure sensor 7. Pump unit 3. Test 11C Urea solution temperature sensor MID233 control unit.SCR > SCR > Diesel engine fundamentals.01_en .1.0. urea dosing system Filter Flow direction valve Cooling control valve Non-return valve Exhaust temperature sensor NOx sensor (only used for OBD .On Board Diagnostics) Notes Page 192 GT120017A v. SCR > SCR > Diesel engine fundamentals. Test 11C Trainer notes Page 192 (trainer) . 0.CCV > CCV > CCV .01_en Page 193 .1.CrankCase Ventilation .CrankCase Ventilation .Closed CCV .Closed  Hose connection  Connector  Turbine  Drive shaft  Discs  Pressure regulator  Diaphragm Notes GT120017A v. Be sure that the participants have understood the main purpose of this information. Trainer notes Page 193 (trainer) . fault tracing. Ask question to be sure that the participants have understand the main purpose of this information/text. Show the participants the engine parts and explain how they are connected to each other.CCV > CCV > CCV .Closed Key points  CCV = Closed Crankcase Ventilation  Hose connection (1)  Connector (2)  Turbine (3)  Drive shaft (4)  Discs (5)  8 000 rpm  Pressure regulator (6)  Diaphragm (7)  Clean gases  Oil and heavier particles  Function Working procedure Go through the text in the student material and also add your own experience/knowledge.g. do not forget to tell them what is happen if they do not understand the basic when they shall e.CrankCase Ventilation . Hose connection Connector Turbine Drive shaft Discs Pressure regulator Diaphragm What is CCV stands for? Closed crankcase ventilation Clear combustion valve Cooled crankcase by Volvo What is the maximum revolution for the disc inside the separator? 8 000 rpm 18 000 rpm 6 000 rpm Page 194 GT120017A v. Test 11D Put the numbers in the appropriate boxes.0. Test 11D Diesel engine fundamentals.CCV > CCV > Diesel engine fundamentals.1.01_en . Let each participants work with the question for about 5-10 minutes. After that shall the trainer go through the correct answer. Hose connection (1) Connector (2) Turbine (3) Drive shaft (4) Discs (5) Pressure regulator (6) Diaphragm (7) What is CCV stands for? *Closed crankcase ventilation Clear combustion valve Cooled crankcase by Volvo What is the maximum revolution for the disc inside the separator? *8 000 rpm 18 000 rpm 6 000 rpm Where are the clean gases led after the CCV? *The clean gases are led to the turbocharger inlet side via connector. The clean gases are led to the inlet side just before air filter. Additional information Introduction to diesel engines. Test 11D Key Put the numbers in the appropriate boxes. Questions that could help to improve the format of the questionnaire in the future may arise.CCV > CCV > Diesel engine fundamentals. The clean gases are led to the turbocharger outlet side via connector. Trainer notes Page 194 (trainer) . Test 11D Key points  Question  Answer Working procedure Discuss the answers with the participants if there have been any misunderstandings or linguistic problems. 1.0. The clean gases are led to the inlet side just before air filter. Notes GT120017A v. The clean gases are led to the turbocharger outlet side via connector. Test 11D Where are the clean gases led after the CCV? The clean gases are led to the turbocharger inlet side via connector.01_en Page 195 .CCV > CCV > Diesel engine fundamentals. Test 11D Trainer notes Page 195 (trainer) .CCV > CCV > Diesel engine fundamentals. . . 01_en .GT120017A v.0.1.
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