sd 110 step 1 training engine

D5 Engine TrainingD5 Engine Training

Road machine

Engine Identification - 010102g

Engine serial number

Engine identification plate Also on engine cover

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D5 engine training Road machine

168 2012-12-20

Engine serial number

Engine Identification plate - 010103g p

Engine Type plate: Engine model• Engine model

• Engine spec No• Engine serial number (8 digits)• Rated engine speedRated engine speed• Injection timing and type of cam shaft• Injection pump code• Piston class

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D5 engine training Road machine

169 2012-12-20

Engine view from right g g

1. Crank case breather2. Lubricating oil filling3 Injection pump3. Injection pump4. Lubricating oil stick5. Lube oil cooler6. Lube oil replacement filterp7. Lubricating oil drain plug8. Exchangeable fuel filter N/A9. V-belts10. Generator

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Paver D5 engine

170 2012-12-20

Engine view from leftg

1 C b ti i i l t1. Combustion air inlet2. Coolant out let3. Coolant inlet4 Connection charge air cooler4. Connection charge air cooler5. Exhaust outlet6. Starter

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Paver D5 engine

171 2012-12-20

Engine Ignition order - 010104g g

Di ti f t ti C t l k iDirection of rotation: Counter clockwiseAs seen from the fly wheel

Engine Ignition order : 1 – 3 – 4 - 2

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D5 engine training Road machine

172 2012-12-20

g g

Cylinder head valves - 010202y

Valves:

• There are some difference in valve guide• There are some difference in valve guide

• The valve springs of D5D / D7D have nospecial direction of installation and arespecial direction of installation and arereplaceable

• D5D / D7D valve guide are seal with ‘O” rings

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D5 engine training Road machine

173 2012-12-20

Crank mechanism - 010301

• Crank mechanism

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D5 engine training Road machine

174 2012-12-20

Crank mechanism - 010302

D5D & D7D: Wet liner replaceableD5D & D7D: Wet liner replaceable

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D5 engine training Road machine

175 2012-12-20

Crank mechanism - 010303

Connecting rod:

• The connecting rod is made of forged steel and the bearing cap (1) is guided using two guide pin (3)using two guide pin (3)

• Locating lug (2) are provided in bearing shellsbearing shells

• Connecting rod and bearing are marked (4)a ed ( )

• Marking (5) on the piston is to face the fly wheel

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D5 engine training Road machine

176 2012-12-20

Piston - 010304

Max injection pressure 1500 bar

• The pistons are made of special aluminum alloy. The piston is slightly off – Centrep p y p g y(A) in relation to the piston guide pin

• The piston must be installed with fly wheel symbol on the piston top facing the fly wheel

• There are three piston rings. The top ring has a ring carrier made of cast iron

6 h l l

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D5 engine training Road machine

177 2012-12-20

• 6 hole nozzle

Selecting gasket - 010305g g

Gasket holesGasket holes1, 2 & 3

Piston crown clearance:• To obtain the power, fuel consumption and exhaust gas emission specified

for engine the piston height above the block face has to me measured andcorrect thickness for the cylinder head gasket has to be determined

• The piston height is measured using a dial gauge (1) fixture (2) and spacer (3)• The procedure is described in service manual

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D5 engine training Road machine

178 2012-12-20

Engine Timing gear - 010401g g g

1. Governor gearg2. Transfer gear

3. Cam shaft gear

4. Crank shaft gear

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D5 engine training Road machine

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Lubricating oil diagramg g

1. Lubricating oil sump2 Lubricating oil pump2. Lubricating oil pump3. Pressure limiting valve TCD20134. Lube oil cooler5. Check valve TCD 20125. Check valve TCD 20126. Bypass valve7. Bypass valve8. Pressure control valve9. Lubricating oil filter10. Main lube oil channel11. Piston cooling nozzle12. Rocker arm13. Internally switched exhaust gas return14. Turbo charger15 Air compressor

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Paver D5 engine

180 2012-12-20

15. Air compressor

Lubrication system - 020103y

Lubrication system D5D

7. Lube oil filter with integrated by pass valve 2.5 bar

8. By pass valve oil cooler located in oilcooler housing 4.0 bar

9 Oil l l d i il l9. Oil pressure valve located in oil coolerhousing 10 bar

10 Lube oil pump 90 l/min at 2500 rpm10. Lube oil pump 90 l/min at 2500 rpm

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D5 engine training Road machine

181 2012-12-20

Oil pump - 020202p p

1 Suction1. Suction

2. Pressure chamber to crank housing

3. Inner Rotor

4. Outer Rotor

5. Driven from crank shaft

6. Safety valve

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D5 engine training Road machine

182 2012-12-20

Piston Cooling Nozzle - 020301g

• The piston cooling nozzle made of plastic are fitted in the main bearingpedestals

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D5 engine training Road machine

183 2012-12-20

Fuel system - 030101y

• Change unit injector pump for cylinder number 3 on D5D with injection timer• Read off EP code for cylinder No 3 on the engine identification plate under

column EP (1)• Read sequence

Line 1 = cylinder 1Li 2 li d 2 d

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D5 engine training Road machine

184 2012-12-20

Line 2 = cylinder 2 and so on……

Fuel system - 030104 1 Injection pumpy 1. Injection pump

2. Delivery pipe

3. Engine block

4. Shim

5. Roller tappet

6 C h ft6. Cam shaft

7. Fuel rack

8. Fuel duct

9 Injector

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D5 engine training Road machine

185 2012-12-20

9. Injector

Mechanical single injection pump systemg j p p y

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Paver D5 engine

186 2012-12-20

Fuel system - 030105y

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D5 engine training Road machine

187 2012-12-20

Fuel schematic

1. Fuel tank2. Fuel pre-filter3 Fuel pump3. Fuel pump4. Exchangeable fuel filter5. Fuel supply line to the FCU6. Control block fuel control unit7. High pressure pump8. Rail (Not applicable)9. Injector10. Fuel return to fuel tank

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Paver D5 engine

188 2012-12-20

Fuel schematic

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Paver D5 engine

189 2012-12-20

Fuel block diagramg

1. Diesel Tank 2. Water separator 3. Feed pump

4. Fuel filter 5. Fuel supply to fuel control unit / Control block

6. U. I High pressure pump 7. Injector

8. Excess leak return 9. Diesel Tank

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D5 engine training Road machine

8 cess ea e u

Coolant diagram (example)g ( p )

1. Cooler2 Cooler inlet2. Cooler inlet3. Coolant pump4. Coolant partial flow to the lubricating oil cooler5. Lube oil cooler56. Coolant supply for engine cooling7. Cylinder pipe head cooling8. Connection possibility for cab heating9. Heat exchanger10. Return line11. Coolant return to thermostat12 C l t t l t12. Coolant out let13. Compensation line14. Venting pipe

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Paver D5 engine

191 2012-12-20

Schematic outlet controlled cooling systemg y

Expansion Tank

Water out let

Water inlet

Water out let

Thermostat

Water PumpWater Pump

RadiatorEngine oil cooler

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Paver D5 engine

192 2012-12-20

Coolant block diagram (example)g ( p )

1. Oil cooler inlet 2. Water pump 3. Engine cooler

4. Engine block / Head / Engine cylinder Head

5. Thermostat cooler out let 6. By pass thru special lines

7. Oil cooler outlet

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D5 engine training Road machine

Working descriptiong p

The coolant pump (“water pump”) draws in the coolant via hose lines directlyfrom the cooler and delivers it first via the engine-integrated lube oil coolerfrom the cooler and delivers it first via the engine integrated lube oil cooler,thereafter enters the engine, flows along the cylinder, upwards into thecylinder head and to the thermostat at the coolant outlet. From there, the coolant is directed via special lines to the cooler inlet.p

When the engine is still cold the coolant is short circuited through the engineuntil thermostat response temperature has been reached (starting opening)according to the volume of hot coolant flowing off, the water pump draws incold coolant from the cooler

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Paver D5 engine

194 2012-12-20

Coolant thermostat

Checking the thermostat when removed

1. Measure dimension “a” on thermostat

Note: “a” starts of lift at approx 83+2 (T1)Note: a starts of lift at approx. 83+2 (T1)“b” end of lift at approx. 95+5 (T2)

Lift movement with indicated temp T2,Min. 8 mm

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D5 engine training Road machine

Fuel system cylinder No positions -y y p030113

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D5 engine training Road machine

196 2012-12-20

Internal exhaust gas recirculationg

1 Additional cam for exhaust gas recirculation1. Additional cam for exhaust gas recirculation

Inlet valve opens briefly during the outlet cycleand emits an exhaust gas partial flow to theand emits an exhaust gas partial flow to thesuction system.

This partial volume is sucked back in the nextpsuction cycle

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Paver D5 engine

197 2012-12-20

Charging C

g gTurbine

Compressor

Turbo charger with charge air cooling

Advantages:

From filter

g

Volumetric efficiency of engine increasesIncrease Horse PowerEmission improvedCompact in size

To CAC

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Paver D5 engine

198 2012-12-20

Charging piping connectiong g p p g

Air filter

Compressor

CAC

Engine Inlet manifold

Engine exhaust

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Paver D5 engine

199 2012-12-20

Fuel shut off solenoid

Resistance 4.9 ohms

1. Fuel shut off solenoid operates whenth i i iti l 2nd itithere is ignition supply – 2nd position

2. Fuel shut off solenoid + excess fuelsolenoid in 3rd start position

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D5 engine training Road machine

200 2012-12-20

Excess fuel solenoid

1. Excess fuel solenoid

2. Sensor Not applicable

1. Fuel shut off solenoid operates whenth i i iti l 2nd itithere is ignition supply – 2nd position

2. Fuel shut off solenoid + excess fuelsolenoid in 3rd start position

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Electrical Harness Installation –SD110

201 2012-12-20

Engine oil pressure switchg p

Engine oil pressure switchEngine oil pressure switch

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D5 engine training Road machine

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Engine water temperature switchg p

Engine Water temperature switchEngine Water temperature switch

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D5 engine training Road machine

203 2012-12-20

Engine glow plugg g p g

Engine Glow plugEngine Glow plug

Time - 8 seconds

Temperature 950 0 c

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D5 engine training Road machine

204 2012-12-20

Diesel tank fuel sender

Fuel sender

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D5 engine training Road machine

205 2012-12-20

Mechanical governorg

Governor adjustment screws

Full load “G”J

Torque maximum “E”

EG

NA based fuel charge “J”

Excess fuel start solenoid

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Paver D5 engine

206 2012-12-20

Engine V- beltg

Procedure Change Engine V beltProcedure Change Engine V belt

V – belt AVX 11 (Width 11 mm)

Belt tensioning – Automatic tensioningSpring – loaded clamping roller

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D5 engine training Road machine

Removing the Starter motorg

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D5 engine training Road machine

Installing the Starter motorg

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D5 engine training Road machine

EK code - 030114

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D5 engine training Road machine

210 2012-12-20

A measurement - 030115

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D5 engine training Road machine

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Dimensions, definitions - 030116

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Theoretical shim thickness - 030118

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D5 engine training Road machine

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Actual shim thickness - 030119

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D5 engine training Road machine

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Reinstallation - 030120

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D5 engine training Road machine

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Special tools - 030121p

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D5 engine training Road machine

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Unit pump installation - 030122p p

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D5 engine training Road machine

217 2012-12-20

Unit pump installation - 030123p p

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D5 engine training Road machine

218 2012-12-20

Assembly injection pumpy j p p

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D5 engine training Road machine

219 2012-12-20

Unit injection pump systemj p p y

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D5 engine training Road machine

220 2012-12-20

Explanation Lo & EP- code for D5D enginesp g

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D5 engine training Road machine

221 2012-12-20

EP-Code on identification platep

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D5 engine training Road machine

222 2012-12-20

Determination compensation shimp

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D5 engine training Road machine

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From value TS to SSS S

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D5 engine training Road machine

224 2012-12-20

F I P installation, step 1p

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D5 engine training Road machine

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F I P installation, step 2p

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D5 engine training Road machine

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Example – Lubricating oil consumptionp g p(at least 100 operating hours) engine in high load operation

Op. h Fuel Lts Lube oil Date Driver Example9 423 2 15.2 12 Paul12 551 2 16.2.1213 523 2 17.2.1213 523 2 17.2.1211 600 2 18.2.12 Shashi13 620 2 19.2.1214 590 2 20 2 1214 590 2 20.2.1210 450 2 21.2.12 Ballal11 597 2 22.2.1212 580 2 23.2.1213 620 2 24.2.12 Ramalu

118 5554 20

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118 5554 20

D5 engine training Road machine

Example – Lubricating oil consumptionp g p(at least 100 operating hours) engine in high load operation

Calculation example:

Fuel consumption = 5554 lLubricating oil consumption = 20 l

Calculation:

5554 l = 100%

20 l = x

100 %20 L

5554 L= 0.36 %X =

20 l = x

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D5 engine training Road machine