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Product:EXCAVATOR
Model:235EXCAVATOR81X
Configuration:235EXCAVATOR81X00001UP(MACHINE)POWEREDBY
3306ENGINE

SystemsOperation
3306DIRECTINJECTIONENGINEFORCATERPILLARBUILTMACHINES
MediaNumberSENR205703

PublicationDate01/12/1992

DateUpdated17/10/2001

SystemsOperation

Introduction
NOTE:ForSpecificationswithillustrations,makereferencetoSpecificationsfor3306DirectInjectionVehicularEngineWithNewScrollFuel
System,FormNo.SENR2056.IftheSpecificationsinFormSENR2056arenotthesameasintheSystemsOperationandtheTestingandAdjusting,
lookattheprintingdateonthebackcoverofeachbook.UsetheSpecificationsgiveninthebookwiththelatestdate.

EngineDesign


CylinderAndValveLocation

Bore...120.7mm(4.75in.)
Stroke...152.4mm(6.00in.)
NumberofCylinders...6
CylinderArrangement...inline
ValvesperCylinder...2
Combustion...DirectInjection
FiringOrder(InjectionSequence)...1,5,3,6,2,4
RotationofCrankshaft(whenseenfromflywheelend)...counterclockwise
NOTE:TheNo.1cylinderisoppositetheflywheelend.

FuelSystem

FuelFlow

FuelSystemSchematic
(1)Fueltank.(2)Fuelreturnline.(3)Primingpump.(4)Fuelinjectionnozzle.(5)Fuelinjectionline.(6)Fuelinjectionpump.(7)Primaryfuelfilter.(8)Checkvalves.(9)Fuel
transferpump.(10)Secondaryfuelfilter.(11)Constantbleedvalve.(12)Fuelinjectionpumphousing.

Fuelispulledfromfueltank(1)throughprimaryfuelfilter(7)andcheckvalves(8)byfueltransferpump(9).Fromthefueltransferpumpthefuelis
pushedthroughsecondaryfuelfilter(10)andtothefuelmanifoldinfuelinjectionpumphousing(12).Abypassvalveinthefueltransferpumpkeeps
thefuelpressureinthesystemat25to40psi(170to280kPa).Constantbleedvalve(11)letsaconstantflowoffuelgothroughfuelreturnline(2)

backtofueltank(1).Theconstantbleedvalvereturnsapproximately9gal.(34liters)perhouroffuelandairtothefueltank.Thishelpskeepthefuel
coolandfreeofair.Thereisalsoamanualbleedvalvethatcanbeusedwhenthefuelprimingpumpisusedtoremoveairfromthesystem.Fuel
injectionpump(6)getsfuelfromthefuelmanifoldandpushesfuelatveryhighpressurethroughfuelline(5)tofuelinjectionnozzle(4).Thefuel
injectionnozzlehasverysmallholesinthetipthatchangetheflowoffueltoaveryfinespraythatgivesgoodfuelcombustioninthecylinder.

FuelInjectionPump
Thefuelinjectionpumpincreasesthepressureofthefuelandsendsanexactamountoffueltothefuelinjectionnozzle.Thereisonefuelinjection
pumpforeachcylinderintheengine.
Thefuelinjectionpumpismovedbycam(14)ofthefuelpumpcamshaft.Whenthecamshaftturns,thecamraiseslifter(11)andpumpplunger(6)to
thetopofthestroke.Thepumpplungeralwaysmakesafullstroke.Asthecamshaftturnsfarther,spring(8)returnsthepumpplungerandliftertothe
bottomofthestroke.
Whenthepumpplungerisatthebottomofthestroke,fuelattransferpumppressuregoesintoinletpassage(2),aroundpumpbarrel(4)andtobypass
closedport(5).Fuelfillstheareaabovethepumpplunger.
Afterthepumpplungerbeginstheupstroke,fuelwillbepushedoutthebypassclosedportuntilthetopofthepumpplungerclosestheport.Asthe
pumpplungertravelsfartherup,thepressureofthefuelincreases.Atapproximately100psi(690kPa),checkvalve(1)opensandletsfuelflowinto
thefuelinjectionlinetothefuelinjectionnozzle.Whenthepumpplungertravelsfartherup,scroll(9)uncoversspillport(10).Thefuelabovethe
pumpplungergoesthroughslot(7),alongtheedgeofscroll(9)andoutspillport(10)backtofuelmanifold(3).Thisistheendoftheinjectionstroke.
Thepumpplungercanhavemoretravelup,butnomorefuelwillbesenttothefuelinjectionnozzle.


FuelInjectionPump
(1)Checkvalve.(2)Inletpassage.(3)Fuelmanifold.(4)Pumpbarrel.(5)Bypassclosedport.(6)Pumpplunger.(7)Slot.(8)Spring.(9)Scroll.(10)Spillport.(11)Lifter.(12)Fuel
rack.(13)Gear.(14)Cam.

Whenthepumpplungertravelsdownanduncoversbypassclosedport(5),fuelbeginstofilltheareaabovethepumpplungeragain,andthepumpis
readytobeginanotherstroke.

Theamountoffueltheinjectionpumpsendstotheinjectionnozzleischangedbytherotationofthepumpplunger.Gear(13)isattachedtothepump
plungerandisinmeshwithfuelrack(12).Thegovernormovesthefuelrackaccordingtothefuelneedsoftheengine.Whenthegovernormovesthe
fuelrack,andthefuelrackturnsthepumpplunger,scroll(9)changesthedistancethepumpplungerpushesfuelbetweenbypassclosedport(5)and
spillport(10)opening.Thelongerthedistancefromthetopofthepumpplungertothepointwherescroll(9)uncoversspillport(10),themorefuel
willbeinjected.
Tostoptheengine,thepumpplungerisrotatedsothatslot(7)onthepumpplungerisinlinewithspillport(10).Thefuelwillnowgooutthespill
portandnottotheinjectionnozzle.

FuelInjectionNozzle
Thefuelinjectionnozzlegoesthroughthecylinderheadintothecombustionchamber.Thefuelinjectionpumpsendsfuelwithhighpressuretothe
fuelinjectionnozzlewherethefuelismadeintoafinesprayforgoodcombustion.

FuelInjectionNozzle
(1)Carbondam.(2)Seal.(3)Passage.(4)Filterscreen.(5)Orifice.(6)Valve.(7)Diameter.(8)Spring.

Seal(2)goesagainstthecylinderheadandpreventsleakageofcompressionfromthecylinder.Carbondam(1)keepscarbonoutoftheboreinthe
cylinderheadforthenozzle.
Fuelwithhighpressurefromthefuelinjectionpumpgoesintotheinletpassage.Fuelthengoesthroughfilterscreen(4)andintopassage(3)tothe
areabelowdiameter(7)ofvalve(6).Whenthepressureofthefuelthatpushesagainstdiameter(7)becomesgreaterthantheforceofspring(8),valve
(6)liftsup.ThisoccurswhenthefuelpressuregoesabovetheValveOpeningPressureofthefuelinjectionnozzle.Whenvalve(6)lifts,thetipofthe
valvecomesoffthenozzleseatandthefuelwillgothroughorifices(5)intothecombustionchamber.
Theinjectionoffuelcontinuesuntilthepressureoffuelagainstdiameter(7)becomeslessthantheforceofspring(8).Withlesspressureagainst
diameter(7),spring(8)pushesvalve(6)againstthenozzleseatandstopstheflowoffueltothecombustionchamber.
Thefuelinjectionnozzlecannotbedisassembledandnoadjustmentscanbemade.

FuelTransferPump(7N6831)

FuelTransferPumpSchematic(UpStroke)
(1)Bypassvalve.(2)Pumpingspring.(3)Smallpiston.(4)Outlet.(5)Inletcheckvalve.(6)Pushplate.(7)Pumpingcheckvalve.(8)Outletcheckvalve.(9)Largepiston.(10)Push
rod.

Thefueltransferpumpisatwopistonpumpthatismovedbyacam(eccentric)onthecamshaftforthefuelinjectionpump.Thetransferpumpis
locatedontherightsideofthefuelinjectionpumphousing.

Whenthecamshaftturns,thecamliftspushrod(10)up.Thepushrodliftslargepiston(9),pushplate(6)andsmallpiston(3).Asthepistonsmove
up,inletcheckvalve(5)andoutletcheckvalve(8)close.Pumpingcheckvalve(7)inthelargepistonopensandfuelgoesthroughtheholesinthe
bottomofthelargepistonandfillsthepassagesandchamberbetweenthebottomofthelargepistonandoutletcheckvalve(8).Assmallpiston(3)
movesup,thepressureofthefuelabovethepistonincreasesandflowsoutofthepumpthroughoutlet(4).

FuelTransferPumpSchematic(DownStroke)
(1)Bypassvalve.(2)Pumpingspring.(3)Smallpiston.(4)Outlet.(5)Inletcheckvalve.(6)Pushplate.(7)Pumpingcheckvalve.(8)Outletcheckvalve.(9)Largepiston.(10)Push
rod.

Asthecamshaftcontinuestoturn,thecamlowerspushrod(10)down.Pumpingspring(2)pushessmallpiston(3),pushplate(6)andlargepiston(9)
down.Whenthepistonmovesdown,inletcheckvalve(5)andoutletcheckvalve(8)open.Pumpingcheckvalve(7)inthelargepistonclosesandthe
pressureofthefuelbelowthecheckvalveincreases.Fuelnowflowsthroughtheoutletcheckvalve.Apartofthefuelgoesthroughoutlet(4)andthe
remaindergoestotheareaabovesmallpiston(3).
Asthelargepistonmovesdown,fuelfromthefueltankispulledthroughinletcheckvalve(5)intotheareabetweenthelargeandsmallpiston.The
pumpisnowreadytostartanewcycle.
Bypassvalve(1)controlstheoutletpressureofthefuel.Ifthefuelpressuregoesbeyond170to280kPa(25to40psi),thebypassvalveopensand
fuelflowstotheinletofthepump.

FuelTransferPump(1W1695)

Thefueltransferpumpisapistonpumpthatismovedbyacam(eccentric)onthecamshaftforthefuelinjectionpump.Thetransferpumpislocated
onthebottomsideofthefuelinjectionpumphousing.

FuelTransferPump(StartOfDownStroke)(ArrowsIndicateFuelFlowDirection)

(1)Pushrod.(2)Piston.(3)Outletcheckvalve.(4)Pumpingcheckvalve.(5)Pumpingspring.(6)Pumpinletport.(7)Inletcheckvalve.(8)Pumpoutletport.

Whenthefuelinjectionpumpcamshaftturns,thecammovespushrod(1)andpiston(2)down.Asthepistonmovesdown,inletcheckvalve(7)and
outletcheckvalve(3)close.Pumpingcheckvalve(4)opensandallowsthefuelbelowthepistontomoveintotheareaabovethepiston.Pumping
spring(5)iscompressedasthepistonispusheddownbypushrod(1).
Asthefuelinjectionpumpcamshaftcontinuestoturn,thecamnolongerputsforceonpushrod(1).Pumpingspring(5)nowmovespiston(2)up.
Thiscausespumpingcheckvalve(4)toclose.Inletcheckvalve(7)andoutletcheckvalve(3)willopen.Asthepistonmovesup,thefuelinthearea
abovethepistonispushedthroughtheoutletcheckvalve(3)andoutpumpoutletport(8).Fuelalsomovesthroughpumpinletport(6)andinlet
checkvalve(7)tofilltheareabelowpiston(2).Thepumpisnowreadytostartanewcycle.


FuelTransferPump(StartOfUpStroke)(ArrowsIndicateFuelFlowDirection)
(1)Pushrod.(2)Piston.(3)Outletcheckvalve.(4)Pumpingcheckvalve.(5)Pumpingspring.(6)Pumpinletport.(7)Inletcheckvalve.(8)Pumpoutletport.

OilFlowForFuelPumpAndGovernor
Oilfromthesideofthecylinderblockgoestosupport(9)andintothebottomoffrontgovernorhousing(4).Theflowofoilnowgoesinthree

differentdirections.
Apartoftheoilgoestotherearcamshaftbearinginfuelpumphousing(5).Thebearinghasagroovearoundtheinsidediameter.Oilgoesthroughthe
grooveandintotheoilpassageinthebearingsurface(journal)ofcamshaft(7).Adrilledpassagethroughthecenterofthecamshaftgivesoiltothe
frontcamshaftbearingandtothethrustfaceofthecamshaftdrivegear.Drainhole(6)inthefrontoffuelpumphousing(5)keepstheleveloftheoil
inthehousingevenwiththecenterofthecamshaft.Theoilreturnstotheoilpanthroughthetiminggearhousing.

FuelPumpAndGovernor
(1)Cover.(2)Servo.(3)Reargovernorhousing.(4)Frontgovernorhousing.(5)Fuelpumphousing.(6)Drainhole.(7)Camshaft.(8)Drainhole.(9)Support.

Oilalsogoesfromthebottomofthefrontgovernorhousingthroughapassagetothefuelpumphousingandtogovernorservo(2).Thegovernor
servogiveshydraulicassistancetomovethefuelrack.
Theremainderoftheoilgoesthroughpassagestotherearofreargovernorhousing(3),throughcover(1)andbackintoanotherpassageintherear

governorhousing.Nowtheoilgoesintothecompartmentforthegovernorcontrols.Drainhole(8)keepstheoilatthecorrectlevel.Theoilinthis
compartmentisusedforlubricationofthegovernorcontrolcomponentsandtheoilisthesupplyforthedashpot.
Theinternalpartsofthegovernorarelubricatedbyoilleakagefromtheservoandtheoilisthrownbypartsinrotation.Theflyweightcarrierthrust
bearinggetsoilfromthepassageattherearofthecamshaft.
Oilfromthegovernorreturnstotheoilpanthroughaholeinthebottomofthefrontgovernorhousingandthroughpassagesinthesupportand
cylinderblock.

Governor
Thegovernorcontrolstheamountoffuelneededbytheenginetomaintainadesiredrpm.


Governor
(1)Governorspring.(2)Sleeve.(3)Valve.(4)Piston.(5)Governorservo.(6)Fuelrack.(7)Lever.(8)Flyweights.(9)Overfuelingspring.(10)Riser.(11)Springseat.(12)Stopbolt.
(13)Torquespring.(14)Powersettingscrew.(15)Torquerisesettingscrew.(16)Stopcollar.(17)Stopbar.

Thegovernorflyweights(8)aredrivendirectlybythefuelpumpcamshaft.Riser(10)ismovedbyflyweights(8)andgovernorspring(1).Lever(7)
connectstheriserwithsleeve(2)whichisfastenedtovalve(3).Valve(3)isapartofgovernorservo(5)andmovespiston(4)andfuelrack(6).The
fuelrackmovestowardthefrontofthefuelpumphousing(totherightintheillustration)whenmovedintheFUELOFFdirection.

Theforceofgovernorspring(1)alwayspushestogivemorefueltotheengine.Thecentrifugal(rotating)forceofflyweights(8)alwayspushtogeta
reductionoffueltotheengine.Whenthesetwoforcesareinbalance(equal),theenginerunsataconstantrpm.
Whentheengineisstartedandthegovernorisatthelowidleposition,overfuelingspring(9)movestheriserforwardandgivesanextraamountof
fueltotheengine.Whentheenginehasstartedandbeginstorun,theflyweightforcebecomesgreaterthantheforceoftheoverfuelingspring.The
risermovestotherearandreducestheamountoffueltothelowidlerequirementoftheengine.
Whenthegovernorcontrolleverismovedtothehighidleposition,governorspring(1)isputincompressionandpushesriser(10)towardthe
flyweights.Whentherisermovesforward,lever(7)movessleeve(2)andvalve(3)towardtherear.Valve(3)stopsoilflowthroughgovernorservo
(5)andtheoilpressuremovespiston(4)andthefuelracktotherear.Thisincreasestheamountoffueltotheengine.Asenginespeedincreases,the
flyweightforceincreasesandmovestherisertowardthegovernorspring.Whentherisermovestotherear,lever(7)movessleeve(2)andvalve(3)
forward.Valve(3)nowdirectsoilpressuretotherearofpiston(4)andmovesthepistonandfuelrackforward.Thisdecreasestheamountoffuelto
theengine.Whentheflyweightforceandthegovernorspringforcebecomeequal,theenginespeedisconstantandtheenginerunsathighidlerpm.
Highidlerpmisadjustedbythehighidleadjustmentscrew.Theadjustmentscrewlimitstheamountofcompressionofthegovernorspring.
Withtheengineathighidle,whentheloadisincreased,enginespeedwilldecrease.Flyweights(8)moveinandgovernorspring(1)pushesriser(10)
forwardandincreasestheamountoffueltotheengine.Astheloadisincreasedmore,govenorspring(1)pushesriser(10)fartherforward.Springseat
(11)pullsonstopbolt(12).Stopcollar(16)ontheoppositeendhaspowersettingscrew(14)andtorquerisesettingscrew(15)thatcontrolthe
maximumamountoffuelracktravel.Thepowersettingscrewmovesforwardandmakescontactwithtorquespring(13).Thisisthefullloadbalance
point.Ifmoreloadisaddedtotheengine,enginespeedwilldecreaseandpushriser(10)forwardmore.Thiswillcausepowersettingscrew(14)to
bend(deflect)torquespring(13)untiltorquerisesettingscrew(15)makescontactwithstopbar(17).Thisisthepointofmaximumfueltotheengine.

GovernorServo
Thegovernorservogiveshydraulicassistancetothemechanicalgovernorforcetomovethefuelrack.Thegovernorservohascylinder(3),cylinder
sleeve(4),piston(2)andvalve(1).


GovernorServo(FuelOnPosition)
(1)Valve.(2)Piston.(3)Cylinder.(4)Cylindersleeve.(5)Fuelrack.(A)Oilinlet.(B)Oiloutlet.(C)Oilpassage.(D)Oilpassage.

WhenthegovernormovesintheFUELONdirection,valve(1)movestotheleft.Thevalveopensoiloutlet(B)andclosesoilpassage(D).Pressure
oilfromoilinlet(A)pushespiston(2)andfuelrack(5)totheleft.Oilbehindthepistongoesthroughoilpassage(C),alongvalve(1)andoutoil
outlet(B).

GovernorServo(BalancedPosition)
(1)Valve.(2)Piston.(3)Cylinder.(4)Cylindersleeve.(5)Fuelrack.(A)Oilinlet.(B)Oiloutlet.(C)Oilpassage.(D)Oilpassage.

Whenthegovernorspringandflyweightforcesarebalancedandtheenginespeedisconstant,valve(1)stopsmoving.Pressureoilfromoilinlet(A)
pushespiston(2)untiloilpassages(CandD)areopened.Oilnowflowsthroughoilpassage(D)alongvalve(1)andoutthroughoiloutlet(B).With
nooilpressureonthepiston,thepistonandfuelrack(5)stopmoving.


GovernorServo(FuelOffPosition)
(1)Valve.(2)Piston.(3)Cylinder.(4)Cylindersleeve.(5)Fuelrack.(A)Oilinlet.(B)Oiloutlet.(C)Oilpassage.(D)Oilpassage.

WhenthegovernormovesintheFUELOFFdirection,valve(1)movestotheright.Thevalveclosesoiloutlet(B)andopensoilpassage(D).
Pressureoilfromoilinlet(A)isnowonbothsidesofpiston(2).Theareaofthepistonisgreaterontheleftsidethanontherightsideofthepiston.
Theforceoftheoilisalsogreaterontheleftsideofthepistonandmovesthepistonandfuelrack(5)totheright.

Dashpot
Thedashpothelpsgivethegovernorbetterspeedcontrolwhentherearesuddenspeedandloadchanges.Thedashpothascylinder(1),piston(2),
dashpotspring(3),needlevalve(5)andcheckvalve(6).Piston(2)andspringseat(4)arefastenedtodashpotspring(3).

Dashpot(GovernorMovingtoFuelOn)

(1)Cylinder.(2)Piston.(3)Dashpotspring.(4)Springseat.(5)Needlevalve.(6)Checkvalve.(7)Oilreservoir.

WhenthegovernormovestowardFUELON,springseat(4)andpiston(2)movetotheright.Thismovementpullsoilfromoilreservoir(7)through
checkvalve(6)andintocylinder(1).

Dashpot(GovernorMovingtoFuelOff)
(1)Cylinder.(2)Piston.(3)Dashpotspring.(4)Springseat.(5)Needlevalve.(6)Checkvalve.(7)Oilreservoir.

WhenthegovernormovestowardFUELOFF,springseat(4)andpiston(2)movetotheleft.Thismovementpushesoiloutofcylinder(1),through
needlevalve(5)andintooilreservoir(7).
Ifthegovernormovementisslow,theoilgivesnorestrictiontothemovementofthepistonandspringseat.Ifthegovernormovementisfastinthe
FUELOFFdirection,theneedlevalvegivesarestrictiontotheoilandthepistonandspringseatwillmoveslowly.

AirInletAndExhaustSystem
Theairinletandexhaustsystemcomponentsare:aircleaner,inletmanifold,cylinderhead,valvesandvalvesystemcomponents,exhaustmanifold
andturbocharger.


AirInletAndExhaustSystem
(1)Exhaustmanifold.(2)Inletmanifoldpipe.(3)Enginecylinders.(4)Airinlet.(5)Turbochargercompressorwheel.(6)Turbochargerturbinewheel.(7)Exhaustoutlet.

Cleaninletairfromtheaircleanerispulledthroughtheairinlet(4)oftheturbochargerbytheturningcompressorwheel(5).Thecompressorwheel
causesacompressionoftheair.Theairthengoestotheinletmanifold(2)oftheengine.Whentheintakevalvesopen,theairgoesintotheengine
cylinder(3)andismixedwiththefuelforcombustion.Whentheexhaustvalvesopen,theexhaustgasesgooutoftheenginecylinderandintothe
exhaustmanifold(1).Fromtheexhaustmanifold,theexhaustgasesgothroughthebladesoftheturbinewheel(6).Thiscausestheturbinewheeland
compressorwheeltoturn.Theexhaustgasesthengoouttheexhaustoutlet(7)oftheturbocharger.

TurbochargerAndAftercooler


TurbochargerAndAftercoolerInstalled
(1)Aftercoolerhousing.(2)Exhaustoutlet.(3)Turbinewheelhousing.(4)Airoutlet.(5)Compressorwheelhousing.(6)Airinlet.(7)Cylinderhead.(8)Exhaustmanifold.(9)
Exhaustinlet.(10)Cylinderbore.

Aftercooler
(1)Aftercoolerhousing.(3)Turbinewheelhousing.(4)Airoutlet.(7)Cylinderhead.

Theaftercoolercoolstheaircomingoutoftheturbochargerbeforeitgoesintotheinletmanifold.Thepurposeofthisistomaketheairgoingintothe
combustionchambersmoredense.Themoredensetheairis,themorefueltheenginecanburnefficiently.Thisgivestheenginemorepower.

Turbocharger
(1)Aftercoolerhousing.(2)Exhaustoutlet.(3)Turbinewheelhousing.(4)Airoutlet.(5)Compressorwheelhousing.(6)Airinlet.(8)Exhaustmanifold.(9)Exhaustinlet.

Turbocharger
Theturbochargerisinstalledontheexhaustmanifold.Alltheexhaustgasesfromtheenginegothroughtheturbocharger.


Turbocharger(TypicalExample)
(1)Airinlet.(2)Compressorhousing.(3)Nut.(4)Compressorwheel.(5)Thrustbearing.(6)Centerhousing.(7)Lubricationinletpassage.(8)Turbinehousing.(9)Sleeve.(10)
Turbinewheel.(11)Exhaustoutlet.(12)Sleeve.(13)Oildeflector.(14)Bearing.(15)Lubricationoutletpassage.(16)Bearing.(17)Exhaustinlet.

Theexhaustgasesentertheturbinehousing(8)andgothroughthebladesofturbinewheel(10),causingtheturbinewheelandcompressorwheel(4)
toturn.
Whenthecompressorwheelturns,itpullsfilteredairfromtheaircleanersthroughthecompressorhousingairinlet.Theairisputincompressionby
actionofthecompressorwheelandispushedtotheinletmanifoldoftheengine.
Whenengineloadincreases,morefuelisinjectedintotheenginecylinders.Thevolumeofexhaustgasincreaseswhichcausestheturbocharger
turbinewheelandcompressorimpellertoturnfaster.Theincreasedrpmoftheimpellerincreasesthequantityofinletair.Astheturbocharger
providesadditionalinletair,morefuelcanbeburned.Thisresultsinmorehorsepowerfromtheengine.
Maximumrpmoftheturbochargeriscontrolledbytheracksetting,thehighidlespeedsettingandtheheightabovesealevelatwhichtheengineis

operated.

NOTICE
IfthehighidlerpmorthefuelsettingishigherthangivenintheFuel
SettingAndReleatedInformationFiche(fortheheightabovesealevel
atandwhichtheengineisoperated),therecanbedamagetoengineor
turbochargerparts.Damagewillresultwhenincreasedheatand/or
friction,duetothehigherengineoutput,goesbeyondtheengine
coolingandlubricationsystemsabilities.

Thebearingsfortheturbochargeruseengineoilforlubrication.Theoilcomesinthroughthelubricationinletpassage(7)andgoesthroughpassages
inthecentersectionforlubricationofthebearings.Oilfromtheturbochargergoesoutthroughthelubricationoutletpassage(15)inthebottomofthe
centersectionandgoesbacktotheenginelubricationsystem.

CylinderHeadAndValves
Thereisonecylinderheadforallcylinders.Eachcylinderhasoneintakeandoneexhaustvalve.Eachintakeandexhaustvalvehasavalverotator.
Thevalverotatorcausesthevalvetoturnasmallamounteachtimethevalveopensandcloses.Thisactionhelpskeepcarbondepositsoffofthevalve
faceandvalveseat.
Thecylinderheadhasvalveseatsinstalledandtheycanbereplaced.
Thevalveguidescanbereplaced.Therearethreadsontheinsidediameterofthevalveguidestoholdoilthatlubricatesthevalvestem.

ValveMechanism
Thevalvemechanismcontrolstheflowofinletairandexhaustgasesinandoutofthecylinders.Thevalvemechanismconsistsofrockerarms,push
rods,valveliftersandcamshaft.
Thecamshaftisdrivenbyandtimedtothecrankshaft.Whenthecamshaftturns,thecamshaftlobesmovethevalveliftersupanddown.Thevalve
liftersmovethepushrodswhichmovetherockerarms.Movementoftherockerarmsmaketheintakeandexhaustvalvesopenaccordingtothefiring
order(injectionsequence)oftheengine.Avalvespringforeachvalvemakesthevalvegobacktotheclosedpositionandholdsitthere.

LubricationSystem
SystemOilFlow


LubricationSystemSchematic(EngineWarm)

(1)Oilpassage(tofrontidlergear).(2)Oilpassage(toturbochargerandfuelinjectionpump).(3)Rockerarmshaft.(4)Oilpressureconnection.(5)Oilmanifold.(6)Pistoncooling
orifices.(7)Camshaftbearingbore.(8)Oilcoolerbypassvalve.(9)Oilfilterbypassvalve.(10)Engineoilcooler.(11)Oilfilter.(12)Turbocharger.(13)Oilpump.(14)Oilpan.

Oilpump(13)pullsoilfromoilpan(14)andthenpushestheoiltooilcooler(10).Fromtheoilcoolertheoilgoestooilfilter(11)andthentooil
manifold(5).Fromtheoilmanifold,oilgoestoallmainbearings,andpistoncoolingorifices(6).Oilpassagesinthecrankshaftsendoiltothe
connectingrodbearings.Oilfromthefrontmainbearinggoesthroughoilpassage(1)tothebearingforthefuelinjectionpumpidlergear.Oilfrom
thefrontmainbearingalsogoestocamshaftbearingbore(7).Thefrontcamshaftbearingistheonlybearingtogetpressurelubrication.
Oilpassage(2)fromNo.4mainbearingsendsoiltoturbocharger(12)andthefuelinjectionpumphousingontherightsideoftheengine.
Anoilpassagefromtherearofthecylinderblockgoesbelowtheheadboltholeandconnectswithadrilledpassagethatgoesupnexttotheheadbolt
hole.Ahollowdowelconnectstheverticaloilpassageinthecylinderblocktotheoilpassageinthehead.Thespacerplatehasaholewitha
counterboreoneachsidethatthehollowdowelgoesthrough.AnOringisineachcounterboretopreventoilleakagearoundthehollowdowel.Oil
flowsthroughthehollowdowelintoaverticalpassageinthecylinderheadtotherockerarmshaftbracket.Therockerarmshafthasanorificeto
restricttheoilflowtotherockerarms.TherearrockerarmbracketalsohasanOringthatsealsagainsttheheadbolt.Thissealpreventsoilfrom
goingdownaroundtheheadboltandleakingpasttheheadgasketorspacerplategasket.TheOringmustbereplacedeachtimetheheadboltis
removedfromtherearrockerarmbracket.


RockerArmOilSupply

Holesintherockerarmshaftslettheoilgivelubricationtothevalvesystemcomponentsinthecylinderhead.Afterthelubricationoilhasdoneits
work,itgoesbacktotheengineoilpan.
Thereisabypassvalveintheoilpump.Thisbypassvalvecontrolsthepressureoftheoilcomingfromtheoilpump.Theoilpumpcanputmoreoil
intothesystemthanisneeded.Whenthereismoreoilthanneeded,theoilpressureincreasesandthebypassvalvewillopen.Thisallowstheoilthat
isnotneededtogobacktotheengineoilpan.
Withtheenginecold(startingconditions),bypassvalves(8and9)willopenandgiveimmediatelubricationtoallcomponentswhencoldoilwith
highviscositycausesarestrictiontotheoilflowthroughoilcooler(10)andoilfilter(11).Oilpump(13)sendsthecoldoilthroughthebypassvalves
aroundtheoilcoolerandoilfiltertooilmanifold(5)inthecylinderblock.
Whentheoilgetswarm,thepressuredifferenceinthebypasvalvesdecreasesandthebypassvalvesclose.Nowthereisanormalflowofoilthrough
theoilcoolerandoilfilter.

Thebypassvalveswillalsoopenwhenthereisarestrictionintheoilcooleroroilfilter.Thisactiondoesnotletanoilcooleroroilfilterwitha
restrictionpreventlubricationoftheengine.

FlowOfOil(EngineCold)
(8)Oilcoolerbypass.(9)Oilfilterbypass.(10)Engineoilcooler.(11)Oilfilter.(12)Turbocharger.(13)Oilpump.(14)Oilpan.

CoolingSystem
CoolantFlow(EngineWithWaterCooledTurbocharger)


CoolantFlow(EngineWithWaterCooledTurbocharger)
(1)Radiator.(2)Inletlinetoradiator.(3)Turbochargerventline.(4)Watertemperatureregulator.(5)Returnlinefromturbocharger.(6)Inletlinetoturbocharger.(7)Cylinder
head.(8)Cylinderblock.(9)Inletlinetowaterpump.(10)Waterpump.(11)Internalbypass.(12)Engineoilcooler.(13)Elbow.(14)Cylinderliner.

Waterpump(10)isontheleftfrontoftheengine.Thewaterpumpisgeardrivenbythefronttiminggears.Therotationoftheimpellerinthewater
pumppushescoolantthroughthecoolingsystem.
Coolantfromthebottomofradiator(1)ispulledthroughinletline(9)bywaterpump(10).Thewaterpumppushescoolanttoengineoilcooler(12).
Coolantflowsfromtheengineoilcoolerthroughelbow(13)intothesideofcylinderblock(8)andflowsaroundcylinderliners(14)andupthrough

thecoolantdirectorsintocylinderhead(7).Thecoolantdirectorsmakethecoolantflowaroundthevalvesandaroundtheexhaustports(passages)in
thecylinderhead.Thecoolantnowgoestothefrontofthecylinderhead.Atthefrontofthecylinderheadwatertemperatureregulator(4)controlsthe
directionofthecoolantflow.Ifthecoolanttemperatureislessthannormalforengineoperation,thewatertemperatureregulatorisclosed.The
coolantmustgothroughinternalbypass(11)tothewaterpump.Whenthecoolantgetstothetemperatureofnormaloperationthewatertemperature
regulatoropensandmostofthecoolantflowsthroughradiatorinletline(2)totheradiator.Apartofthecoolantstillgoesthroughinternalbypass
(11).
NOTE:Thewatertemperatureregulator(4)isanimportantpartofthecoolingsystem.Itdividescoolantflowbetweenradiator(1)andinternal
bypass(11)asnecessarytomaintainthecorrecttemperature.Ifthewatertemperatureregulatorisnotinstalledinthesystem,thereisnomechanical
control,andmostofthecoolantwilltakethepathofleastresistancethroughthebypass.Thiswillcausetheenginetooverheatinhotweather.Incold
weather,eventhesmallamountofcoolantthatgoesthroughtheradiatoristoomuch,andtheenginewillnotgettonormaloperatingtemperatures.
Coolantgoesfromelbow(13)throughline(6)tothecenterhousingoftheturbocharger.Coolantflowsthroughreturnline(5)fromtheturbocharger
tothecylinderhead.Thereisaventline(3)fromtheturbochargertotheradiatortoletanyairinthecoolingsystemgotothetopoftheradiator.
Whencoolantisputintothecoolingsystem,airispushedoutthroughventline(3)intothetopoftheradiator.

CoolantFlow(EngineWithoutAftercooler)


CoolantFlow(EngineWithoutAftercooler)
(1)Radiator.(2)Pressurecap.(3)Inletlinetoradiator.(4)Watertemperatureregulator.(5)Cylinderhead.(6)Cylinderblock.(7).Inletlinetowaterpump.(8)Waterpump.(9)
Internalbypass(shunt)line.(10)Engineoilfilter.(11)Engineoilcooler.(12).Elbow.(13)Cylinderliner.

Thewaterpump(8)isonthefrontsideoftheengine.Itisgeardrivenbythetiminggears.Coolantfromthebottomoftheradiator(1)goestothe
waterpumpinlet.Therotationoftheimpellerinthewaterpump(8)pushesthecoolantthroughthesystem.
Allofthecoolantflowfromthewaterpump(8),goesthroughtheengineoilcooler(11).Theelbow(12)ontheoutletsideoftheengineoilcooler
(11)connectstothesideofthecylinderblock(6).Thecoolantenterstheblockandflowsaroundcylinderliners(13)andupthroughthecoolant

directorsintocylinderhead(5).Thecoolantdirectorsmakethecoolantflowaroundthevalvesandaroundtheexhaustports(passages)inthecylinder
head.Thecoolantnowgoestothefrontofthecylinderhead.Atthefrontofthecylinderheadwatertemperatureregulator(4)controlsthedirectionof
thecoolantflow.Ifthecoolanttemperatureislessthannormalforengineoperation,thewatertemperatureregulatorisclosed.Thecoolantmustgo
throughinternalbypass(9)tothewaterpump.Whenthecoolantgetstothetemperatureofnormaloperationthewatertemperatureregulatoropens
andmostofthecoolantflowsthroughradiatorinletline(3)totheradiator.Apartofthecoolantstillgoesthroughinternalbypass(9).

CoolantFlow(EngineWithAftercooler)

CoolantFlow(EngineWithAftercooler)
(1)Radiator.(2)Pressurecap.(3)Inletlineforradiator.(4)Aftercooler.(5)Aftercoolerinletline.(6)Returnlinefromaftercooler.(7)Internalbypass(shunt)line.(8)Waterpump.
(9)Inletlineforwaterpump.(10)Engineoilcooler.(11)Bonnet.

Waterpump(8)isontheleftfrontsideoftheengine.Itisgeardrivenbythetiminggears.Coolantfromthebottomofradiator(1)goestothewater
pumpinlet.Therotationoftheimpellerinwaterpump(8)pushesthecoolantthroughthesystem.
Thecoolantflowfromthewaterpump(8)isdivided.Somegoesthroughengineoilcooler(10).Bonnet(11)ontheoutletsideofengineoilcooler
(10)connectstothesideofthecylinderblock.Thecoolantenterstheblockandflowsaroundthecylinderlinersandupthroughthecoolantdirectors
intothecylinderhead.
Thecoolantdirectorsmakethecoolantflowaroundthevalvesandaroundtheexhaustports(passages)inthecylinderhead.Thecoolantnowgoesto
thefrontofthecylinderhead.Atthefrontofthecylinderheadwaterthetemperatureregulatorcontrolsthedirectionofthecoolantflow.Ifthecoolant
temperatureislessthannormalforengineoperation,thewatertemperatureregulatorisclosed.Thecoolantmustgothroughinternalbypass(7)tothe
waterpump.Whenthecoolantgetstothetemperatureofnormaloperationthewatertemperatureregulatoropensandmostofthecoolantflows
throughradiatorinletline(3)totheradiator.Apartofthecoolantstillgoesthroughinternalbypass(7).
Theremainderofthecoolantflowgoesthroughaftercoolerinletline(5)intothecoreofaftercooler(4).Thecoreofaftercooler(4)isagroupofplates
andfins.Thecoolantgoesthroughtheplates.Theinletairfortheenginegoesaroundthefins.Thiscoolstheinletair.Thecoolantcomesoutofthe
aftercooler(4)attherearoftheengineandgoesthroughreturnline(6)tobonnet(11)onengineoilcooler(10).Itmixeswiththerestofthecoolant
fromengineoilcooler(10)inbonnet(11)andgoesintothecylinderblock.

CoolingSystemComponents
WaterPump
Thecentrifugaltypewaterpumphastwoseals,onepreventsleakageofwaterandtheotherpreventsleakageoflubricant.
Anopeninginthebottomofthepumphousingallowsanyleakageatthewatersealortherearbearingoilsealtoescape.

Fan
ThefanisdrivenbytwoVbelts,fromapulleyonthecrankshaftandthefandrive.Belttensionisadjustedbymovingthealternator.

BasicBlock

CylinderBlockAndLiners
Asteelspacerplateisusedbetweenthecylinderheadandtheblocktoeliminatelinercounterboreandtoprovidemaximumlinerflangesupportarea
(thelinerflangesitsdirectlyonthecylinderblock).
Enginecoolantflowsaroundthelinerstocoolthem.ThreeOringsealsatthebottomandafillerbandatthetopofeachcylinderlinerformaseal
betweenthelinerandthecylinderblock.

Pistons,RingsAndConnectingRods
Thepistonhasthreeringstwocompressionandoneoilring.Allringsarelocatedabovethepistonpinbore.Thetwocompressionringsseatinan
ironbandwhichiscastintothepiston.Pistonsinsomeenginesusecompressionringswithstraightsides.Pistonsinotherenginesusecompression
ringswhichareoftheKEYSTONEtype.KEYSTONEringshaveataperedshapeandthemovementoftheringsinthepistongroove(alsooftapered
shape)resultsinaconstantlychangingclearance(scrubbingaction)betweentheringandthegroove.Thisactionresultsinareductionofcarbon
depositandpossiblestickingofrings.
Theoilringisastandard(conventional)typeandisspringloaded.Holesintheoilringgrooveprovideforthereturnofoiltothecrankcase.
Thepistonpinboreinthepistonisoffset(movedaway)fromthecenterofthepiston0.76mm(.030in.).Thefullfloatingpistonpinisheldinthe
pistonbytwosnapringswhichfitintogroovesinthepistonpinbore.
Thepistonpinendoftheconnectingrodistaperedtogivemorebearingsurfaceattheareaofhighestload.Theconnectingrodisinstalledonthe
pistonwiththebearingtabslotsonthesamesideasthe"V"markonthepiston.

Crankshaft
Thecrankshaftchangesthecombustionforcesinthecylinderintousablerotatingtorquewhichpowersthemachine.Thereisagearatthefrontofthe
crankshaftthatdrivesthetiminggearsandtheengineoilpump.Theconnectingrodbearingsurfacesgetoilforlubricationthroughpassagesdrilledin
thecrankshaft.Aliptypesealandwearsleeveisusedtocontroloilleakageinthefrontcrankshaftseal.Ahydrodynamicgroovedsealassemblyis
usedtocontrolrearcrankshaftoilleakage.Thehydrodynamicgroovesintheseallipmovelubricationoilbackintothecrankcaseasthecrankshaft
turns.

VibrationDamper
Thetwistingofthecrankshaft,duetotheregularpowerimpactsalongitslength,iscalledtwisting(torsional)vibration.Thevibrationdamperis

installedonthefrontendofthecrankshaft.Itisusedforreductionoftorsionalvibrationsandstopsthevibrationfrombuildinguptoamountsthatcan
causedamage.

CrossSectionOfAVibrationDamper(TypicalExample)
(1)Flywheelring.(2)Rubberring.(3)Innerhub.

Thedamperismadeofaflywheelring(1)connectedtoaninnerhub(3)byarubberring(2).Therubbermakesaflexiblecouplingbetweenthe

flywheelringandtheinnerhubwhichreducesthevibrationsofthecrankshaft.

ElectricalSystem
Theengineelectricalsystemhasthreeseparatecircuits:thechargingcircuit,thestartingcircuitandthelowamperagecircuit.Someoftheelectrical
systemcomponentsareusedinmorethanonecircuit.Thebattery(batteries),disconnectswitch,circuitbreaker,ammeter,cablesandwiresfromthe
batteryareallcommonineachofthecircuits.
Thechargingcircuitisinoperationwhentheengineisrunning.Analternatormakeselectricityforthechargingcircuit.Avoltageregulatorinthe
circuitcontrolstheelectricaloutputtokeepthebatteryatfullcharge.

NOTICE
Thedisconnectswitch,ifsoequipped,mustbeintheONpositiontolet
theelectricalsystemfunction.Therewillbedamagetosomeofthe
chargingcircuitcomponentsiftheengineisrunningwiththe
disconnectswitchintheOFFposition.

Ifthemachinehasadisconnectswitch,thestartingcircuitcanoperateonlyafterthedisconnectswitchisputintheONposition.
Thestartingcircuitisinoperationonlywhenthestartswitchisactivated.
Thelowamperagecircuitandthechargingcircuitarebothconnectedtothesamesideoftheammeter.Thestartingcircuitconnectstotheopposite
sideoftheammeter.

ChargingSystemComponents
NOTICE
Neveroperatethealternatorwithoutthebatteryinthecircuit.Making
orbreakinganalternatorconnectionwithheavyloadonthecircuitcan
causedamagetotheregulator.

Alternator(DelcoRemy)
ThealternatorisdrivenbyVbeltsfromthecrankshaftpulley.Thisalternatorisathreephase,selfrectifyingchargingunit,andtheregulatorispartof
thealternator.
Thisalternatordesignhasnoneedforslipringsorbrushes,andtheonlypartthathasmovementistherotorassembly.Allconductorsthatcarry
currentarestationary.Theconductorsare:thefieldwinding,statorwindings,sixrectifyingdiodes,andtheregulatorcircuitcomponents.
Therotorassemblyhasmanymagneticpoleslikefingerswithairspacebetweeneachoppositepole.Thepoleshaveresidualmagnetism(like
permanentmagnets)thatproduceasmallamountofmagnetlikelinesofforce(magneticfield)betweenthepoles.Astherotorassemblybeginsto
turnbetweenthefieldwindingandthestatorwindings,asmallamountofalternatingcurrent(AC)isproducedinthestatorwindingsfromthesmall
magneticlinesofforcemadebytheresidualmagnetismofthepoles.ThisACcurrentischangedtodirectcurrent(DC)whenitpassesthroughthe
diodesoftherectifierbridge.Mostofthiscurrentgoestochargethebatteryandtosupplythelowamperagecircuit,andtheremainderissenttothe
fieldwindings.TheDCcurrentflowthroughthefieldwindings(wiresaroundanironcore)nowincreasesthestrengthofthemagneticlinesofforce.
ThesestrongerlinesofforcenowincreasetheamountofACcurrentproducedinthestatorwindings.Theincreasedspeedoftherotorassemblyalso
increasesthecurrentandvoltageoutputofthealternator.
Thevoltageregulatorisasolidstate(transistor,stationaryparts)electronicswitch.Itfeelsthevoltageinthesystemandswitchesonandoffmany
timesasecondtocontrolthefieldcurrent(DCcurrenttothefieldwindings)forthealternatortomaketheneededvoltageoutput.

DelcoRemyAlternator
(1)Regulator.(2)Rollerbearing.(3)Statorwinding.(4)Ballbearing.(5)Rectifierbridge.(6)Fieldwinding.(7)Rotorassembly.(8)Fan.

Alternator(Bosch)
ThealternatorisdrivenbyVbeltsfromthecrankshaftpulley.Thisalternatorisathreephase,selfrectifyingchargingunit.Theregulatorispartofthe
alternator.

BoschAlternator
(1)Fan.(2)Statorwinding.(3)Fieldwinding.(4)Regulator.(5)Ballbearing.(6)Rollerbearing.(7)Rotor.(8)Rectifierassembly.

Thisalternatordesignhasnoneedforslipringsorbrushes,andtheonlypartthathasmovementistherotorassembly.Allconductorsthatcarry
currentarestationary.Theconductorsare:thefieldwinding,statorwindings,sixrectifyingdiodes,andtheregulatorcircuitcomponents.
Therotorassemblyhasmanymagneticpoleslikefingerswithairspacebetweeneachoppositepole.Thepoleshaveresidualmagnetism(like
permanentmagnets)thatproduceasmallamountofmagnetlikelinesofforce(magneticfield)betweenthepoles.Astherotorassemblybeginsto
turnbetweenthefieldwindingandthestatorwindings,asmallamountofalternatingcurrent(AC)isproducedinthestatorwindingsfromthesmall
magneticlinesofforcemadebytheresidualmagnetismofthepoles.ThisACcurrentischangedtodirectcurrent(DC)whenitpassesthroughthe
diodesoftherectifierbridge.Mostofthiscurrentgoestochargethebatteryandtosupplythelowamperagecircuit,andtheremainderissenttothe
fieldwindings.TheDCcurrentflowthroughthefieldwindings(wiresaroundanironcore)nowincreasesthestrengthofthemagneticlinesofforce.
ThesestrongerlinesofforcenowincreasetheamountofACcurrentproducedinthestatorwindings.Theincreasedspeedoftherotorassemblyalso
increasesthecurrentandvoltageoutputofthealternator.
Thevoltageregulatorisasolidstate(transistor,stationaryparts)electronicswitch.Itfeelsthevoltageinthesystemandswitchesonandoffmany
timesasecondtocontrolthefieldcurrent(DCcurrenttothefieldwindings)forthealternatortomaketheneededvoltageoutput.

Alternator(Nippondenso)

ThealternatorisdrivenbyVbeltsfromthecrankshaftpulley.TheNippondensoalternatorhasthreephase,fullwaverectifiedoutput.Itisbrushless.
Therotorandbearingsaretheonlymovingparts.Theregulatorispartofthealternator.

NippondensoAlternator
(1)Fan.(2)Frontframeassembly.(3)Statorassembly.(4)Rotorassembly.(5)Fieldwinding(coilassembly).(6)Regulatorassembly.(7)Condenser(suppressioncapacitor).(8)
Rectifierassembly.(9)Rearframeassembly.

Whentheengineisstartedandtherotorturnsinsidethestatorwindings,threephasealternatingcurrent(AC)andrapidlyrisingvoltageisgenerated.
Asmallamountofalternatingcurrent(AC)ischanged(rectified)topulsatingdirectcurrent(DC)bytheexciterdiodesontherectifierassembly.
Outputcurrentfromthesediodesaddstotheinitialcurrentwhichflowsthroughtherotorfieldwindingsfromresidualmagnetism.Thiswillmakethe
rotorastrongermagnetandcausethealternatortobecomeactivatedautomatically.Asrotorspeed,currentandvoltagesincrease,therotorfield
currentincreasesenoughuntilthealternatorbecomesfullyactivated.
Themainbatterychargingcurrentischarged(rectified)fromACtoDCbytheotherpositiveandnegativediodesintherectifierandpack(main
outputdiodes)whichoperateinafullwavelinkagerectifiercircuit.
Alternatoroutputiscontrolledbyaregulator,whichisinsidethealternatorrearframe.

AlternatorRegulator(DelcoRemy)


Regulator(DelcoRemy)

Thevoltageregulatorisanelectronicswitch.Itfeelsthevoltageinthesystemandgivesthenecessaryfieldcurrent(currenttothefieldwindingsof
thealternator)forthealternatortomaketheneededvoltage.Thevoltageregulatorcontrolsthefieldcurrenttothealternatorbyswitchingonandoff
manytimesasecond.

AlternatorRegulator(Bosch)


Regulator(Bosch)

Thevoltageregulatorisanelectronicswitch.Itfeelsthevoltageinthesystemandgivesthenecessaryfieldcurrent(currenttothefieldwindingsof
thealternator)forthealternatortomaketheneededvoltage.Thevoltageregulatorcontrolsthefieldcurrenttothealternatorbyswitchingonandoff
manytimesasecond.

AlternatorRegulators(Nippondenso)


Regulator(Nippondenso)

Theregulatorisfastenedtothealternatorbytwodifferentmethods.Onemethodfastenstheregulatortothetop,rearofalternator.Withtheother
methodtheregulatorisfastenedseparatelybyuseofawireandaconnectorthatgoesintothealternator.
Thevoltageregulatorisasolidstate(transistor,nomovingparts)electronicswitch.Itfeelsthevoltageinthesystemandgivesthenecessaryfield
current(currenttothefieldwindingsofthealternator)forthealternatortomaketheneededvoltage.Thevoltageregulatorcontrolsthefieldcurrentto
thealternatorbyswitchingonandoffmanytimesasecond.Thereisnovoltageadjustmentforthisregulator.

StartingSystemComponents
Solenoid
Asolenoidisamagneticswitchthatdoestwobasicoperations.
a.Closesthehighcurrentstartermotorcircuitwithalowcurrentstartswitchcircuit.
b.Engagesthestartermotorpinionwiththeringgear.


TypicalSolenoidSchematic

Thesolenoidswitchismadeofanelectromagnet(oneortwosetsofwindings)aroundahollowcylinder.Thereisaplunger(core)withaspringload
insidethecylinderthatcanmoveforwardandbackward.Whenthestartswitchisclosedandelectricityissentthroughthewindings,amagneticfield
ismadethatpullstheplungerforwardinthecylinder.Thismovestheshiftlever(connectedtotherearoftheplunger)toengagethepiniondrivegear
withtheringgear.Thefrontendoftheplungerthenmakescontactacrossthebatteryandmotorterminalsofthesolenoid,andthestartermotorbegins
toturntheflywheeloftheengine.
Whenthestartswitchisopened,currentnolongerflowsthroughthewindings.Thespringnowpushestheplungerbacktotheoriginalposition,andat
thesametime,movesthepiniongearawayfromtheflywheel.
Whentwosetsofwindingsinthesolenoidareused,theyarecalledtheholdinwindingsandthepullinwindings.Bothhavethesamenumberof
turnsaroundthecylinder,butthepullinwindingsusesalargerdiameterwiretoproduceagreatermagneticfield.Whenthestartswitchisclosed,
partofthecurrentflowsfromthebatterythroughtheholdinwindings,andtherestflowsthroughthepullinwindingstomotorterminal,then
throughthemotortoground.Whenthesolenoidisfullyactivated(connectionacrossbatteryandmotorterminaliscomplete),currentisshutoff
throughthepullinwindings.Nowonlythesmallerholdinwindingsareinoperationfortheextendedperiodoftimeittakestostarttheengine.The
solenoidwillnowtakelesscurrentfromthebattery,andheatmadebythesolenoidwillbekeptatanacceptablelevel.

StarterMotor

Thestartermotorisusedtoturntheengineflywheelfastenoughtogettheenginetostartrunning.
Thestartermotorhasasolenoid.Whenthestartswitchisactivated,thesolenoidwillmovethestarterpiniontoengageitwiththeringgearonthe
flywheeloftheengine.Thestarterpinionwillengagewiththeringgearbeforetheelectriccontactsinthesolenoidclosethecircuitbetweenthe
batteryandthestartermotor.Whenthecircuitbetweenthebatteryandthestartermotoriscomplete,thepinionwillturntheengineflywheel.Aclutch
givesprotectionforthestartermotorsothattheenginecannotturnthestartermotortoofast.Whenthestartswitchisreleased,thestarterpinionwill
moveawayfromtheringgear.

StarterMotorCrossSection
(1)Field.(2)Solenoid.(3)Clutch.(4)Pinion.(5)Commutator.(6)Brushassembly.(7)Armature.

OtherComponents
CircuitBreaker


CircuitBreakerSchematic
(1)Resetbutton.(2)Discinopenposition.(3)Contacts.(4)Disc.(5)Batterycircuitterminals.

Thecircuitbreakerisaswitchthatopensthebatterycircuitifthecurrentintheelectricalsystemgoeshigherthantheratingofthecircuitbreaker.
Aheatactivatedmetaldiscwithacontactpointmakescompletetheelectriccircuitthroughthecircuitbreaker.Ifthecurrentintheelectricalsystem
getstoohigh,itcausesthemetaldisctogethot.Thisheatcausesadistortionofthemetaldiscwhichopensthecontactsandbreaksthecircuit.A
circuitbreakerthatisopencanbereset(anadjustmenttomakethecircuitcompleteagain)afteritbecomescool.Pushtheresetbuttontoclosethe
contactsandresetthecircuitbreaker.
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