ENGINE MECHANISM

KS-Overseas Service
1. Introduction
2. Engine body
3. Lubricating System
4. Cooling System
5. Intake / Exhaust System
6. Fuel System
7. Electrical System
1.Introduction
 Classification of Heat Engines
Diesel Engine

Volume Type Gasoline Engine

Internal Combustion
Engine LPG Engine

Gas Engine
Heat Engine
Fluid Type
Jet Engine

External Combustion
Steam Engine
Engine
 Heat Engines Steam Pressure

Combustion

Force
Force

Hot Water
Piston
Piston
Combustion

Internal Combustion Engine External Combustion Engine

 Displacement
D
TDC

πＤ ２ＬＮ
Vh L Vh 
４
Vh : Total displacement (cc)
BDC
D : Cylinder bore (cm)
L : Cylinder stroke (cm)
N : Number of cylinders
 Compression ratio
VC TDC VC

Vh
BDC VC  Vh
ε
VC
ε : Compression ratio
VC : Combustion chamber volume
Vh : Stroke volume
 Power

75 kg

1m

1 m/s

1 PS = 75 kgf・m/s = 0.9859 HP = 0.7355 kW

HP ( HORSE POWER ) = 550 Feet/s × 1 lb

= 167.64m/s × 0.4535924 kg

= 76.0422994 kg m/s

= 0.745974 kW

PS ( PFERDE STÄRKE ) = 1 m/s × 75 kg

= 75 kg m/s

= 0.73575 kW
 4-Cycle Engine

Suction Compression Combustion Exhaust

 Valve Timing
TDC
FI IO EC

TDC : Top Dead Center

BDC : Bottom Dead Center
IO : Inlet Open
IC : Inlet Close
FI : Fuel Injection
EO : Exhaust Open
EO EC : Exhaust Close

IC
BDC
 Valve System ⑧ ③

②
②

①
①

④ ⑦
⑦

Side Valve Over Head Valve Over Head Cam

①Piston ④Tappet ⑦Connecting rod
②Valve ⑤Push rod ⑧Lever
③Camshaft ⑥Rocker arm
Direct Injection ＆ Indirect Injection
Main Combustion Pre-Combustion
Chamber Chamber

Water
Jacket

Direct Injection Indirect Injection

 DIRECT INJECTION
vs.
INDIRECT INJECTION

Advantage of DI Disadvantage of DI
- Higher fuel efficiency. - Lower rpm applications.
- Easier starting at lower - Higher noise.
temperatures. - Higher emissions output.

Advantage of IDI Disadvantage of IDI

- High RPM range - Requires preheating for cold start
- Lower emissions output - Requires higher compression ratio
- Lower noise level - Lower fuel efficiency
2.Engine Body
 Head Cover
Rocker Arm
Cylinder Head
Air Cleaner
Exhaust Manifold

Intake Manifold

Crank Case Muffler

Gear Case
Flywheel

Oil Filter Cartridge Oil Pan

 Crank Case
Water Jacket
Cylinder Liner

Main Journal
 Cylinder Head
Valve Guide Nozzle

Intake
Cylinder Head

Head Gasket Exhaust

 Crankshaft

Crankshaft

Main Bearing
solid type Crankshaft Sleeve

Main Bearing Thrust Bearing

split type
 Piston & Piston Ring
Fan-Shaped
Concave
Valve Recess

Top Ring

Second Ring

Oil Ring
Scuff
Resistance
Groove
 E-TVCS
Nozzle
Pre-Combustion
Chamber Glow Plug

Three Vortex
Fan-shaped
Concave

Valve Recess
 Valve Mechanism
Rocker Arm
Valve Spring

Push Rod
In/Ex Valve

Tappet

Camshaft
 Flywheel
Flywheel

Crankshaft

1. Reduces crankshaft rotating speed fluctuation.

2. Stores the rotating force as inertial energy.
3. Maintains the smooth rotating conditions.
3.Lubricating System
LUBRICATING SYSTEM

1. Reduces friction between moving parts.

2. Seals the piston rings and cylinder walls.
3. Cleans and flushes moving parts.
4. Helps reduce the noise of the engine.
 Oil Pump

Outer Rotor

Inner Rotor Inlet Port Outlet Port

4.Cooling System
 Cooling System
Construction
Radiator
Cooling fan Coolant

By-pass pipe Thermostat

Water Jacket

Water pump
 Cooling System

Thermostat closes
By-pass pipe
 Cooling System
High temp. Water

Thermostat open

AIR

Low temp. Water

5.Intake / Exhaust System
 Air Cleaner
Dusty air from outside

Fresh air to cylinder

 Ｍｕｆｆｌｅｒ
Main Body

exhaust gases

Grass Wool Inner Tube Outer Tube

Reduces the noise of the exhaust gases.

6.Fuel System
Fuel Tank Injection Nozzle

Injection Pump
Fuel Filter

Fuel Feed Pump

 Injection Pump
Damping Valve

Delivery Valve

Fuel Chamber

Control Rack

Plunger
 Governor System
Start Spring
Governor Spring1

Governor Spring1
Torque Pin

Fork Lever2
Fork Lever1

1. Keeps constant the rotation of the engine.

2. Controls the output of the engine.
Stop
Start Position
At Start
No-Load Hi-Idling
Rated
Over Load
Torque Pin
Rated
Stop
7.Electrical System
(1) Starter Auto Reduction Unit (7) Key Switch (13) Glow Lamp (19) Timer
(2) External Relay (8) Glow Plug (!4) Pilot Lamp (Glow Lamp)
(3) Alternator (9) Fuse Box (15) Water Temperature Switch
(4) Starter (10) Water Temperature Lamp (16) Oil Switch
(5) Battery (11) Oil Pressure Lamp (17) Fuel Feed Pump
(6) Fuse (12) Charge Lamp (18) Stop Solenoid