Basic Knowledge of Engine: For Indonesia KTB Area Coordinators

Basic Knowledge of Engine
based on the textbook

‘Truck Technology: The Facts You Need (Ⅰ)-Engine-’
for Indonesia KTB Area Coordinators
27 February 2006 @ KTB 1
Jakarta
Self-introduction
田島卓士
TAJIMA TAKASHI
(Family name – First name)
MITSUBISHI FUSO TRUCK & BUS CORPORATION
REPRESENTATIVE OFFICE in Singapore
MFTBC R&D division 27 February 2006 @ KTB Jakarta page 2

Major in University
Metallurgy

Career in Mitsubishi FUSO
1987 Join Mitsubishi Motors

Chassis design for Special purpose truck
1991 Chassis design for Heavy duty truck
1993 Product development for Domestic market
1996 Product development for Export market
2003 REPRESENTATIVE OFFICE in Singapore

Rep office member

General schedule
No. Item Contents Textbook Pages Video Instructor Duration
Application & Classification (1) MITSUBISHI P1～P37 -
Dimension TRUCK MANUAL
Weight (2) Engine P1～P13 - 30 Jan 2005
1 Basic Tajima
Running Performance (3) Chassis P1～P4 0～6min (Finished)
Fuel consumption (4) Rear Body P1～P5 0～6min
Exhaust emission
Basic (1) Engine All
2 Engine Structure Tajima 27 Feb 2006
Others
Clutch (2) Chassis P5～P33
Transmission
Reduction
Steering
3 Chassis Yamamoto 29 Mar 2006
Brake
Tire
Suspension
Battery
Weight Calculation (3) Rear Body P6～P65
Cargo
Crane
4 Rear Body Yabe 27 Apr 2006
Van
Dump
Others
Contents
1 Indonesia current engine line-up
2 Classification of engine
1 Basic 3 Performance & dimension
4 Stroke cycle
5 Comparison between Diesel & Gasoline
1 General system of engine
2 Main body
3 Lubrication
2 Structure 4 Cooling system
5 Fuel system
6 Intake & exhaust
7 Electrical system
1 Fuel & engine oil
2 Indonesia EURO2 engine line-up
3 Others
3 Exhaust emission reduction
4 Introduction of low emission vehicle
1-1. Indonesia current engine line-up
4 Stroke cycle
2 Main body
3 Lubrication
5 Fuel system
6 Intake & exhaust
7 Electrical system
1 Fuel & engine oil
3 Others
Engine model coding system [Text p10]
1 2 3 4 5 6 7 8
4 D 3 4 - 2 A T 8
D igits
N um ber S equence in S equence

A spi- V ari-
of E ngine developm ent in U se
ration ation
cylinders by series rem odeling
M eaning
D: A: T:
D iesel A uto- W ith
engine m obile turbo-
charger

Indonesia current engine line-up [Text p10]
bore x Piston C om p-
O utput Torque
Engine stroke displace- ression M ounted on
PS / rpm kgfm /rpm
[m m ] m ent[cc] ratio
FE304/304B C
1 4D 31-0A 100/3,500 24/2,200 100x105 3,298 17.5
FE334/334H D
115/3,200
2 4D 34-0A (C atalogue 28/1,800 104x115 3,907 17.5 FE349/349H D
:120PS)
130/3,200
FE347
3 4D 33-4A (C atalogue 31/1,800 108x115 4,214 18.0
FE447/447F
:135PS)
FM 517H /H 2
4 6D 16-1A 190/2,900 53/1,400 118x115 7,545 18.0
FN 517M /M L
FM 517H 3/L2
5 6D 16-1AT 220/2,800 65/1,400 118x115 7,545 16.0 FN 527M 2/M 2L
FN 527M 3/M 3L
1-2. Classification of engine
4 Stroke cycle
2 Main body
3 Lubrication
5 Fuel system
6 Intake & exhaust
7 Electrical system
1 Fuel & engine oil
3 Others
Cylinder layout [Text p10]
Colt diesel
Straight
4 cylinder
Straight (6 cylinder)
Straight V (8 cylinder)
FUSO class
Horizontal (6 cylinder) Boxer (4 cylinder)

Combustion chamber [Text p18]
All MFTBC engine

for KTB

Classification of combustion chamber [Text p19]

Classification of Valve mechanism [Text p21]
Rocker arm Camshaft
Rocker arm Cam- Tappet
shaft
Valve
Push Valve
rod Valve
Cylinder Piston
Tappet head Cylinder
Piston head
Cam-
shaft Piston
OHV OHC DOHC
All MFTBC
engine
for KTB
6M60T2 (4valve) 4M50T3 (4valve)
1-3. Performance & Dimension
4 Stroke cycle
2 Main body
3 Lubrication
5 Fuel system
6 Intake & exhaust
7 Electrical system
1 Fuel & engine oil
3 Others
(Review) Drive line components [Text p8~9]
① ② ③
Drive line components ①～④ specifications

determines the vehicle running performance.
(Review) Engine Performance Curves [Text p11]
①Output Curve
②Torque Curve
③Brake Specific Fuel

Consumption Curve
Fuel consumption
of engine unit
Conversion between SI & current units [Text p11]

[PRACTICE] Conversion of output & torque [Text p11]
① Convert FE349 engine output &torque to SI.

Refer ‘spec comparison table’
Round off the figures after the decimal fractions.
② How about DYNA 125LT?

Compression Ratio [Text p15]

Piston displacement [Text p20]

[PRACTICE] Piston displacement [Text p20]
① Calculate 4D34-2AT5 piston displacement.

Bore x Stroke : 104mm x 115mm
1st digit of MFTBC engine model name shows
number of cylinder.
② How about 6D16-3AT2 (118mm x 115mm)?

1-4. Stroke cycle
4 Stroke cycle
2 Main body
3 Lubrication
5 Fuel system
6 Intake & exhaust
7 Electrical system
1 Fuel & engine oil
3 Others
Theoretical 4 Stroke cycle (Savathe cycle) [Text p14~15]
Pressure
Pressure
Pressure
Pressure
Ignition
BDC
TDC
BDC
BDC
BDC
TDC
TDC
TDC
Volume Volume Volume Volume
Intake Compression Combustion Exhaust

Actual & theoretical 4 Stroke cycle [Text p14~15]
Actual cycle Theoretical cycle
Pressure
Pressure
Ignition
TDC
BDC
BDC
Volume
TDC
Volume

1-5. Comparison between Diesel & Gasoline
4 Stroke cycle
2 Main body
3 Lubrication
5 Fuel system
6 Intake & exhaust
7 Electrical system
1 Fuel & engine oil
3 Others
[PRACTICE] What’s the difference? [Text p14~15]
What’s the difference between diesel & gasoline

engine?

Comparison between Gasoline & Diesel [Text p14~15]

Merits & demerits of Diesel engine [Text p14~15]

Structure of Diesel & Gasoline [Text p14~15]
Diesel engine Gasoline engine

4 Stroke cycle of Diesel & Gasoline [Text p14~15]
Diesel
engine
Gasolin
e
engine
Intake Compression Combustion Exhaust

Theoretical cycle of Diesel & Gasoline [Text p12]
: Ignition
Pressure
Pressure
Pressure
Volume Volume Volume
Otto cycle Diesel cycle Savathe cycle
Gasoline engine Current Diesel engine

Combustion condition of diesel engine [Text p18]
Rapid Immediate
combustion combustion
injection
Pressure
Start of
injection
End of
(kg/cm2)
Ignition Combustion
Injection
Ignition In case of
delay no ignition
Top dead center

Crank rotation angle
Diesel knock [Text p18]
When combustion pressure in a cylinder rises abnormally, it creates a
shockwave that severely vibrates engine, resulting in a knocking noise.
Measures to prevent diesel knock include improvements in ①fuel ignitability,
②shapes of combustion chambers, and ③injection systems.
Possible causes
1. Intake air
temperature too low
2. Injection timing too
early
3. Compression
pressure too low
4. Fuel ignitability low
(Use fuel with
Cetane number of
50 or more.)

Gasoline knock [Text p18]

Coffee break
Diesel & Gasoline engine inventors [Text p15]
Diesel engine Gasoline engine

invented in 1897 invented in 1885
Rudolf Diesel Gottlieb Daimler

1858 - 1913 1834 - 1900

2-1. General system of engine
4 Stroke cycle
2 Main body
3 Lubrication
5 Fuel system
6 Intake & exhaust
7 Electrical system
1 Fuel & engine oil
3 Others
Intake & exhaust system [Text p22]
Exhaust Exhaust system
pipe
Exhaust
manifold
Muffler
Air cleaner
Intake system
Inlet manifold
Fuel, cooling, & electrical system [Text p22]

2-2. Main body
4 Stroke cycle
2 Main body
3 Lubrication
5 Fuel system
6 Intake & exhaust
7 Electrical system
1 Fuel & engine oil
3 Others
Main body structure [Text p20]
Cylinder head
Cylinder liner
Cylinder Piston
Crankcase
(cylinder Piston
block) rings
Flywheel Connecting
Oil pan rod
Crankshaft
2-3. Lubrication
4 Stroke cycle
2 Main body
3 Lubrication
5 Fuel system
6 Intake & exhaust
7 Electrical system
1 Fuel & engine oil
3 Others
Engine oil flow in lubrication system [Text p32]
Engine oil is necessary for lubricating moving parts

& prevents wear or seizing.

Lubrication of piston & cylinder wall [Text p32]
Engine oil has lubricating, cooling & cleansing function.

Oil cooler [Text p35]
Engine oil must be cooled to keep its lubricating performance.

(Engine oil deteriorates by being heated.)

Oil filter [Text p32]
Replacement interval
4D3 series 6D1 series
1st
5,000km 4,000km
replacement
every every
2nd & after
10,000km 16,000km

2-4. Cooling system
4 Stroke cycle
2 Main body
3 Lubrication
5 Fuel system
6 Intake & exhaust
7 Electrical system
1 Fuel & engine oil
3 Others
Cooling system [Text p34]
Hot coolant is cooled by radiator before further recirculation

Cooling device [Text p34~35]
Thermostat
Radiator
Cooling fan
Auto 4D33 6D16T
cool 4D34T(EURO2) 6D16T(EURO2)
4D31
Rigid 6D16
Water pump 4D34
Replacing coolant [Text p34~35]
every 50,000km
every 2 years
or 2 years
To prevent freezing and corrosion in
the cooling system, be sure to add
FUSO DIESEL LONG LIFE COOLANT
(Ethylene glycol base antifreeze SAE
J814-C) mixed with water
Water to use
Use soft water having the properties listed
below. Do not use hard water taken from a
well or river as it causes scale and rust.
Total hardness 300ppm or below
Sulfate SO4 100ppm or below
Chloride Cl 100ppm or below
Total dissolved solids 500ppm or below
PH 6 to 8
2-5. Fuel system
4 Stroke cycle
2 Main body
3 Lubrication
5 Fuel system
6 Intake & exhaust
7 Electrical system
1 Fuel & engine oil
3 Others
Basic fuel supply path [Text p25]
Reduction of PM
by converting to
water & CO2
Water separator

Injection pump [Text p25]
Governor
Pump main
body
Fuel feed pump
Timer for 6 cylinder engine

Structure of fuel injection pump [Text p25]
Reduction of PM
by converting to
water & CO2

Pump element [Text p26]
(In-out port)
Reduction of PM
by converting to
water & CO2
To pressurize fuel
before delivery to
injection nozzles

Plunger operation [Text p26]
Reduction of PM
by converting to
water & CO2

Control of fuel delivery quantity [Text p26]
Reduction of PM
by converting to
water & CO2

Effective stroke [Text p26]
Reduction of PM
by converting to
water & CO2
Partial load

Governor [Text p28]
A device that automatically controls the fuel injection amount to

stabilize the engine speed
Operating principle
Reduction of PM
by converting to
water & CO2
Revolution
Centrifugal
force

Basic structure of governor [Text p28]
Injection
decrease
Floating
Control lever Control
rack
lever
Reduction of PM
by converting to
water & CO2
Camshaft
Accelerator
Flyweight
pedal
Sliding
bolt

Flyweight working mechanism [Text p28]
Increase Decrease
Control
rack
Floating
lever Reduction of PM
by converting to
water & CO2
Spring
expansion
Decrease Increase
Camshaft
Governor spring
Flyweight
Flyweight lift
Classification of governor [Text p28]
Low idle High idle
control control
Controlled
by accelerator
Increase
Full accelerator
Control rack position

Minimum–maximum
(injection amount)
speed governor
(2-speed governor)
IdlingReduction of PM
Mechanical by converting to
governor water & CO
Pump rotation speed High2
Starting
Full load control

Increase
High idle control
Control rack position

(injection amount)
All speed governor
Partial load control
All MFTBC
engine
for KTB Low idle control Pump rotation speed High

Structure of ‘all speed governor’ [Text p28]
Adaptor screw Full load stopper
Stop cam
Control rack Floating arm
Control lever
Damper spring
Stop lever
Return spring
Cam plate
Start spring
Floating lever
Flyweight holder
Adjusting lever shaft

Flyweight Supporting lever

(Automatic) Timer [Text p28]
A device that automatically controls the fuel injection timing

Drives camshaft
of injection pump
Driven by engine

Operation of Automatic timer [Text p28]
Timer advances injection timing as the engine speed increases.
Reduction of PM
by converting to
water & CO2

Fuel feed pump [Text p25]
Priming pump
Reduction of PM
Outlet by converting to
water & CO2
Gauze filter
Outlet
Inlet
Inlet

Operation of Fuel feed pump [Text p25]
① Preparation ② Suction / ejection ③ Pausing
Cam
Reduction of PM
High fuel pressure
Pressure chamber by converting to
water & CO2
Piston
Spring
Inlet valve
Outlet valve
Suction chamber

Cleaning feed pump gauze filter [Text p25]
・Remove the eyebolt 1 from the suction port side of the fuel feed pump.
・Remove the gauze filter 2 from the eyebolt 1.
・Clean the gauze filter 2.
・Refit the gauze filter 2 and eyebolt 1 in the opposite order to their removal.
・Bleed all air out of the fuel system.
・Start the engine and check for fuel leaks.
Construction of nozzle & nozzle holder [Text p25~26]
Reduction of PM
by converting to
water & CO2

Construction & operation of nozzle [Text p25~26]
for
Swirl chamber
engine
for Direct injection engine

Variation of ‘Hole type nozzle’ [Text p25~26]
Reduction of PM
by converting to
water & CO2
All MFTBC
engine
for KTB

Water separator [Text p25]
Inspection interval : every week
Check the condensate level in
the water separator by
examining the level of the
float ①. If it has risen to the
red line ②, drain the
Reduction of PM
condensate. by converting to
To remove, proceed as follows.
water & CO2
1) Loosen the plug ③ to
discharge the condensate.
2) After the float has come
down, tighten the plug.
3) Wipe & clean the water
separator and surrounding
parts.
4) Check for fuel leaks.

Structure of fuel filter [Text p25]
for 4D33
Fuel filter head
Fuel filter element

Replacing fuel filter element [Text p25]
Replacement interval 1) Remove the element assembly ① by turning it
counterclockwise.
every every ☆ lf the assembly is hard to turn, use filter wrench.
25,000km 48,000km 2) To install a new element, apply a light coat of engine
oil to the gasket ② of the element assembly and
screw the assembly into the filter head ③. After the
gasket has come into contact with the filter head,
screw in the assembly three quarters to one turn
more for a tight fit.
3) After opening the air plug ④, operate the fuel feed
pump to feed fuel. Bleed air from the fuel system.
4) Wipe clean any fuel spilt on engine parts.
5) Start the engine and check for fuel leaks.
CAUTION
Wipe clean spilt diesel fuel, as it could start a fire.

Air bleeding (running out of gas) [Text p25]
When the vehicle runs out of fuel,
③
air becomes trapped in the fuel
system and the engine cannot
be started only by refueling.
Perform the following
procedures to bleed air from the
system. Reduction of PM
1. Loosen the priming bypump ① ofto
converting
② the fuel injection pump by& CO2
water
turning it counterclockwise.
Priming 2. Loosen air plug ③ of the fuel
pump ① filter ②.
3. Move the priming pump ① up
and down by hand to feed fuel
until no air bubbles come out
from the air plug ③. During the
procedure, keep the air plug
covered with cloth.
Air bleeding (running out of gas) [Text p25]
When the vehicle runs out of fuel,
air becomes trapped in the fuel
system and the engine cannot
be started only by refueling.
Perform the following
procedures to bleed air from the
system. Reduction of PM
1. Loosen the priming bypump ① ofto
converting
the fuel injection pump by& CO2
water
turning it counterclockwise.
2. Loosen air plug ③ of the fuel
filter ②.
3. Move the priming pump ① up
and down by hand to feed fuel
until no air bubbles come out
from the air plug ③. During the
4D31 / 4D34 engine procedure, keep the air plug
covered with cloth.
2-6. Intake & exhaust
4 Stroke cycle
2 Main body
3 Lubrication
5 Fuel system
6 Intake & exhaust
7 Electrical system
1 Fuel & engine oil
3 Others
Intake air & exhaust gas flow [Text p23 & 30]
Forced
induction

Air cleaner element (Colt Diesel) [Text p23]
Cleaning intervals Every 5,000km
Replacement intervals Every 40,000km
Reduction of PM
by converting to
water & CO2
1 ) Loosen the three hook bolt wing nuts ① and remove the dust pan ②.
2 ) Remove the wing bolt ③ tightening the element and withdraw the element ④.
3 ) Clean the element by blowing air from the inside or by tapping it to loosen dust.
☆ Avoid applying excessive air pressure. Do not strike the element hard or hit it badly against
other object.
4 ) Remove the cover from the dust pan and clean dust collected in the dust pan. Clean the
inside of air cleaner case, too
5 ) Install by reversing order of the steps used for removal, making sure that arrow marks on
the case and dust pan are aligned.

Air cleaner element (FUSO class) [Text p23]
Check the dust indicator once a week.
When the red mark appears at the window ①,
the air cleaner element is clogged. Clean the element
regardless of the distance driven.
After cleaning, press the reset button ② to reset the red mark.
Cleaning intervals 1st 4,000km

Dry paper (for outer element only) Every 12,000km
single element Replacement intervals Every 48,000km
Remove wing nut ① and draw the element ② straight out.
Clean the element.
Reinstall the element by reversing the above procedure.
Dry paper dual element Do not remove the inner element ③ unless it is to be replaced.
It must be replaced simultaneously with the outer element.
CAUTION!
The element will not function properly if not installed
securely, causing dust, etc. to be drawn into the engine .
Air cleaner element (FUSO class) [Text p23]
Cleaning a paper element

1 . Blow clean compressed air evenly up and down
from inside the element to remove the dust.
☆ Do not strike the element or hit it against another
object. Make sure that the pressure of the
compressed air used for cleaning does not exceed
7 kgf/cm2 ( 685 kPa )
2 If the element is contaminated with oil smoke , soot
or oil dust, replace the element regardless of the
distance driven.
Checks to make after cleaning
Check the filter paper for damage, pinholes and thin
portions. If a defective portion or broken packing is
evident, replace the element with a new one.

Turbocharger [Text p23]
Reduction of PM
by converting to
water & CO2

Intercooler [Text p24]
Intercooler increases
the air’s density for
effective forced
induction.
Reduction of PM
by converting to
water & CO2
Used together

Exhaust brake [Text p31]
A device that uses exhaust gases to boost the engine brake effect
All MFTBC engine
for KTB
Reduction of PM
by converting to
water & CO2

Service brake ineffectiveness [Text p31]
On long downhill roads, use both the engine braking &
exhaust brake to prevent service brake ineffectiveness
such as,
Brake fade : Decrease of brake lining friction by overheating
Vapor locking : Boiling of the brake fluid in the brake fluid of PM
Reduction
by converting to
hydraulic circuit. water & CO2

2-7. Electrical system
4 Stroke cycle
2 Main body
3 Lubrication
5 Fuel system
6 Intake & exhaust
7 Electrical system
1 Fuel & engine oil
3 Others
Electricity supply & starting system [Text p36]
Alternator charges batteries & generates electricity as engine runs.

3-1. Fuel & Engine oil
4 Stroke cycle
2 Main body
3 Lubrication
5 Fuel system
6 Intake & exhaust
7 Electrical system
1 Fuel & engine oil
3 Others
Comparison of fuel [Text p16]
Gasoline Kerosene Diesel fuel
Flash point 40 to 20℃ 40℃ over 50 to 70℃
Ignition point Approx. 300℃ Approx. 250℃ Approx. 250℃
C olorless
C olor Orange~Pink Pale yellow
Transparent
Specific weight 0.75 0.8 0.85
C alorific value
10,300～11,000 10,000 10,000
[kC al/kg]
Flash point:
the lowest temperature at which fuel catches fire
when brought near source (fire, static electricity, and so on)
Ignition point:
the lowest temperature at which fuel spontaneously ignites
as a result of its own heat

Classification of fuel [Text p16]
Cooling tower
→LPG
Refinery gas
Gasoline
Distillation temperature (℃)
Naphtha
Heavy oil Kerosene

Aviation
turbine
fuel Diesel fuel
Diesel fuel
Kerosene Tray Liquefied
LP gas Liquid
(Liquefied petroleum gas) Pressurized surface
Gasoline petroleum
Oil vapor
Distilled volume (%)

Vapor
Petroleum distillation curve Heavy oil
Indonesian diesel fuel [Text p16]
Pertam ina D EX Solar
item s　　　　　　　unit
(EU RO 2) (N on-EU RO )
D ensity at 15℃　　　　　，g/cm 3 0.820-0.850 0.815－0.870
C etane Index 50 m in. 45 m in
C etane N um ber 53 m in. 48 m in
Viscosity ＠ 40℃　　　　　，m m 2/s 2.0－4.0 1.6－5.8(at 100oF)
Flash Point　　　　　　　℃ 55 m in 65.5 m in
Lubricity （H FRR）　　　，μm 400 m ax
Sulfur　　　　　　　　　，ppm 300 m ax 5,000 m ax
10% C arbon Residue　　，w t% 0.30 m ax 0.10 m ax
Appearance C lear ＆ B right
W ater　　　　　　　　　，m g/kg 200 m ax 500 m ax
O xidation Stability　　　　，g/m 3 25 m ax
C opper C orrosion C lass 1 C lass 1
Particulates　　　　　　，m g/L 10 m ax
TAN （Total Acid N um ber），m g KO H /gr 0.08 m ax 0.6m ax
Ash content　　　　　　，w t% 0.01 m ax. 0.01 m ax
Vice M inistry O il & N atural G as
Specification，based on : Pertam ina Presentation
N o.113.K/72/D D JM /1999
(M inistry D ecree or Pertam ina Letter) 11Aug 2005
27 O ctober 1999
Released to the m arket (the latest spec) Aug 2005 O ct 1999

Cetane number (Diesel fuel) [Text p16]
The higher the cetane number, the less likely the diesel fuel is to knock. The
ignition quality (ignition lag) is expressed by the cetane number. The normal
cetane (C6H34) which has the shortest ignition lag is assigned a cetane
number of 100, whereas the alpha-methylnapthalene (C11H10) with the longest
ignition lag, is assigened a cetane number of 0.
The cetane number is defined as the percentage by volume of the normal cetane
in a blend with alpha-methylnapthalene. The cetane number of a diesel fuel is
determined by comparing its ignition quality, as measured by using a CFR
(variable compression ratio) test engine, to the normal cetane and alpha-
methylnapthalene blend with the same ignition quality as the test fuel; that is,
the percentage of the normal cetane contained in the blend becomes the
cetane number of the test fuel. The cetane numbers of diesel fuels currently
available on the market range from 45 to 50.

Octane number (Gasoline) [Text p16]
A number that indicates the antiknock quality of a gasoline.
To determine the octane number of a gasoline the test results of that gasoline are
compared with the quality of a standard fuel which is a blend of isooctane
(assigned an octane number of 100) and normal heptane (assigned an octane
number of 0).

Engine oil (Viscosity categories) [Text p33]

weaker Engine oil (Performance classifications) [Text p33]
Oil film
stronger
for Turbo
engine for all MFTBC engine

Inspection & Pre-operational
replenishment check
every every
replacement
5,000km 8,000km
3-2. Indonesia EURO2 engine line-up
4 Stroke cycle
2 Main body
3 Lubrication
5 Fuel system
6 Intake & exhaust
7 Electrical system
1 Fuel & engine oil
3 Others
Indonesia EURO2 engine line-up [tentative]
EU RO 2 C urrent m odel (N on-EU RO )
O utput Torque O utput Torque KTB
Engine Engine
PS rpm kgf・
m rpm PS rpm kgf・
m rpm Pet N am e
FE304
FE304B C
1 4D 34-2AT5 110 2,900 28 1,600 4D 31-0A 100 3,500 24 2,200
FE334
FE334H D
FE349
2 4D 34-2AT8 125 2,900 33 1,600 4D 34-0A 115 3,200 28 1,800
FE349H D
FE347
3 4D 34-2AT7 136 2,900 38 1,600 4D 33-4A 130 3,200 31 1,800 FE447
FE447F
FM 517H
FM 517H 2
4 6D 16-1A 190 2,900 53 1,400
FN 517M
FN 517M L
FM 517H 3
6D 16-3AT2 220 2,800 65 1,400
FM 517L2
FN 527M 2
5 6D 16-1AT 220 2,800 65 1,400
FN 527M 3
FN 527M 3L
FN 527M 2L
3-3. Exhaust emission reduction
4 Stroke cycle
2 Main body
3 Lubrication
5 Fuel system
6 Intake & exhaust
7 Electrical system
1 Fuel & engine oil
3 Others
Exhaust gas generation mechanism [Text p17]
Blow-by gas
The compressed
air-fuel mixture
or the burned
gases leaking
from the
combustion
chamber past
the piston rings
and into the
crankcase. Most
Blow-by gas Exhaust gas
of it is the ･CO ･HC
unburned fuel ･HC
･NOx ･PM
(HC) with the ･Black smoke
CO: C+02→2CO (imperfect combustion)
remainder
Diesel engine exhausts few CO.
burned gases.
HC: unburned fuel
NOx: N2+O2 →2NO 2NO+O2 →2NO2
(generated @ high temperature)
PM: Particulate matter (unburned fuel & oil + soot mixture)
Black smoke: Separated soot (originally carbon in fuel)
Toxic substances in exhaust gas [Text p17]
CO (carbon monoxide) : Toxicity for the human body is extremely high.
HC (hydrocarbon) :
* Ultraviolet rays in sunlight changes HC to ‘photochemical oxidant’
which causes photochemical smog.
* Stimulation to mucous membranes such as respiratory organs
* Bad influence to farm products.
NOx (nitrogen oxides) :
*A small amount of nitrogen oxides helps growth of a plant.
*If its density is high, it causes air pollution, photochemical smog, acid rain.
SPM (suspended particulate matter) :
*Particulate matters (PM) equal to or less than a diameter of 10μm
that are harmful to the human body.
*SPM which reached an alveolus cannot drained outside the body.
*It is thought to be a cause of lung cancer.
CO2 (Carbon dioxide) :
*Carbon dioxide of the low density is essential to breathing and is not harmful.
*It is thought to be a cause of global warming.
SOx (Sulfur oxides, mainly sulfur dioxide SO2 and sulfur trioxide SO3) :
*Generated by the combustion of insufficiently refined fuel includes sulfur.
*One of the causes of air pollution and acid rain
(Review) Reduction of toxic substance [Text p17]
Combustion temperature excessively high Combustion temperature excessively low

(Review) Exhaust Emission Regulations [Text p17]
Indonesia EURO2 : Jan 2007 ~
EURO2
0.15
(particulate
matter)
7
(nitrogen oxides)
EURO2 testing method (GVW over 3.5ton) [Text p17]
Test cycle : Steady 13 mode
Revolution
Load
Hot start
Time [min]
Testing time : 78min

Overview of Full Dilution Tunnel System [Text p17]

(Review) Improvement of fuel injection pump [Text p17]

(Review) Turbocharger [Text p17]

(Review) Intercooler [Text p17]

Coffee break
High pressure injection cuts PM generation [Text p29]
Reduction of PM
by converting to
water & CO2

Coffee break
Environmental measures in future (Image) [Text p29]
Atmosphere environment Anti-global warming

measures measures
Importance
Reduction of PM
Petroleum independence by converting to
measures water & CO2
Year
3-4. Introduction of low emission vehicle
4 Stroke cycle
2 Main body
3 Lubrication
5 Fuel system
6 Intake & exhaust
7 Electrical system
1 Fuel & engine oil
3 Others
CANTER & GUTS CNG [Text p37]
CNG : Compressed Natural Gas
Three way catalyst CNG tank

combined muffler
Fuel filler After muffler

CANTER & GUTS LPG [Text p37]
LPG : Liquefied Petroleum Gas
Three way catalyst
combined muffler
LPG tank
After muffler (only for long body)
Fuel filler

AERO NONSTEP HEV [Text p37]
Starting & low speed driving
Battery Inverter
Motor Engine
Acceleration & hill-climbing
① Electronic controller
② Inverter Braking
③ Diesel engine
④ Generator
⑤ Propulsion motor
⑥ Accessory drive motor
⑦ Lithium-Ion battery
⑧ Fuel tank
Terima Kasih!

Basic Knowledge of Engine: For Indonesia KTB Area Coordinators

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Basic Knowledge of Engine

based on the textbook

MFTBC R&D division 27 February 2006 @ KTB Jakarta page 2

MFTBC R&D division 27 February 2006 @ KTB Jakarta page 3

1987 Join Mitsubishi Motors

1991 Chassis design for Heavy duty truck

1993 Product development for Domestic market

1996 Product development for Export market

2003 REPRESENTATIVE OFFICE in Singapore

MFTBC R&D division 27 February 2006 @ KTB Jakarta page 5

N um ber S equence in S equence

MFTBC R&D division 27 February 2006 @ KTB Jakarta page 9

Horizontal (6 cylinder) Boxer (4 cylinder)

MFTBC R&D division 27 February 2006 @ KTB Jakarta page 12

All MFTBC engine

MFTBC R&D division 27 February 2006 @ KTB Jakarta page 13

MFTBC R&D division 27 February 2006 @ KTB Jakarta page 14

OHV OHC DOHC

Drive line components ①～④ specifications

③Brake Specific Fuel

MFTBC R&D division 27 February 2006 @ KTB Jakarta page 19

① Convert FE349 engine output &torque to SI.

② How about DYNA 125LT?

MFTBC R&D division 27 February 2006 @ KTB Jakarta page 20

MFTBC R&D division 27 February 2006 @ KTB Jakarta page 21

MFTBC R&D division 27 February 2006 @ KTB Jakarta page 22

① Calculate 4D34-2AT5 piston displacement.

② How about 6D16-3AT2 (118mm x 115mm)?

MFTBC R&D division 27 February 2006 @ KTB Jakarta page 23

Intake Compression Combustion Exhaust

Actual cycle Theoretical cycle

MFTBC R&D division 27 February 2006 @ KTB Jakarta page 26

What’s the difference between diesel & gasoline

MFTBC R&D division 27 February 2006 @ KTB Jakarta page 28

MFTBC R&D division 27 February 2006 @ KTB Jakarta page 29

MFTBC R&D division 27 February 2006 @ KTB Jakarta page 30

MFTBC R&D division 27 February 2006 @ KTB Jakarta page 31

Intake Compression Combustion Exhaust

Volume Volume Volume

Otto cycle Diesel cycle Savathe cycle

Gasoline engine Current Diesel engine

MFTBC R&D division 27 February 2006 @ KTB Jakarta page 33

Top dead center

MFTBC R&D division 27 February 2006 @ KTB Jakarta page 35

MFTBC R&D division 27 February 2006 @ KTB Jakarta page 36

Diesel engine Gasoline engine

Rudolf Diesel Gottlieb Daimler

MFTBC R&D division 27 February 2006 @ KTB Jakarta page 37

MFTBC R&D division 27 February 2006 @ KTB Jakarta page 40

Engine oil is necessary for lubricating moving parts

MFTBC R&D division 27 February 2006 @ KTB Jakarta page 44

Engine oil has lubricating, cooling & cleansing function.

MFTBC R&D division 27 February 2006 @ KTB Jakarta page 45

Engine oil must be cooled to keep its lubricating performance.

MFTBC R&D division 27 February 2006 @ KTB Jakarta page 46

MFTBC R&D division 27 February 2006 @ KTB Jakarta page 47

Hot coolant is cooled by radiator before further recirculation

MFTBC R&D division 27 February 2006 @ KTB Jakarta page 49

MFTBC R&D division 27 February 2006 @ KTB Jakarta page 53

Fuel feed pump

Timer for 6 cylinder engine

MFTBC R&D division 27 February 2006 @ KTB Jakarta page 55