New Generation Volvo Diesel Engine Fundamentals Classroom Training en

Service training
Diesel 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
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
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

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
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
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
Oil pump - parts ................................................................................................................ 106

Oil filter housing ................................................................................................................ 107
Oil flows through the filter ................................................................................................. 108
Oil cooler........................................................................................................................... 109
Oil sump............................................................................................................................ 110
Diesel engine fundamentals. Test 6 ................................................................................. 111
Fuel system
Fuel system
Fuel injection system ........................................................................................................ 114
Injection pump .................................................................................................................. 115
Mechanical regulator or governor..................................................................................... 116
Supply pump..................................................................................................................... 117
Smoke limiter .................................................................................................................... 118
Fuel filter ........................................................................................................................... 119
Pressure pipes.................................................................................................................. 120
Injector - copper sleeve .................................................................................................... 121
Nozzle sleeve - needle ..................................................................................................... 122
Injector - function .............................................................................................................. 123
Diesel engine fundamentals. Test 7B............................................................................... 124
Fuel systems with unit injectors........................................................................................ 126
Unit injector - system function .......................................................................................... 127
Diesel engine fundamentals. Test 7C............................................................................... 128
Common rail ..................................................................................................................... 130
Injector .............................................................................................................................. 131
Diesel engine fundamentals. Test 7D............................................................................... 132
Engine management system
Engine management system
EMS - Engine Management System ................................................................................ 133
Engine control unit ............................................................................................................ 134
Sensors on the engine...................................................................................................... 135
Other sensors ................................................................................................................... 136
Example of communication .............................................................................................. 137
Diesel engine fundamentals. Test 7A............................................................................... 138
Intake and exhaust system
Intake and exhaust system............................................................................................... 140
Air filter ............................................................................................................................. 141

Cyclone filter .................................................................................................................... 142
Starter element ................................................................................................................. 143
Exhaust pressure governor .............................................................................................. 144
Compression brake VEB .................................................................................................. 145
Compression brake VEB+ ................................................................................................ 146
Compression brake JAK................................................................................................... 147
Engine brake function....................................................................................................... 148
Turbocharger
Turbocharger
Turbocharger history......................................................................................................... 151
Turbocharging................................................................................................................... 152
Turbocharger bearing ....................................................................................................... 153
Wastegate......................................................................................................................... 154
Turbocharger system........................................................................................................ 155
Exhaust pressure governor .............................................................................................. 156
Turbocharger type VGT .................................................................................................... 157
Charge air cooling............................................................................................................. 158
Air to air cooling ................................................................................................................ 159
Cooling system
Cooling system
Volvo coolant .................................................................................................................... 162
Cooling system ................................................................................................................ 163
External components of the cooling system..................................................................... 164
Thermostat ....................................................................................................................... 165
Schematic presentation of the cooling system ................................................................. 166
Radiator ............................................................................................................................ 167
Cooling fans in vehicles.................................................................................................... 168
Cooling fans in bus ........................................................................................................... 169
Cooling fans in VCE ......................................................................................................... 170
Diesel engine fundamentals. Test 10 ............................................................................... 171
Emissions
Emissions
Vehicle emissions and environmental impact .................................................................. 174
Engine emission ............................................................................................................... 175

Carbon dioxide and Hydrocarbons ................................................................................... 176
Nitrogen oxides (NOX) ..................................................................................................... 177
Particulate matter.............................................................................................................. 178
Diesel engine fundamentals. Test 11A............................................................................. 180
EGR
EGR
Emisson control, schematic description of the system..................................................... 181
EGR system...................................................................................................................... 182
I-EGR, Large engine platform........................................................................................... 183
I-EGR, Medium engine platform ....................................................................................... 184
I-EGR Function, Medium engine platform ........................................................................ 185
Diesel engine fundamentals. Test 11B............................................................................. 186
SCR
SCR
SCR - Selective Catalytic Reduction ................................................................................ 187
Main components in the Volvo SCR system .................................................................... 188
Solution principle for the Volvo SCR system.................................................................... 189
Overview of the exhaust gas processing system ............................................................. 190
Diesel engine fundamentals. Test 11C ............................................................................ 191
CCV
CCV
CCV - CrankCase Ventilation - Closed............................................................................. 193
Diesel engine fundamentals. Test 11D ............................................................................ 194
Introduction > Course content
Notes
GT120017A v.1.0.01_en
Page 1
Introduction > Course content

Key points
Course content
Practical exercises
Theoretical summary
Course schedule
Working procedure
Go through Course content (overview).
Explain briefly what the different subjects will include - give examples.
Explain that each practical session will start with theory and after there it will be a practical
session.
Test questions are also included.
Remind the participants that later there will be a written test to complete the course.
Go through the schedule.
Additional information
Course guide
Start by welcoming the participants to the course.
Introduce yourself and let all the participants introduce themselves, e.g. give their name,
company, say where they come from, 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).
Also mention practical issues such as breaks, smoking, mobile phones, etc.
If this is the first time the participants have been on a Volvo course, tell them a little about the
Volvo Company.
Hand out the student material and inform the participants of the post test that will be held on the
last day. The use of the student material, including any personal notes the participants may have
made, will be allowed during the written post test.
Mention that some of the tasks from the practical training can be performed as individual tests.
Morning and afternoon breaks should be adapted to suit local times.
Trainer notes
Page 1 (trainer)
Introduction > Course objectives
Course objectives
After completing the course, you should be able to
Select and use appropriate tools and equipment.
Carry out jobs in a safe way, without causing damage to equipment, component, vehicle or
person.
Check and adjust a range of engine components. e.g. valves, unit injectors, engine brake
system, fuel systems, belts etc.
Verify proper operation after adjustment.
The purpose of this training is to give you a good knowledge of the Basic Diesel Technology in
practical and theoretical.
Notes
Page 2
GT120017A v.1.0.01_en
Introduction > Course objectives
Key points
Course objectives
Check and adjust
Appropriate tools and equipment.
Damage
Verify proper operation
Working procedure
Go through Course objectives (overview).
Course guide
Trainer notes
Page 2 (trainer)
Engine history > The diesel engine, yesterday and today
The diesel engine, yesterday and today

It all began in 1892 when Rudolf Diesel was granted a patent for a new type of engine. 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. Rudolf Diesel initially intended powering his new engine with coal
dust, but soon switched his attention to liquid fuel. Today, all diesel engines are driven by diesel
oil.
Diesel's first engine was completed in 1893. It suffered a host of problems and did not produce
enough power to keep itself running.
Not before 1897 did Diesel manage to produce an engine which functioned anything like he had
envisioned.
Since then, considerable effort has been invested in research and development to bring the
diesel engine to today's levels of superb efficiency and operational reliability.
The picture on the left shows one of the very earliest engines. It has a bore of 220 mm and a
stroke of 400 mm. And it's 3 metres tall.
The engine on the right is a Volvo TAD 1630. Roughly 80 years of development separate Rudolf
Diesel's first engine from this hyper-modern power unit.
Diesel engines today weigh less than half as much as their first ancestors, and they pump out
more than 30 times as much power.
GT120017A v.1.0.01_en
Page 3
Engine history > The diesel engine, yesterday and today

Key points
History
Rudolf Diesel
Frenchman
Born 1858
1876 Otto patent 4-stroke engine
1892 patent diesel
Coaldust
First working engine = 4.5 ton - 20hp - 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.
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.
Trainer notes
Page 3 (trainer)
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. Rather, 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). It
was used to power industrial machines and was in regular operation until 1930. It was produced
by a German manufacturer, MAN in Augsburg.
Notes
Page 4
GT120017A v.1.0.01_en
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
Trainer notes
Page 4 (trainer)
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.
The very first vehicle engines came in the early 1920s. One of the first, a Benz from 1922, can be
seen here on the right. It had two cylinders and produced just 22 kW or 30 horsepower.
Notes
GT120017A v.1.0.01_en
Page 5
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
Trainer notes
Page 5 (trainer)
Engine history > Engines for heavier vehicles
Engines for heavier vehicles

The first engines were made for heavier vehicles such as trucks and tractors. The truck pictured
here is a Daimler-Benz made in 1923.
Lightweight series-manufactured diesel engines for passenger cars first made an entry about ten
years later. The first such engines bore the Daimler-Benz badge and they had a power output of
about 33 kW or 45 horsepower.
Rudolf Diesel, the inventor of the diesel engine, died in 1913, 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 MD1.
Volvo Construction Equipment launch diesel engine in 1954.
Volvos busses got a new diesel engine 1945 and one year later it was also introduce in the
trucks. The engine type was called VDA.
Notes
Page 6
GT120017A v.1.0.01_en
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, the inventor of the diesel engine, died in 1913
Volvo Penta launch diesel engine in 1958. 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
Trainer notes
Page 6 (trainer)
Engine history > Diesel engines in Volvo vehicles
Diesel engines in Volvo vehicles

Diesel engines were first fitted to Volvo trucks in 1946. The first engine was a six-cylinder unit
producing 71 kilowatts (96 horsepower). It carried the VDA designation (Volvo Diesel engine type
A).
More than a decade previously, however, in 1933, Volvo's trucks were powered by an engine
similar in concept to the diesel engine. It was known as the Hesselman engine and it ran on the
same fuel as the diesel engine, but featured an electrical ignition system. The Hesselman unit is
often referred to as a "semi-diesel" engine.
The latest generation of engines with which you work are developments of these early units.
Everyone concerned has invested enormous effort and expertise in making the diesel engine
better and better.
And the result can be seen if you compare the first VDA engine with a similarly-sized engine of
today.
Just look at the power outputs, for example. The VDA produced 71 kW and had a displacement
of 6.12 litres. A corresponding engine of today, the D6A (slightly smaller but with a turbocharger
and intercooler) produces more then 150 kW!
And there's more.
Fuel consumption is lower. Durability and service life are longer. Operating reliability is far higher.
So a lot has happened since 1946!
But what of the future?
Well, 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.
GT120017A v.1.0.01_en
Page 7
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 6.12 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
Trainer notes
Page 7 (trainer)
Engine range > Engine range
Engine range
We shall look at the diesel engine range on the engine that we have today. Volvo have engines in
a range from approx. 240 horsepower and up to 700 horsepower. The cylinder volume is
between 7 litres and up to 16 litres.
The smallest engine is the D7E and it was launched in 2006...
_
...the next engine in range is the D9 engine and it was launched in 2001...
_
...and the D11 engine, launched in 2008...
_
... we have also the D13 engine. This engine was launched in 2005 and the biggest of them all
is...
_
...the D16 and this is also the most powerful of them all.
Notes
Page 8
GT120017A v.1.0.01_en
Engine range > Engine range

Key points
Range
D7E
D9
D11
D13
D16
Working procedure
Talk with the participants about the Volvo engine range.
Explain why we have overlap for different engines power and torque.
There is overlapping of different engine powers and torques. That has to do with different taxation
in different markets. Some markets have tax depending on power other markets set the tax
depending on volume.
Go through the information shown in the additional information.
Her it is possible to run the movie AN INTRO TO DIESEL ENGINE. This is like a teaser for the
participants. The movie going through the fundamentals estimated time 15 min. An another way
is to show each chapter where it belongs. This decision is up to the teacher to decide. In the
tranier notes under headline "Additional information" the trainer find information when it is time to
run each chapter.
Trainer notes
Page 8 (trainer)
General and basic priciples > General and basic principles > Diesel engine
Diesel engine
High demands are placed on modern engines.
They must meet demands for low fuel consumption combined with high performance, while at the
same time having low levels of noise and exhaust emissions.
There are few power sources on which so much research and development work is expended as
on the diesel engine, which is basically quite an old invention.
Development work has essentially been concentrated on refining existing technology, but a great
number of completely new solutions have been developed in recent years.
Electronic Management Systems (EMS) have been used for a number of years, and electronics
are steadily taking on a more central role in each new generation of engines.
The earlier fuel injection system EDC (Electronic Diesel Control), 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.
Notes
GT120017A v.1.0.01_en
Page 9
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
information/text.
Walk around different engines if it is possible and let the participants point out engine main part
on the outside.
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.
Her it is time to run the movie AN INTRO TO DIESEL ENGINE chapter

"Introduction" and "Basic design". This is like a teaser for the participants.
Trainer notes
Page 9 (trainer)
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.1.0.01_en
General and basic priciples > General and basic principles > Internal combustion engine
Key points
Internal combustion engine
Combustion chamber
Piston
Cylinder
Working procedure
information/text.
tracing.
Trainer notes
Page 10 (trainer)
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.1.0.01_en
Page 11
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
information/text.
tracing.
Trainer notes
Page 11 (trainer)
General and basic priciples > General and basic principles > Rotating movement
Rotating movement
Connecting rod
Crankshaft
Notes
Page 12
GT120017A v.1.0.01_en
General and basic priciples > General and basic principles > Rotating movement
Key points
Movement of the piston
Rotating movement
Connecting rod
Crankshaft.
The force -piston-connecting rod-crankshaft
Propel the vehicle
Working procedure
information/text.
tracing.
Trainer notes
Page 12 (trainer)
General and basic priciples > General and basic principles > Power from crankshaft
Power from crankshaft

Vehicle
Transmission components
Driven wheels
Driveline
Notes
GT120017A v.1.0.01_en
Page 13
General and basic priciples > General and basic principles > Power from crankshaft
Key points
Crankshaft-gearbox-rear axle-wheel
Driveline
Working procedure
information/text.
tracing.
Trainer notes
Page 13 (trainer)
General and basic priciples > General and basic principles > Diesel engine - petrol engine
Diesel engine - petrol engine

Petrol engine
Ready-mixed blend of petrol and air
Compressed
Ignited
Spark
Notes
Page 14
GT120017A v.1.0.01_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
information/text.
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
information/text.
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
information/text.
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)
700-900C
Fuel injection occurs at the end of the compression stroke
2000-2500C
Operating stroke
Exhaust stroke
Working procedure
information/text.
tracing.
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
General and basic priciples > General and basic principles > Four stroke - six cylinder
Key points
Four-stroke principle
Firing order, 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
Working procedure
information/text.
tracing.

"Induction stroke", "Compression stroke", "Working stroke" and "Exhaust stroke".
This is like a teaser for the participants. 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.
Trainer notes
Page 18 (trainer)
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.1.0.01_en
Page 19
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, combustion has taken place in all the cylinders
One combustion stroke does not have time to be completed before the next starts
Working procedure
information/text.
tracing.
Operating strokes are coloured red.
With the engine operating at 2000 rpm. per minute, there are 6000 combustion strokes per
minute or 100 per second.
If the engine is run at that speed, it takes just three minutes to reach a million combustion
strokes.
Her it is time to run the movie AN INTRO TO DIESEL ENGINE chapter "Firing order". This is
like a teaser for the participants.
Trainer notes
Page 19 (trainer)
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.1.0.01_en
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.
Sankey diagram
Energy 100%.
Cooling losses ca. 25% (diesel engine)
Exhaust losses ca. 25% (diesel engine)
Friction losses ca. 10% (diesel engine)
Efficiency rating ca. 40% (diesel engine)
Working procedure
information/text.
tracing.
Diesel engines have the highest efficiency rating of all, up to 43-44% in a truck engine (D13 up to
47%).
Passenger-car diesels are somewhat less efficient, at about 38%, roughly the same level as twostroke diesel engines for vehicles. Petrol engines have an efficiency rating of about 30%.
The first engines from the end of the previous century had an efficiency rating of a mere 2-5%.
Trainer notes
Page 20 (trainer)
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.1.0.01_en
Page 21
General and basic priciples > General and basic principles > Three diesel engine types
Key points
Three diesel engine types
All Volvo diesel engines are direct-injection units
Working procedure
information/text.
tracing.
Trainer notes
Page 21 (trainer)
General and basic priciples > General and basic principles > Precombustion indirect-injection
engines

Fuel
Pre-chamber
Combustion
Glowplug
Notes
Page 22
GT120017A v.1.0.01_en
General and basic priciples > General and basic principles > Precombustion indirect-injection
engines
Key points
Roughly 25%, 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
information/text.
tracing.
Trainer notes
Page 22 (trainer)
General and basic priciples > General and basic principles > Swirl-chamber engine
Swirl-chamber engine
Combustion chamber
Swirl-chamber
Notes
GT120017A v.1.0.01_en
Page 23
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
information/text.
tracing.
Trainer notes
Page 23 (trainer)
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.1.0.01_en
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
information/text.
tracing.
Trainer notes
Page 24 (trainer)
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, up to about 6000 rpm.
Greater losses
Lower efficiency
High fuel consumption
Notes
GT120017A v.1.0.01_en
Page 25
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, up to about 6000 rpm
Greater losses than for direct-injection engines
Lower efficiency rating
Higher fuel consumption
Working procedure
information/text.
tracing.
Trainer notes
Page 25 (trainer)
General and basic priciples > General and basic principles > Diesel engine fundamentals. Test 1
Diesel engine fundamentals. Test 1

Decide which is correct.
A petrol engine takes in a ready-mixed blend of fuel and air.
The diesel engine works under higher pressure than a petrol engine.
The diesel engine is sometimes equipped with an electrical ignition system.
The highest pressure resulting from combustion is known as peak pressure.
In a diesel engine, finely atomised fuel is sprayed into the combustion chamber.
These parts are subjected to greater mechanical stresses in a diesel engine than in a
petrol engine.
True
False
State the correct sequence for the following processes (put the figures in the appropriate
boxes 1 -6 ).
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, putting the figures in the appropriate boxes ( 1 - 4 ).
Page 26
GT120017A v.1.0.01_en
Key points
Question
Answer
Working procedure
It is now time to hand out the question to the participants.
Let each participants work with the question for about 5-10 minutes. After that shall the trainer go
through the correct answer.
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.
Introduction to diesel engines. Test 1 Key

*A petrol engine takes in a ready-mixed blend of fuel and air.
*The diesel engine works under higher pressure than a petrol engine.
The diesel engine is sometimes equipped with an electrical ignition system.
*The highest pressure resulting from combustion is known as peak pressure.
*In a diesel engine, finely atomised fuel is sprayed into the combustion chamber.
These parts are subjected to greater mechanical stresses in a diesel engine than in a petrol
engine.
*True
False
State the correct sequence for the following processes (put the figures in the appropriate boxes 1
-6 ).
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, putting the figures in the appropriate boxes ( 1 - 4 ).
Inlet stroke 1
Exhaust stroke 4
Operating stroke 3
Compression stroke 2
During one of the strokes in a diesel engine, the piston is on its way down and both valves are
shut. Which stroke is this?
Inlet stroke
Exhaust stroke
Compression stroke
*Opearating stroke
Page 26 (trainer)
nlet stroke
Exhaust stroke
Operating stroke
Compression stroke
During one of the strokes in a diesel engine, the piston is on its way down and both valves
are shut. Which stroke is this?
Inlet stroke
Exhaust stroke
Compression stroke
Opearating stroke
Peak pressure in a diesel engine can approach 20 MPa (200 bar).
No, not so high.
Yes, this is true.
No, much higher.
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.
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
GT120017A v.1.0.01_en
Page 27
Peak pressure in a diesel engine can approach 20 MPa (200 bar).

No, not so high.
*Yes, this is true.
No, much higher.
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.
*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
Trainer notes
Page 27 (trainer)
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
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, smooth operation
Service on this engine is simple
Large crankshaft bearing surface
Crankshaft is journalled in seven main bearings
Working procedure
information/text.
tracing.
Trainer notes
Page 28 (trainer)
General and basic priciples > General and basic principles > V-engine
V-engine
Volvo 8-cylinder engine
Notes
GT120017A v.1.0.01_en
Page 29
General and basic priciples > General and basic principles > V-engine
Key points
V-engine
Forties
400 bhp
Military vehicles
Truck
120 bhp
Working procedure
information/text.
tracing.
Trainer notes
Page 29 (trainer)
General and basic priciples > General and basic principles > Volvo - V8 engines
Volvo - V8 engines
Here are a few reasons why Volvo no longer builds V-engines:
Five main bearings
Two connecting rods - one crankshaft journal
Service is much more difficult
Notes
Page 30
GT120017A v.1.0.01_en
General and basic priciples > General and basic principles > Volvo - 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
information/text.
tracing.
Trainer notes
Page 30 (trainer)
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, Connecting rod, Piston, Flywheel
Stiffening frame (on some engines)
Oil sump
Notes
GT120017A v.1.0.01_en
Page 31
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.
Cylinder block with cylinder liners, pistons, 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, Connecting rod, Piston, Flywheel
Stiffening frame (on some engines)
Oil sump
Other components
Inlet manifold
Exhaust manifold
Oil cooler
Oil filter
Coolant pump
Injection equipment.
Working procedure
information/text.
tracing.
Trainer notes
Page 31 (trainer)
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.1.0.01_en
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
information/text.
tracing.
Trainer notes
Page 32 (trainer)
General and basic priciples > General and basic principles > Cylinder block - inside
Cylinder block - inside

Coolant jacket
Cylinder liners
O-rings
Main bearings
Bearings for the camshaft
Lubricating oil ducts
Piston cooling duct
Notes
GT120017A v.1.0.01_en
Page 33
General and basic priciples > General and basic principles > Cylinder block - 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
information/text.
tracing.
Trainer notes
Page 33 (trainer)
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.1.0.01_en
General and basic priciples > General and basic principles > Camshaft in cylinder block
Key points
Location
Lifters
Pushrods
Rocker arms
Transmission gears
Working procedure
information/text.
tracing.
Trainer notes
Page 34 (trainer)
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.1.0.01_en
Page 35
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
information/text.
tracing.
Trainer notes
Page 35 (trainer)
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
General and basic priciples > General and basic principles > Cylinder bore
Key points
High degree of precision
Cylindrical throughout
Smooth surface.
Milled and honed
Plateau honing
Oil pockets
Constant film of oil
Shorter running-in period
Tapered profile
Prevents carbon on the piston
Working procedure
information/text.
tracing.
Trainer notes
Page 36 (trainer)
General and basic priciples > General and basic principles > Cylinder head
Cylinder head
Cast-iron alloy
Huge stresses
Combustion process
Notes
GT120017A v.1.0.01_en
Page 37
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
information/text.
tracing.
Trainer notes
Page 37 (trainer)

Place the right figure beside the appropriate name.
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.
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.1.0.01_en
Key points
Question
Answer
Working procedure
problems.
Let each participants work with the question for about 5-10 minutes.
After that shall the trainer go through the correct answer.

Place the right figure beside the appropriate name.
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.
*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.
*True
False
The diesel engine's cylinder head gasket is made of
a heat-resistant copper alloy
Page 38 (trainer)
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.
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.
True
False
Decide which is/are correct.
The upper liner seal is a thin O-ring.
The cylinder head gasket can withstand high peak pressures.
The lower cylinder liner gasket consists of two or three O-rings.
Notes
GT120017A v.1.0.01_en
Page 39
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.
True
*False
*The upper liner seal is a thin O-ring.
*The cylinder head gasket can withstand high peak pressures.
*The lower cylinder liner gasket consists of two or three O-rings.
Trainer notes
Page 39 (trainer)
General and basic priciples > General and basic principles > Cylinder head - Inlet and exhaust
ducts
Cylinder head - Inlet and exhaust ducts

Cooling jacket
Exhaust outlet
Injector sleeve
Inlet and exhaust ducts
Valve seat
Valve guide
Notes
Page 40
GT120017A v.1.0.01_en
General and basic priciples > General and basic principles > Cylinder head - Inlet and exhaust
ducts
Key points
Direct contact
Large cooling jacket
The hottest areas
Inlet duct
Exhaust duct
Valve seat
Valve guide
Working procedure
information/text.
tracing.
Trainer notes
Page 40 (trainer)
General and basic priciples > General and basic principles > Cylinder head - Copper sleeve
Cylinder head - Copper sleeve

Injector
Copper sleeve
Cooling jacket
Notes
GT120017A v.1.0.01_en
Page 41
General and basic priciples > General and basic principles > Cylinder head - Copper sleeve
Key points
Injector
Copper sleeve
Cooling jacket
Working procedure
information/text.
tracing.
Trainer notes
Page 41 (trainer)
General and basic priciples > General and basic principles > Cylinder head - Details
Cylinder head - Details

Cylinder head
Hole for injector
Valve guide
Injector sleeve
Valve seat, exhaust
Valve seat, inlet
Notes
Page 42
GT120017A v.1.0.01_en
General and basic priciples > General and basic principles > Cylinder head - Details
Key points
Cylinder head
Hole for injector
Valve guide
Injector sleeve
Valve seat, exhaust
Valve seat, inlet
Working procedure
information/text.
tracing.
Trainer notes
Page 42 (trainer)
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, which also contains chemical additives
Engine oil, which contains chemical additives
Notes
GT120017A v.1.0.01_en
Page 43
seals
Key points
Seals
Cylinder head gasket-highest forces
High pressure
Coolant
Engine oil
Steel plate
O-rings
Ridges or grooves
Working procedure
information/text.
tracing.
Trainer notes
Page 43 (trainer)
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.1.0.01_en
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
information/text.
tracing.
Trainer notes
Page 44 (trainer)
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.1.0.01_en
Page 45
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
Thrust washers (axial bearings)
Crankshaft
Working procedure
information/text.
tracing.
Trainer notes
Page 45 (trainer)
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 - 130 cm2
140 kN (kilo Newton), in other words about 14 tonnes
Notes
Page 46
GT120017A v.1.0.01_en
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, the peak pressure is 20 MPa
Working procedure
information/text.
tracing.
Trainer notes
Page 46 (trainer)
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.1.0.01_en
Page 47
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
information/text.
tracing.
Trainer notes
Page 47 (trainer)
General and basic priciples > General and basic principles > Power impulse
Power impulse
Power impulse
Torsional tendencies
Notes
Page 48
GT120017A v.1.0.01_en
General and basic priciples > General and basic principles > Power impulse
Key points
Power impulse
Torsional tendencies
Working procedure
information/text.
tracing.
Trainer notes
Page 48 (trainer)
General and basic priciples > General and basic principles > Crankshaft - Oscillation
Crankshaft - Oscillation
Rapid oscillation
Vibration damper
Flywheel
Notes
GT120017A v.1.0.01_en
Page 49
General and basic priciples > General and basic principles > Crankshaft - Oscillation
Key points
Rapid oscillation
Snap the crankshaft
Vibration damper
Flywheel
Pulsationes and vibrations
Working procedure
information/text.
tracing.
Trainer notes
Page 49 (trainer)
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
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
information/text.
tracing.
Trainer notes
Page 50 (trainer)
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
information/text.
tracing.
Trainer notes
Page 51 (trainer)
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.1.0.01_en
General and basic priciples > General and basic principles > Seven main bearings
Key points
Seven main bearings
Long service life
Working procedure
information/text.
tracing.
Trainer notes
Page 52 (trainer)
General and basic priciples > General and basic principles > Seven main bearings - connecting
rod
Seven main bearings - 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
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
information/text.
tracing.
Trainer notes
Page 53 (trainer)
General and basic priciples > General and basic principles > V-engine, two connecting rods
V-engine, two connecting rods

Bearing
Vital difference
V-engine - two connecting rods
Notes
Page 54
GT120017A v.1.0.01_en
General and basic priciples > General and basic principles > V-engine, two connecting rods
Key points
In-line six-V-engine
Two connecting rods-same crankshaft bearing journal
Not be as generously dimensioned
Working procedure
information/text.
tracing.
Trainer notes
Page 54 (trainer)
General and basic priciples > General and basic principles > Lubrication ducts
Crankshaft - Lubrication ducts

Pressure-lubricated
Drilled oil ducts in the crankshaft
Notes
GT120017A v.1.0.01_en
Page 55
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
information/text.
tracing.
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.
Pistons 2 and 5 move together.
Pistons 3 and 4 move together.
120 crankshaft degrees
Ignition impulses
Notes
Page 56
GT120017A v.1.0.01_en
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.
120 crankshaft degrees
Working procedure
information/text.
tracing.
Trainer notes
Page 56 (trainer)
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.1.0.01_en
Page 57
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
information/text.
tracing.
Trainer notes
Page 57 (trainer)
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
information/text.
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
information/text.
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
information/text.
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
information/text.
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.1.0.01_en
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
information/text.
tracing.
Trainer notes
Page 62 (trainer)
General and basic priciples > General and basic principles > Connecting rod - details
Connecting rod - details

Classified
Marked
Front marking
Trapezoidal
Lubricated via ducts
Splash lubrication
Diagonally split
Notes
GT120017A v.1.0.01_en
Page 63
General and basic priciples > General and basic principles > Connecting rod - 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
information/text.
tracing.
Trainer notes
Page 63 (trainer)
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.1.0.01_en
General and basic priciples > General and basic principles > Gudgeon pin
Key points
Gudgeon pin
Considerable stress and load
High-quality material
Chrome-manganese steel
Chrome-molybdenum steel alloys
Tubular
Surface-hardened
Finely-ground
Fine tolerances
Working procedure
information/text.
tracing.
Trainer notes
Page 64 (trainer)
General and basic priciples > General and basic principles > Gudgeon pin hole
Gudgeon pin hole

Larger diameter
Changes shape
High load
Notes
GT120017A v.1.0.01_en
Page 65
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
information/text.
tracing.
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)
General and basic priciples > General and basic principles > Gudgeon pin - journal led
Gudgeon pin - journal led

Journal led
Floating fit
Locking rings
Notes
Page 66
GT120017A v.1.0.01_en
General and basic priciples > General and basic principles > Gudgeon pin - journal led
Key points
Journal led
Floating fit
Locking rings
Working procedure
information/text.
tracing.
Trainer notes
Page 66 (trainer)
General and basic priciples > General and basic principles > Connecting rod bearing

Two bearing shells
Machined big end
Guide lugs
Pressure-lubricated
Notes
GT120017A v.1.0.01_en
Page 67
General and basic priciples > General and basic principles > Connecting rod bearing
Key points
Machined big end
Guide lugs
Fit properly
Pressure-lubricated
Working procedure
information/text.
tracing.
Trainer notes
Page 67 (trainer)

Place the right number beside the appropriate name.
Crank bearing
Vibration damper
Crankshaft
Thrust washers
Piston
Connecting rods
Flywheel
Main bearing
Piston rings
Gudgeon pin
Volvo diesel engines have fluid-type vibration dampers.
The crankshaft is balanced in a special machine.
Imbalance in the crankshaft affects the main bearings but does not cause vibration in the engine
or particularly heavy load on the crankshaft.
The ducts in the crankshaft's counterbalances are part of the lubrication system.
The crankshafts in Volvo diesel engines are forged from special steel.
True
False
Page 68
GT120017A v.1.0.01_en
Key points
Question
Answer
Working procedure
problems.

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
*Volvo diesel engines have fluid-type vibration dampers.
*The crankshaft is balanced in a special machine.
Imbalance in the crankshaft affects the main bearings but does not cause vibration in the engine
or particularly heavy load on the crankshaft.
The ducts in the crankshaft's counterbalances are part of the lubrication system.
The crankshafts in Volvo diesel engines are forged from special steel.
*True
False
Nitro-carburisation is a heat-treatment method for crankshafts.
*True
False
A bearing shell is made of a steel shell lined with bearing metal.
*True
False
The term "seven-bearing crankshaft" means that the crankshaft has as many main bearing pins
as crankshaft pins.
True
*False
This illustration shows the crank weight positions in relation to each other.
Page 68 (trainer)
itro-carburisation is a heat-treatment method for crankshafts.

True
False
A bearing shell is made of a steel shell lined with bearing metal.
True
False
The term "seven-bearing crankshaft" means that the crankshaft has as many main bearing
pins as crankshaft pins.
True
False
This illustration shows the crank weight positions in relation to each other.
Pistons 1 and 3 make their vertical movements at the same time.
There are 120:2 crankshaft degrees between ignition points.
There are 120 crankshaft degrees between ignition points.
The main bearings and crankshaft bearings are slider bearings.
True
False
The support bearing, the fourth main bearing, keeps the crankshaft in a pre-determined
axial position.
True
False
Decide what is correct.
The flywheel evens out variations in rpm.
The starter ring gear is on the flywheel.
The clutch acts on the flywheel's surface-ground face.
The connecting rod's big-end is split diagonally.
True
False
Notes
GT120017A v.1.0.01_en
Page 69

*Pistons 2 and 5 make their vertical movements at the same time.
There are 120:2 crankshaft degrees between ignition points.
*There are 120 crankshaft degrees between ignition points.
The main bearings and crankshaft bearings are slider bearings.
*True
False
The support bearing, the fourth main bearing, keeps the crankshaft in a pre-determined axial
position.
*True
False
*The flywheel evens out variations in rpm.
*The starter ring gear is on the flywheel.
*The clutch acts on the flywheel's surface-ground face.
The connecting rod's big-end is split diagonally.
*True
False
Trainer notes
Page 69 (trainer)
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.1.0.01_en
General and basic priciples > General and basic principles > Piston
Key points
Piston
Immense load
Transfer considerable force
Gudgeon pin - connecting rod - crankshaft
Piston roof
Guide surface
Combustion pressure leakage
Piston and cylinder wall
Piston rings
Piston ring groove
Working procedure
information/text.
tracing.
Trainer notes
Page 70 (trainer)
General and basic priciples > General and basic principles > Piston - Thermal stress and
mechanical stress
Piston - 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.1.0.01_en
Page 71
General and basic priciples > General and basic principles > Piston - 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
information/text.
tracing.
Trainer notes
Page 71 (trainer)
General and basic priciples > General and basic principles > Piston - Materials
Piston - Materials
Aluminium alloy
Silicon
Iron
Nickel
Manganese
Copper
Magnesium
Extremely durable
Thermal expansion
Notes
Page 72
GT120017A v.1.0.01_en
General and basic priciples > General and basic principles > Piston - Materials
Key points
Aluminium alloy
Steel
Diameter
Working procedure
information/text.
tracing.
Trainer notes
Page 72 (trainer)
General and basic priciples > General and basic principles > Articulated piston
Articulated piston
Articulated pistons - split pistons
Separately journal led
Gudgeon pin
Top section - steel
Bottom section - aluminium
Notes
GT120017A v.1.0.01_en
Page 73
General and basic priciples > General and basic principles > Articulated piston
Key points
Articulated pistons (split pistons)
Separately journal led
Top section - steel
Bottom section - aluminium
Small gap prevent heat transference
Higher temperature
Higher co-efficient of efficiency
Working procedure
information/text.
tracing.
Trainer notes
Page 73 (trainer)
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.1.0.01_en
General and basic priciples > General and basic principles > Piston - Tolerance
Key points
Tight dimensional tolerances
Differences 0.07-0.08 mm
Pistons and liners - complete kits
Heat is transferred
Vulnerable to wear
Piston ring carrier made of cast-iron
Working procedure
information/text.
tracing.
Trainer notes
Page 74 (trainer)
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.1.0.01_en
Page 75
General and basic priciples > General and basic principles > Piston cooling
Key points
Internal piston cooling
Piston crown- channel
Very efficient cooling
Working procedure
information/text.
tracing.
Trainer notes
Page 75 (trainer)
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.1.0.01_en
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 - back to the sump
Working procedure
information/text.
tracing.
Trainer notes
Page 76 (trainer)
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.1.0.01_en
Page 77
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 - Keystone ring
Ability to keep clean
Chrome-plated
Molybdenum
Working procedure
information/text.
tracing.
Trainer notes
Page 77 (trainer)
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.1.0.01_en
General and basic priciples > General and basic principles > Piston rings material second ring
Key points
Chrome-plated
Internal ridge
Twist
"Twistrings"
Working procedure
information/text.
tracing.
Trainer notes
Page 78 (trainer)
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.1.0.01_en
Page 79
General and basic priciples > General and basic principles > Piston rings material oil ring
Key points
Chrome-plated
Two scraper edges
Spring
Working procedure
information/text.
tracing.
Trainer notes
Page 79 (trainer)
General and basic priciples > General and basic principles > Piston rings - Oil ring
Piston rings - Oil ring

Oil
Return holes
Notes
Page 80
GT120017A v.1.0.01_en
General and basic priciples > General and basic principles > Piston rings - Oil ring
Key points
Oil
Led back
Crankcase
Oil sump
Return holes
Working procedure
information/text.
tracing.
Trainer notes
Page 80 (trainer)

The gudgeon pin is prevented from moving towards the cylinder wall
by.
a screw which locks the pin to the connecting rod.
a decive which locks it to the small-end.
lock-rings in the piston.
Put the numbers in the appropriate boxes.
Piston rings
Piston crown
Piston ring groove
Piston shirt
Combustion chamber
Lock ring
Pistons and cylinder liners are classified according to diameter.
Piston and liner are matched together as per the classification letter.
GT120017A v.1.0.01_en
Page 81
Key points
Question
Answer
Working procedure
problems.

The gudgeon pin is prevented from moving towards the cylinder wall by.
a screw which locks the pin to the connecting rod.
a decive which locks it to the small-end.
*lock-rings in the piston.
Piston rings 3
Piston crown 2
Piston ring groove 5
Piston shirt 6
Combustion chamber 1
Lock ring 4
*Pistons and cylinder liners are classified according to diameter.
*Piston and liner are matched together as per the classification letter.
Pistons are marked with classification figures 1, 2, 3 etc.
A twist-ring twists in the ring groove, thus scraping the oil as the piston moves downwards.
*True
False
The Keystone ring has a trapezoidal cross-section.
*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.
*True
Page 81 (trainer)
istons are marked with classification figures 1, 2, 3 etc.

A twist-ring twists in the ring groove, thus scraping the oil as the
piston moves downwards.
True
False
The Keystone ring has a trapezoidal cross-section.
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.
True
False
Notes
Page 82
GT120017A v.1.0.01_en
False
Trainer notes
Page 82 (trainer)
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.1.0.01_en
Page 83
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 - cam
Spherical
Surface-hardened
Working procedure
information/text.
tracing.
Her it is time to run the movie AN INTRO TO DIESEL ENGINE chapter "Valve
mechanism". This is like a teaser for the participants.
Trainer notes
Page 83 (trainer)
General and basic priciples > General and basic principles > Pushrod engine
Pushrod engine
Pushrod act
Rocker arm
Valve yoke
Notes
Page 84
GT120017A v.1.0.01_en
General and basic priciples > General and basic principles > Pushrod engine
Key points
Pushrod engine
Pushrod
Rocker arm
Valves
Valve yoke
Working procedure
information/text.
tracing.
Trainer notes
Page 84 (trainer)
General and basic priciples > General and basic principles > Overhead camshaft
Overhead camshaft
Rocker arm
Directly
Cam
Notes
GT120017A v.1.0.01_en
Page 85
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
information/text.
tracing.
Trainer notes
Page 85 (trainer)
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 - Thrust washer
Notes
Page 86
GT120017A v.1.0.01_en
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 - thrust washer
Working procedure
information/text.
tracing.
Trainer notes
Page 86 (trainer)
General and basic priciples > General and basic principles > Camshaft - Design
Camshaft - Design
Valves open and shut at exactly the right time
Driven by the crankshaft
Engine timing mechanism - Timing gears
A = the total camheight
B = called the basic circle
C = the camlift
Notes
GT120017A v.1.0.01_en
Page 87
General and basic priciples > General and basic principles > Camshaft - 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" - "Timing gears"
A - B = C
A = the total camheight
B = called the basic circle
C = the camlift
Working procedure
information/text.
tracing.
Trainer notes
Page 87 (trainer)
General and basic priciples > General and basic principles > Engine timing mechanism
Engine timing mechanism

Timing gear plate
Crankshaft gear
Idler gear, double
Gear for power take off (extra equipment)
Idler wheel, adjustable
Camshaft gear
Drive gear, air compressor
Drive gear, power steering and fuel feed pump
Intermediary gear, power steering and feed pump
Drive gear, lubrication oil pump
Flywheel damper with teeth for the inductive camshaft sensor
Notes
Page 88
GT120017A v.1.0.01_en
General and basic priciples > General and basic principles > Engine timing mechanism
Key points
Drives the camshaft
Fuel pump
Other ancillaries
1. Timing gear plate
2. Crankshaft gear
3. Idler gear, double
4. Gear for power take off (extra equipment)
5. Idler wheel, adjustable
6. Camshaft gear
7. Drive gear, air compressor
8. Drive gear, power steering and fuel feed pump
9. Intermediary gear, power steering and feed pump
10. Drive gear, lubrication oil pump
11. Flywheel damper with teeth for the inductive camshaft sensor
Camshaft gear - positioned - crankshaft gear
The gears are marked
Helical teeth
Quietly
Less wear
Working procedure
information/text.
tracing.
Her it is time to run the movie AN INTRO TO DIESEL ENGINE chapter "Engine
timing gear". This is like a teaser for the participants.
Trainer notes
Page 88 (trainer)
General and basic priciples > General and basic principles > Engine timing mechanism - Sound
insulation
Engine timing mechanism - Sound insulation

Timing gear plate
Timing gear casings
Sound insulation
Laminated steel
Notes
GT120017A v.1.0.01_en
Page 89
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
information/text.
tracing.
Trainer notes
Page 89 (trainer)
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.1.0.01_en
General and basic priciples > General and basic principles > Crankshaft seal
Key points
Two different types
Rubber overlap seal - 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
information/text.
tracing.
Trainer notes
Page 90 (trainer)
General and basic priciples > General and basic principles > Valves, valve guides and valve
seats
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.1.0.01_en
Page 91
General and basic priciples > General and basic principles > Valves, 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
information/text.
tracing.
Trainer notes
Page 91 (trainer)
General and basic priciples > General and basic principles > Valves
Valves
Considerable stress
High temperatures
800C
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.1.0.01_en
General and basic priciples > General and basic principles > Valves
Key points
Considerable stress
Direct contact with the combustion process
High temperature
The exhaust valve
800C
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
information/text.
tracing.
Trainer notes
Page 92 (trainer)
General and basic priciples > General and basic principles > Valve stem
Valve stem
Journal led
Cast-iron
Replaceable
Seals
Valve seat rings
Notes
GT120017A v.1.0.01_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
information/text.
tracing.
Trainer notes
Page 93 (trainer)
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.1.0.01_en
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
information/text.
tracing.
Trainer notes
Page 94 (trainer)
General and basic priciples > General and basic principles > Valve seals
Valve seals
Lubrication
High oil consumption
Rubber seals
Notes
GT120017A v.1.0.01_en
Page 95
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
information/text.
tracing.
Trainer notes
Page 95 (trainer)
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.1.0.01_en
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
information/text.
tracing.
Using the correct information from Impact for removing the cylinder head, Oil sump, piston and
connecting rod.
Trainer notes
Page 96 (trainer)

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. It can also drive the...
oil pump
turbocharger
coolant pump
compressed air compressor
power steering servo pump
GT120017A v.1.0.01_en
Page 97
Key points
Question
Answer
Working procedure
problems.

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. It
can also drive the...
*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

*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)
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
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.
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
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, the valves will strike
the piston.
True
False
Notes
Page 98
GT120017A v.1.0.01_en
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, the valves will strike the piston.
*True
False
Trainer notes
Page 98 (trainer)
Lubrication system > Lubrication system > Lubrication system
Lubrication system
If you were to ask anyone why there must be oil in an engine, the answer would almost certainly
be something like "Surely you must understand that the engine has to be lubricated!". 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, these components must be lubricated, and lubricated with clean oil
and the right sort of oil!
Notes
GT120017A v.1.0.01_en
Page 99
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
information/text.
tracing.

"Lubrication system". This is like a teaser for the participants.
Trainer notes
Page 99 (trainer)
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.1.0.01_en
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
information/text.
tracing.
Trainer notes
Page 100 (trainer)
Lubrication system > Lubrication system > Splash lubrication - Pressure lubrication
Splash lubrication - Pressure lubrication

Splash-lubrication
Crankshaft's rotating motion
Pressure lubrication
Oil pump
Lubrication points
Cylinder walls
Timing gears
Notes
GT120017A v.1.0.01_en
Page 101
Lubrication system > Lubrication system > Splash lubrication - Pressure lubrication
Key points
Required points
Splash-lubrication
Crankshaft's rotating motion
Not sufficient for modern high-powered engines
Oil pump
Lubrication points
Cylinder walls and timing gears are splash-lubricated
Working procedure
information/text.
tracing.
Trainer notes
Page 101 (trainer)
Lubrication system > Lubrication system > Pressure lubrication
Oil sump
Oil pump
Oil cooler
Oil filter
Oil ducts
Lubricates
Cools
Cleans
Seals
Oil gallery
Notes
Page 102
GT120017A v.1.0.01_en
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
information/text.
tracing.
Trainer notes
Page 102 (trainer)
Lubrication system > Lubrication system > Lubrication system - Function
Lubrication system - Function

The lubrication system shown on these two pages comes from a 13-litre engine.
The oil flow through the engine is regulated by six valves located inside the engine block, 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.1.0.01_en
Page 103
Lubrication system > Lubrication system > Lubrication system - 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
information/text.
tracing.
Trainer notes
Page 103 (trainer)
Lubrication system > Lubrication system > Lubrication system - schematic
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.1.0.01_en
Lubrication system > Lubrication system > Lubrication system - 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
information/text.
tracing.
Trainer notes
Page 104 (trainer)
Lubrication system > Lubrication system > Oil pump - function
Oil pump - function

Gear-driven pump
Pump housing
Negative pressure
Gaps between the gear teeth
Lubrication ducts
Rotor pump
Notes
GT120017A v.1.0.01_en
Page 105
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
information/text.
tracing.
Trainer notes
Page 105 (trainer)
Lubrication system > Lubrication system > Oil pump - parts
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.1.0.01_en
Lubrication system > Lubrication system > Oil pump - 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
information/text.
tracing.
Trainer notes
Page 106 (trainer)
Lubrication system > Lubrication system > Oil filter housing
Oil filter housing

Number of valves - 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.1.0.01_en
Page 107
Lubrication system > Lubrication system > Oil filter housing

Key points
Oil filter housing
Valves
Spin-on type
Rubber rings
10 bar without leaking.
75,000 times from 0 to 8 bar
Working procedure
information/text.
tracing.
Trainer notes
Page 107 (trainer)
Lubrication system > Lubrication system > Oil flows through the filter
Oil flows through the filter

Filter insert
Filter paper
Particles down to approx. 40 thousandths of a millimetre (40 m)
Bypass filter - 10 m
Oil flow rate is approx. 7 litres/minute
Oil filter replacement
Clogged oil filters
Notes
Page 108
GT120017A v.1.0.01_en
Lubrication system > Lubrication system > Oil flows through the filter
Key points
The oil flow
Filter paper
Particles down to approx. 40 thousandths of a millimetre (40 m).
Particles down to approx. 10 m
7 litres/minute
Working procedure
information/text.
tracing.
Trainer notes
Page 108 (trainer)
Lubrication system > Lubrication system > Oil cooler
Oil cooler
10-15% heat
130C
100C
Common type
Notes
GT120017A v.1.0.01_en
Page 109
Lubrication system > Lubrication system > Oil cooler

Key points
Oil cooler
10-15%
130C
100C
Flat oil cooler
Working procedure
information/text.
tracing.
Trainer notes
Page 109 (trainer)
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.1.0.01_en
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
information/text.
tracing.
Point out main parts/valves and system layout in vehicle. Open an old oil pump.
If their is time you can also using VTT to read out oil pressure.
Trainer notes
Page 110 (trainer)
Lubrication system > Lubrication system > Diesel engine fundamentals. Test 6

Oil has several vital functions, 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.
True
False
A high sulphur content in the fuel has no effect on the engine oil change frequency.
True
False
Oil flow through the engine can be 100 litres/minute in a large engine.
No, not so much
Yes, that is true
No, much more
In Volvo engines, piston cooling features its own oil duct in the cylinder block.
GT120017A v.1.0.01_en
Page 111
Key points
Question
Answer
Working procedure
problems.

Oil has several vital functions, 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.
*True
False
A high sulphur content in the fuel has no effect on the engine oil change frequency.
True
*False
Oil flow through the engine can be 100 litres/minute in a large engine.
No, not so much
*Yes, that is true
No, much more
In Volvo engines, piston cooling features its own oil duct in the cylinder block.
*True
False
The reduction valve prevents oil pressure from rising too high.
*True
False
The piston cooling valve opens when oil pressure reaches a preset value.
*True
False
The oil cooler is a type of heat exchanger.
Page 111 (trainer)
True
False
The reduction valve prevents oil pressure from rising too high.
True
False
The piston cooling valve opens when oil pressure reaches a preset value.
True
False
The oil cooler is a type of heat exchanger.
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, the filters
become clogged. As a result, no oil will get to the lubrication points inside the engine.
True
False
All Volvo diesel engines have full-flow filters.
True
False
Oil filters must be replaced after a certain number of operational kilometers. How do you
find out the replacement interval?
I replacement them now and again.
I check in the maintenance instructions.
I ask a friend.
Page 112
GT120017A v.1.0.01_en
*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 filters become
clogged. As a result, no oil will get to the lubrication points inside the engine.
True
*False
All Volvo diesel engines have full-flow filters.
*True
False
Oil filters must be replaced after a certain number of operational kilometers. How do you find out
the replacement interval?
I replacement them now and again.
*I check in the maintenance instructions.
I ask a friend.
Considerable amounts of heat must be directed away from the engine's interior. 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, the pressure in the filter rises 75,000 times from 0 to 8 bar.
*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)
onsiderable amounts of heat must be directed away from the engine's interior. 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, the pressure in the filter rises 75,000 times from 0 to
8 bar.
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, the oil temperature can reach 130C.
True
False
Notes
GT120017A v.1.0.01_en
Page 113
*Flat radiator
With the engine under high operating load, the oil temperature can reach 130C.
*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.1.0.01_en
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 (1.5 bar)
Fuel filters
Injection pump
Overflow valve
Return pipe
High pressure
Pressure pipe
Injectors
Atomised and sprayed into the combustion chamber
Working procedure
information/text.
tracing.
Her it is time to run the movie AN INTRO TO DIESEL ENGINE chapter "Fuel
system". This is like a teaser for the participants.
Page 114 (trainer)
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.1.0.01_en
Page 115
Fuel system > Fuel system > Injection pump

Key points
The injection pump
Older fuel system
Six pump elements
Piston
Cam on the pump-camshaft
Pressure-valve
Injector's pressure pipe
Working procedure
information/text.
tracing.
Trainer notes
Page 115 (trainer)
Fuel system > Fuel system > Mechanical regulator or governor
Mechanical regulator or governor

Electronic regulators
Linkage system
Accelerator pedal
Notes
Page 116
GT120017A v.1.0.01_en
Fuel system > Fuel system > Mechanical regulator or governor

Key points
Electronic regulators
Control rod's position
Two spring-loaded weights
Linkage system
Accelerator pedal
Throttle arm
Working procedure
information/text.
tracing.
Trainer notes
Page 116 (trainer)
Fuel system > Fuel system > Supply pump
Supply pump
Piston pump
Pump camshaft
Hand-pump
Notes
GT120017A v.1.0.01_en
Page 117
Fuel system > Fuel system > Supply pump

Key points
Supply pump
Specific pressure
Piston pump
Hand-pump
Working procedure
information/text.
tracing.
Trainer notes
Page 117 (trainer)
Fuel system > Fuel system > Smoke limiter
Smoke limiter
Black smoke
Legal limits
Inlet manifold
Turbocharger pressure
Notes
Page 118
GT120017A v.1.0.01_en
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
information/text.
tracing.
Trainer notes
Page 118 (trainer)
Fuel system > Fuel system > Fuel filter
Fuel filter
Clearance - 0.001 to 0.002 mm
Hair - 20 times thicker
Filter insert
Filter housing
Spin-on filter
Box filter
Fuel filter - fine filter
Special paper
Notes
GT120017A v.1.0.01_en
Page 119
Fuel system > Fuel system > Fuel filter

Key points
Fuel filter
Dirt particle
Damage
0.001 to 0.002 mm.
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
information/text.
tracing.
Trainer notes
Page 119 (trainer)
Fuel system > Fuel system > Pressure pipes
Pressure pipes
The pressure pipes - high-pressure leads
Steel
High pressures
Clamps
Notes
Page 120
GT120017A v.1.0.01_en
Fuel system > Fuel system > Pressure pipes

Key points
Pressure pipes (high-pressure leads)
Steel
High pressures
Thick, rigid walls
Inner diameter
Cylinder head's by clamps
Working procedure
information/text.
tracing.
Trainer notes
Page 120 (trainer)
Fuel system > Fuel system > Injector - copper sleeve
Injector - copper sleeve

Cylinder head
Copper sleeve
Considerable heat
Efficient heat dissipation
Notes
GT120017A v.1.0.01_en
Page 121
Fuel system > Fuel system > Injector - copper sleeve

Key points
Injector
Inject
Atomised fuel
Combustion chamber
High pressure
Copper sleeve
Heat
Working procedure
information/text.
tracing.
The injector's job is to inject finely atomised fuel into the combustion chamber.
The fuel is atomised by being sprayed in under high pressure
Trainer notes
Page 121 (trainer)
Fuel system > Fuel system > Nozzle sleeve - 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.1.0.01_en
Fuel system > Fuel system > Nozzle sleeve - 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
0.002-0.004 mm
Lubricates
Cools
Working procedure
information/text.
tracing.
Trainer notes
Page 122 (trainer)
Fuel system > Fuel system > Injector - function
Injector - function
Nozzle holder
Pressure pipe
Return fuel pipe
Spring
Pressure pin
Needle
Pressure chamber
Sleeve
Adjusted
Notes
GT120017A v.1.0.01_en
Page 123
Fuel system > Fuel system > Injector - 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
information/text.
tracing.
Point out main parts/valves and system layout in vehicle. Read out feed pressure by using VTT.
Trainer notes
Page 123 (trainer)
Fuel system > Fuel system > Diesel engine fundamentals. Test 7B
Diesel engine fundamentals. 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.1.0.01_en
Key points
Question
Answer
Working procedure
problems.
Introduction to diesel engines. 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.

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)
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.1.0.01_en
Page 125
*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)
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.
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.
Notes
Page 126
GT120017A v.1.0.01_en
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
information/text.
tracing.
Trainer notes
Page 126 (trainer)
Fuel system > Fuel system > Unit injector - system function
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.1.0.01_en
Page 127
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
information/text.
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
Key points
Question
Answer
Working procedure
problems.
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)
Push rods
Connecting rods
Notes
GT120017A v.1.0.01_en
Page 129
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
information/text.
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
Fuel system > Fuel system > Injector

Key points
Injector body
Nozzle holder
Solenoid valve
Preinjection
Main injection
Post-injection
Working procedure
information/text.
tracing.
Trainer notes
Page 131 (trainer)
Fuel system > Fuel system > Diesel engine fundamentals. Test 7D
Diesel engine fundamentals. 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.

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.1.0.01_en
Fuel system > Fuel system > Diesel engine fundamentals. Test 7D
Key points
Question
Answer
Working procedure
problems.
Diesel engine fundamentals. Test 7D Key

1.
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.
In a common rail system.

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)
Engine management system > Engine management system > EMS - Engine Management
System
EMS (Engine Management System)

Low fuel consumption
Noise
Exhaust emissions
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.1.0.01_en
Page 133
Engine management system > Engine management system > EMS - Engine Management
System
Key points
EDC (Electronic Diesel Control)
Unit Injectors
TEA (Truck Electronic Architecture)
Working procedure
information/text.
tracing.
Trainer notes
Page 133 (trainer)
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.1.0.01_en
Engine management system > Engine management system > Engine control unit
Key points
1. Starter element
2. Unit injectors
3. Exhaust pressure governor (EPG)
4. Compression brake
Working procedure
information/text.
tracing.
Trainer notes
Page 134 (trainer)
Engine management system > Engine management system > Sensors on the engine
Sensors on the engine

The engine control unit includes an atmospheric pressure sensor. 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.1.0.01_en
Page 135
Engine management system > Engine management system > Sensors on the engine
Key points
1. Fuel pressure
2. Charge air temperature and charge pressure
3. Camshaft position
4. Engine coolant level
5. Air temperature and air pressure
6. Engine coolant temperature
7. Crankshaft position and engine speed
8. Oil temperature and oil pressure
Working procedure
information/text.
tracing.
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 management system > Engine management system > Other sensors
Other sensors
Vehicle speed (through sensors in the gearbox)
Cruise control
Retarder
ABS system
Brake, clutch and accelerator pedal
Parking brake
Engine brake
Notes
Page 136
GT120017A v.1.0.01_en
Engine management system > Engine management system > Other sensors
Key points
3. Vehicle speed (through sensors in the gearbox)
4. Cruise control
5. Retarder
6. ABS system
7. Brake, clutch and accelerator pedal
8. Parking brake
9. Engine brake
Working procedure
information/text.
tracing.
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)
Engine management system > Engine management system > Example of communication
Example of communication
When the driver, for example, wants to increase speed and depresses the accelerator pedal, a
signal is transmitted from the accelerator pedal to the vehicle electronic control unit.
This signal is transmitted over the data link to the engine control unit.
The engine control unit checks the signals from its own sensors to ensure that it is possible to
increase the throttle setting. If there is no impediment the engine control unit activates the speed
increase.
The engine control unit then handles the control of the engine independently for as long as
conditions stay the same.
Notes
GT120017A v.1.0.01_en
Page 137
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
information/text.
tracing.
Point out the engine sensors. Run sensor test in VCADS Pro.
Trainer notes
Page 137 (trainer)
Engine management system > Engine management system > Diesel engine fundamentals. Test
7A
Diesel engine fundamentals. 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.
Which one below is correct?
Starter element
Unit injectors
Compression brake
Point out the following sensor on the engine/picture
Fuel pressure
Page 138
GT120017A v.1.0.01_en
7A
Key points
Question
Answer
Working procedure
problems.
Introduction to diesel engines. 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. Fuel pressure
2. Charge air temperature and charge pressure
3. Camshaft position
4. Engine coolant level
5. Air temperature and air pressure
6. Engine coolant temperature
7. Crankshaft position and engine speed
8. Oil temperature and oil pressure
Trainer notes
Page 138 (trainer)
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.1.0.01_en
Page 139
7A
Trainer notes
Page 139 (trainer)
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 - cast in aluminium
O-rings - silicon-sealant
Air filter
Turbocharger
Charge air cooler
The exhaust 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.1.0.01_en
Intake and exhaust system > Intake and exhaust system > Intake and exhaust system
Key points
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
information/text.
tracing.
Trainer notes
Page 140 (trainer)
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.1.0.01_en
Page 141
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
information/text.
tracing.
Trainer notes
Page 141 (trainer)
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
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
information/text.
tracing.
Trainer notes
Page 142 (trainer)
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.1.0.01_en
Page 143
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
information/text.
tracing.
Trainer notes
Page 143 (trainer)
Intake and exhaust system > Intake and exhaust system > Exhaust pressure governor
Exhaust pressure governor

Compressed air
Restricts the flow
Back pressure
Braking effect
Compression brake
Notes
Page 144
GT120017A v.1.0.01_en
Intake and exhaust system > Intake and exhaust system > Exhaust pressure governor
Key points
Engine brake
Compressed air
VEB - Volvo Engine Brake
Compression brake
Working procedure
information/text.
tracing.
Trainer notes
Page 144 (trainer)
Intake and exhaust system > Intake and exhaust system > Compression brake VEB
Compression brake - VEB

Compression brake
Camshaft
Rocker arms
Hydraulic piston
Lubrication system
Hydraulic valve
Rocker arm pistons
Notes
GT120017A v.1.0.01_en
Page 145
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
information/text.
tracing.
Trainer notes
Page 145 (trainer)
Intake and exhaust system > Intake and exhaust system > Compression brake VEB+
Compression brake - VEB+

VEB+ Volvo Engine Brake
Camshaft with four cam lobes
Brake cam - VEB+ function
Notes
Page 146
GT120017A v.1.0.01_en
Intake and exhaust system > Intake and exhaust system > Compression brake VEB+
Key points
VEB+
EPG (Exhaust Pressure Governor).
D16E EPG - butterfly type
VEB+ Volvo Engine Brake
Camshaft with four cam lobes
Inlet cam
Injector cam
Exhaust cam
Brake cam - 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 55C
Turbocharging pressure below 0.5 bar
Accelerator pedal released completely
Working procedure
information/text.
tracing.
Trainer notes
Page 146 (trainer)
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.1.0.01_en
Page 147
Intake and exhaust system > Intake and exhaust system > Compression brake JAK
Key points
Compression brake - Jake brake
1.Control valve
2.Pressure piston
3.Solenoid valve
4.Adjustment screw, 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
information/text.
tracing.
Trainer notes
Page 147 (trainer)
Intake and exhaust system > Intake and exhaust system > Engine brake function
Engine brake function

Compression stroke
Power stroke
Exhaust stroke
Notes
Page 148
GT120017A v.1.0.01_en
Intake and exhaust system > Intake and exhaust system > Engine brake function
Key points
Compression stroke
Power stroke
Exhaust stroke
Working procedure
information/text.
tracing
Trainer notes
Page 148 (trainer)
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. 5 m3/min.
approx. 10 m3/min.
approx. 20 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.1.0.01_en
Page 149
Key points
Question
Answer
Working procedure
problems.

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. 5 m3/min.
approx. 10 m3/min.
*approx. 20 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?
a magnetic air filter
a cyclone filter
*a starter element
a filter cleaner
Page 149 (trainer)
a magnetic air filter

a cyclone filter
a starter element
a filter cleaner
The exhaust manifold is subjected to considerable thermal stress. It
is therefore made of a material with a high nickel content.
True
False
Notes
Page 150
GT120017A v.1.0.01_en
The exhaust manifold is subjected to considerable thermal stress. It

is therefore made of a material with a high nickel content.
*True
False
Trainer notes
Page 150 (trainer)
Turbocharger > Turbocharger > Turbocharger history
Turbocharger history
Notes
GT120017A v.1.0.01_en
Page 151
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.
The movie explains the development of the turbocharged engine through the
years.
Trainer notes
Page 151 (trainer)
Turbocharger > Turbocharger > Turbocharging
Turbocharging
More air into the cylinder
Not steal power
Volvo turbo engines - 1954
40 to 50% higher output
Cleaner exhaust gases
Quieter engine operation
Turbocharger function
Boost pressure - 150 kPa (1,5 bar)
Speed - 1250-1670 rps (75,000-100,000 rpm)
Top speed - 2200 rps (130,000 rpm)
Notes
Page 152
GT120017A v.1.0.01_en
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
Quieter engine
Turbine housing
Exhaust system
Turbine wheel
Compressor wheel
Shaft
Compressor housing
Air filter
Inlet manifold
150 kPa (1,5 bar)
1250-1670 rps (75,000-100,000 rpm)
2200 rps (130,000 rpm)
Working procedure
information/text.
tracing.
Trainer notes
Page 152 (trainer)
Turbocharger > Turbocharger > Turbocharger bearing
Turbocharger bearing
Rotor shaft
Bearing
High speed
Lubrication
Cooled
Clean oil
Notes
GT120017A v.1.0.01_en
Page 153
Turbocharger > Turbocharger > Turbocharger bearing

Key points
Rotor shaft
Slider bearings
Reliable lubrication
Lubricated and cooled by engine oil
Clean oil
Working procedure
information/text.
tracing.
Trainer notes
Page 153 (trainer)
Turbocharger > Turbocharger > Wastegate
Wastegate
Engine torque requirements at low engine speeds
Temperatures
Emissions
Boost pressure
Bypass
Overspeed
Pneumatic actuator
Notes
Page 154
GT120017A v.1.0.01_en
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
information/text.
tracing.
Trainer notes
Page 154 (trainer)
Turbocharger > Turbocharger > Turbocharger system
Turbocharger system
Intake system
Exhaust system
Turbocharger
Starter element
Exhaust pressure governor EPG
Blue exhaust smoke
Notes
GT120017A v.1.0.01_en
Page 155
Turbocharger > Turbocharger > Turbocharger system

Key points
Intake
Exhaust
Turbocharger
Starter element
Exhaust pressure governor - EPG
Reducing white and blue exhaust smoke
Working procedure
information/text.
tracing.
Trainer notes
Page 155 (trainer)
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.1.0.01_en
Turbocharger > Turbocharger > Exhaust pressure governor

Key points
Exhaust pressure governor - EPG
Below the turbocharger
Two functions
Counterpressure
Kept warm
White exhaust smoke
Shutter housing
Shutter
Pneumatic cylinder
Compressed air
Solenoid
Working procedure
information/text.
tracing.
Butterfly, see D16E, design and function.
Trainer notes
Page 156 (trainer)
Turbocharger > Turbocharger > Turbocharger type VGT
Turbocharger type VGT

Variable Geometry Turbine, VGT
EGR, Exhaust Gas Recirculation
EMS
Movable sleeve
Lever
Actuator
Gear ratio
Electric motor
Notes
GT120017A v.1.0.01_en
Page 157
Turbocharger > Turbocharger > Turbocharger type VGT

Key points
VGT - 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
information/text.
tracing.
Trainer notes
Page 157 (trainer)
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.1.0.01_en
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
information/text.
tracing.
Trainer notes
Page 158 (trainer)
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
Positioned in front of the engine cooling radiator
Notes
GT120017A v.1.0.01_en
Page 159
Turbocharger > Turbocharger > Air to air cooling

Key points
Air to air cooling
Reduces the air temperature by roughly 100C
Raising engine power output by about 10%
Torque is also higher
Fuel consumption drops
In front of the engine cooling radiator
Working procedure
information/text.
tracing.
Trainer notes
Page 159 (trainer)
Turbocharger > Turbocharger > Diesel engine fundamentals. Test 9

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.
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.
Page 160
GT120017A v.1.0.01_en

Key points
Question
Answer
Working procedure
problems.

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.
*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.
*True
False
A diesel engine with a turbocharger and intercooler has the best possible efficiency rating.
*True
False
"Intercooler" is another name for charge air cooler.
Page 160 (trainer)
rue
False
A diesel engine with a turbocharger and intercooler has the best possible
efficiency rating.
True
False
"Intercooler" is another name for charge air cooler.
True
False
Notes
GT120017A v.1.0.01_en
Page 161

*True
False
Trainer notes
Page 161 (trainer)
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.1.0.01_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
information/text.
tracing.
Trainer notes
Page 162 (trainer)
Cooling system > Cooling system > Cooling system
Cooling system
Heat
Cylinder block
Cylinder head
_
Coolant
When the ambient temperature is below 0C, the coolant should consist of a mixture of water and
anti-freeze.
On markets where the ambient temperature never drops below 0C, no anti-freeze is needed but
corrosion protection is still essential to prevent engine damage. In such cases, Volvo anticorrosion fluid is added in the ratio of 1:30 (1 litre of fluid to 30 litres of water).
All these fluids which circulate inside the cooling system are known as coolants. Referring to
them as "water" is incorrect since there is always something added to the water.
Notes
GT120017A v.1.0.01_en
Page 163
Cooling system > Cooling system > Cooling system

Key points
Cooling system
10-15% - lubricating oil
Radiated from the sides of the engine itself
20-30% - 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
0C
Mixture of water and anti-freeze
Anti-corrosion fluid
"water"
Working procedure
information/text.
tracing.

"Cooling system". This is like a teaser for the participants.
Trainer notes
Page 163 (trainer)
Cooling system > Cooling system > External components of the cooling system
External components of the cooling system

Coolant filter
Oil cooler
Coolant pump
Air compressor.
Heating cell package in cab
Expansion tank
Level indicator.
Filling cap.
Thermostat
Radiator
Notes
Page 164
GT120017A v.1.0.01_en
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.
Warning lamp
Filling cap - over pressure valves
Thermostat
Return pipe
Radiator
Working procedure
information/text.
tracing.
Trainer notes
Page 164 (trainer)
Cooling system > Cooling system > Thermostat
Thermostat
Shut. (cold engine)
Coolant can only flow through the lower pipe.
Open. (warm engine)
Coolant can only flow through the upper pipe.
.
Notes
GT120017A v.1.0.01_en
Page 165
Cooling system > Cooling system > Thermostat

Key points
Thermostat regulates
Shut. (cold engine)
Open. (warm engine)
Working procedure
information/text.
tracing.
Trainer notes
Page 165 (trainer)
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.1.0.01_en
Cooling system > Cooling system > Schematic presentation of the cooling system
Key points
Schematic
Inner circuit
Outer circuit
Working procedure
information/text.
tracing.
Trainer notes
Page 166 (trainer)
Cooling system > Cooling system > Radiator
Radiator
Heat exchanger
Copper
Brass
Aluminium
Plastic
Upper tank
Lower tank
Honeycomb
Pipes
Thin steel fins
Notes
GT120017A v.1.0.01_en
Page 167
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
information/text.
tracing.
Trainer notes
Page 167 (trainer)
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.1.0.01_en
Cooling system > Cooling system > Cooling fans in vehicles

Key points
Cooling fan
10 kW (14 bhp).
Maximum flow
Thermostat-regulated fan
Fluid coupling which senses the temperature of the air which has flowed through the radiator.
Low temperature 25% of full speed
60C - 95% of full speed
5% slipping of the fluid coupling
Reduces fuel consumption
Less noise
Working procedure
information/text.
tracing.
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, out through the radiator. In a
generator set, this flow of air cools both the generator and the engine. Fixed fans are designed to
provide an ambient temperature of +50
Trainer notes
Page 168 (trainer)
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.1.0.01_en
Page 169
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
information/text.
tracing.
Trainer notes
Page 169 (trainer)
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.1.0.01_en
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
information/text.
tracing.
Point out main parts and system layout in vehicle
Trainer notes
Page 170 (trainer)
Cooling system > Cooling system > Diesel engine fundamentals. Test 10

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?
10C
20C
30C
Since there is an over-pressure in the cooling system, the operational
temperature can be higher than 100C without any risk of the system
boiling over.
True
False
It is the thermostat which provides the cooling system's over-pressure.
True
False
GT120017A v.1.0.01_en
Page 171
Key points
Question
Answer
Working procedure
problems.

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?
*10C
20C
30C
Since there is an over-pressure in the cooling system, the operational temperature can be
higher than 100C without any risk of the system boiling over.
*True
False
It is the thermostat which provides the cooling system's over-pressure.

True
*False

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)
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 0C, 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
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 0C, 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)
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
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
information/text.
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
Emissions > Emissions > Engine emission

Key points
Emission
EGR
SCR
Working procedure
Talk with the participants about the Volvo engine emission.
Go through the information shown below.
From 1st October 2007 all new trucks, 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.
Enforcement authorities will be able to download faults recorded on the vehicle ECU.
Important to do the correct adjustment to get the correct emission.
There is more information about emissions on the violin link below.
http://violin.volvo.net/volvotechnology/corporate/en/business_functions/business_key_technology
_areas
Trainer notes
Page 175 (trainer)
Emissions > Emissions > Carbon dioxide and Hydrocarbons
Carbon dioxide and Hydrocarbons

Carbon dioxide contributes to the greenhouse effect, also called global warming. 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. Carbon dioxide is one of the most
important greenhouse gases. Since the industrial revolution human beings have added to the
greenhouse effect through increased greenhouse gas emissions.
This is expected to lead to climate change. Carbon dioxide is generated by burning material that
contains carbon, and is not poisonous. Diesel, the most common fuel for vehicles, consists of
hydrocarbons and during combustion generates carbon dioxide. Carbon dioxide emissions are
directly related to how much fuel is consumed. Compared with the petrol engine, the diesel
engine has a considerably greater degree of efficiency. This means that the energy content of the
fuel is utilised better, keeping down emissions of carbon dioxide.
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.
Hydrocarbon pollution results when unburned or partially burned fuel is emitted from the engine
as exhaust, (or from the crankcase ventilation) and also when fuel evaporates directly into the
atmosphere. Hydrocarbons include many toxic compounds that cause cancer and other adverse
health effects. Hydrocarbons also react with nitrogen oxides in the presence of sunlight to form
ozone. Hydrocarbons, which may take the form of gases, tiny particles, or droplets, come from a
great variety of industrial and natural processes. In typical urban areas, a very significant fraction
comes from cars, buses, trucks, and non-road mobile sources such as construction vehicles and
boats.
Page 176
GT120017A v.1.0.01_en
Emissions > Emissions > Carbon dioxide and Hydrocarbons

Key points
Carbon dioxide
Greenhouse effect - global warming
Greenhouse gases
Industrial revolution
Climate change
Carbon - not poisonous
Diesel
Hydrocarbon
Fuelconsumption
Working procedure
information/text.
tracing.
Trainer notes
Page 176 (trainer)
Emissions > Emissions > Nitrogen oxides (NOX)
Nitrogen oxides
Nitrogen oxides (NOx) is a collective name for nitrogen monoxide (NO) and nitrogen dioxide
(NO2). Nitrogen oxides contribute to a number of different environmental issues. These include
the formation of tropospheric ozone and the acidification of land and water. Nitrogen oxides are
also irritating when they are breathed in, and can in high concentrations cause damage to the
respiratory system.
Nitrogen oxides are formed during all combustion where air is present, as the oxygen and
nitrogen in the air react with each other.
At ambient temperatures, the oxygen and nitrogen gases in air will not react with each other. In
an internal combustion engine, 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, creating various oxides of nitrogen.
The high degree of efficiency of the diesel engine is achieved through high pressure, high
temperature and excess air during combustion. This increases the formation of NOx. However,
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.
In areas of high motor vehicle traffic, such as in large cities, the amount of nitrogen oxides
emitted into the atmosphere can be quite significant..
GT120017A v.1.0.01_en
Page 177
Emissions > Emissions > Nitrogen oxides (NOX)

Key points
Nitrogen oxides - NOX
Nitrogen monoxide (NO)
Nitrogen dioxide (NO2)
Tropospheric ozone
Irritating
Respiratory system
Working procedure
information/text.
tracing.
Trainer notes
Page 177 (trainer)
Emissions > Emissions > Particulate matter
Particulate matter
Particulates, alternatively referred to as particulate matter (PM) or fine particles, are tiny particles
of solid or liquid suspended in a gas. In contrast, aerosol refers to particles and the gas together.
Sources of particulate matter can be man made or natural. Some particulates occur naturally,
originating from volcanoes, dust storms, forest and grassland fires, living vegetation, and sea
spray. Human activities, such as the burning of fossil fuels in vehicles, power plants and various
industrial processes also generate significant amounts of aerosols. Averaged over the globe,
anthropogenic aerosols -those made by human activities -currently account for about 10 percent
of the total amount of aerosols in our atmosphere. Increased levels of fine particles in the air are
linked to health hazards such as heart disease, altered lung function and lung cancer.
Particles from a diesel engine consist primarily of soot, various hydrocarbons and sulphur. When
they are breathed in the particles are transported into the lungs carrying with them harmful
substances. Particles can exacerbate existing respiratory problems and high concentrations can
probably lead to reduced pulmonary function. Particulate matter also contributes to poor visibility
and soot deposition. Particulate matter is generated by the incomplete combustion of fuel;
however engine lubricating oil is also a factor.
Various technical measures have reduced particulate formation in modern diesel engines. For
really good combustion good fuel must be used. Fuel with a low sulphur content reduces
particulate formation. Good fuel quality also provides greater opportunity for the use of
aftertreatment equipment.
From January 1, 2005 low sulphur fuel with a sulphur content of maximum 10 mg/kg (0.1%, 100
ppm) must be available in all member states of the EU. The USA is also introduced requirements
for greater access to low sulphur vehicle fuel from 2006. Low sulphur fuel does not only produce
lower emissions of particulates and oxides of sulphur, but is also a prerequisite for certain types
of exhaust after-treatment, e.g. particulate filters.
Page 178
GT120017A v.1.0.01_en

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
information/text.
tracing.
Trainer notes
Page 178 (trainer)
The recommended sulphur content for Euro 5 is 50 ppm, (0,05%).
Notes
GT120017A v.1.0.01_en
Page 179
Trainer notes
Page 179 (trainer)
Emissions > Emissions > Diesel engine fundamentals. Test 11A
Diesel engine fundamentals. Test 11A

Which pollutants is lower in Euro 5 comparing to Euro 4.
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, (0,03%)
500 ppm, (0,50%)
5 ppm, (0,005%)
Notes
Page 180
GT120017A v.1.0.01_en
Emissions > Emissions > Diesel engine fundamentals. Test 11A

Key points
Question
Answer
Working procedure
problems.
Introduction to diesel engines. Test 11A Key

Which pollutants is lower in Euro 5 comparing to Euro 4.
*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, (0,03%)
500 ppm, (0,50%)
5 ppm, (0,005%)
Trainer notes
Page 180 (trainer)
EGR > EGR > Emisson control, schematic description of the system
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.1.0.01_en
Page 181
EGR > EGR > Emisson control, 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
information/text.
tracing.
Trainer notes
Page 181 (trainer)
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.1.0.01_en
EGR > EGR > EGR system

Key points
EGR system
EGR valve
Rear exhaust pipe
EGR cooler
Venturi tube
EGR pipe
Mixing chamber
Charge air sensor
EGR = Exhaust Gas Recirculation
Nitrous oxide (NO x)
Combustion temperature
Cooled exhaust
Maximum EGR
Working procedure
information/text.
tracing.
Trainer notes
Page 182 (trainer)
EGR > EGR > I-EGR, Large engine platform
I-EGR, Large engine platform

Internal exhaust Gas Recirculation - I-EGR
Reduce nitrogen oxide emissions - NOx
Specially designed exhaust rocker - double rocker arm
Controlled by the engine ECU
Notes
GT120017A v.1.0.01_en
Page 183
EGR > EGR > I-EGR, Large engine platform

Key points
Internal exhaust Gas Recirculation - I-EGR

Added to the air-fuel mixture
Reduce nitrogen oxide emissions - NOx
High temperature
Peak combustion temperature
Specially designed exhaust rocker - 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.
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 183 (trainer)
EGR > EGR > I-EGR, Medium engine platform
I-EGR, Medium engine platform

Medium range engines
Construction equipment
Mounted on top
Notes
Page 184
GT120017A v.1.0.01_en
EGR > EGR > I-EGR, Medium engine platform

Key points
Medium range engines

Construction equipment
Mounted on top
Working procedure
information.
the basic when they shall e.g. fault tracing
Trainer notes
Page 184 (trainer)
EGR > EGR > I-EGR Function, Medium engine platform
I-EGR Function, 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.1.0.01_en
Page 185
EGR > EGR > I-EGR Function, Medium engine platform

Key points
When the I-EGR is to be turned on/off is controlled by the engine ECU

1. Inlet rocker arm
2. Exhaust rocker arm
3. Slave piston
4. Control valve
5. Low-pressure channel
6. Solenoid valve
7. From engine lubrication system
8. High-pressure circuit
9. Master piston
Working procedure
information.
the basic when they shall e.g. fault tracing
Trainer notes
Page 185 (trainer)
EGR > EGR > Diesel engine fundamentals. Test 11B
Diesel engine fundamentals. Test 11B

EGR valve
Rear exhaust pipe
EGR cooler
Venturi tube
EGR pipe
Mixing chamber
Charge air sensor
Notes
Page 186
GT120017A v.1.0.01_en
EGR > EGR > Diesel engine fundamentals. Test 11B

Key points
Question
Answer
Working procedure
problems.
Introduction to diesel engines. Test 11B Key

1. EGR valve
2. Rear exhaust pipe
3. EGR cooler
4. Differential pressure sensor
5. Venturi tube
6. EGR temperature sensor
7. EGR pipe
8. Mixing chamber
9. Charge air sensor
Trainer notes
Page 186 (trainer)
SCR > SCR > SCR - Selective Catalytic Reduction
SCR - Selective Catalytic Reduction

SCR (Selective Catalytic Reduction) - 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 - nitrogen gas and steam
Euro 4 - 3-4% AdBlue
Notes
GT120017A v.1.0.01_en
Page 187
SCR > SCR > SCR - Selective Catalytic Reduction

Key points
SCR (Selective Catalytic Reduction) - 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 - nitrogen gas and steam
Working procedure
information/text.
tracing.
Trainer notes
Page 187 (trainer)
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.1.0.01_en
SCR > SCR > Main components in the Volvo SCR system
Key points
EU emission
Reductions
Emissions
Particulates (PM)
Nitrous oxides (NOx)
Working procedure
information/text.
tracing.
Trainer notes
Page 188 (trainer)
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.
Solution principle
Notes
GT120017A v.1.0.01_en
Page 189
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
200C
Working procedure
information/text.
tracing.
Trainer notes
Page 189 (trainer)
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, 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 - On Board Diagnostics)
Notes
Page 190
GT120017A v.1.0.01_en
SCR > SCR > Overview of the exhaust gas processing system
Key points
Principles diagram
1. Urea tank (AdBlue tank)
2. Urea tank level sensor
3. Urea tank temperature sensor
4. Urea solution pump
5. Urea solution filter
6. Urea solution pressure sensor
7. Urea solution temperature sensor
8. MID233 control unit, urea dosing system
9. Filter
10. Flow direction valve
11. Cooling control valve
12. Non-return valve
13. Dosing unit
14. Exhaust temperature sensor
15. Catalytic converter
16. NOx sensor (only used for OBD - On Board Diagnostics)
MID128 (EECU - Engine Electronic Control Unit)
Normal operation
10C
15C
Diesel Oxidation Catalyst, DOC (1)
Diesel Particulate Filter, 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.
Pressure sensor (3)
Temperature sensor (4)
Working procedure
information/text.
tracing.
Trainer notes
Page 190 (trainer)
SCR > SCR > Diesel engine fundamentals. Test 11C
Diesel engine fundamentals. Test 11C

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
Urea tank level sensor
Urea tank temperature sensor
Urea solution pump
Urea solution filter
Urea solution pressure sensor
GT120017A v.1.0.01_en
Page 191

Key points
Question
Answer
Working procedure
problems.
Introduction to diesel engines. Test 11C Key

1. Urea tank/AdBlue tank
2. Pump unit
3. 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
2. Urea tank level sensor
3. Urea tank temperature sensor
4. Urea solution pump
5. Urea solution filter
6. Urea solution pressure sensor
7. Urea solution temperature sensor
8. MID233 control unit, urea dosing system
9. Filter
10. Flow direction valve
11. Cooling control valve
12. Non-return valve
14. Exhaust temperature sensor
16. NOx sensor (only used for OBD - On Board Diagnostics)
Page 191 (trainer)
Urea solution temperature sensor

MID233 control unit, 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.1.0.01_en
Trainer notes
Page 192 (trainer)
CCV > CCV > CCV - CrankCase Ventilation - Closed
CCV - CrankCase Ventilation - Closed

Hose connection
Connector
Turbine
Drive shaft
Discs
Pressure regulator
Diaphragm
Notes
GT120017A v.1.0.01_en
Page 193
CCV > CCV > CCV - CrankCase Ventilation - 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
information/text.
tracing.
Trainer notes
Page 193 (trainer)
CCV > CCV > Diesel engine fundamentals. Test 11D
Diesel engine fundamentals. Test 11D

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.1.0.01_en

Key points
Question
Answer
Working procedure
problems.
Introduction to diesel engines. Test 11D Key

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 turbocharger outlet side via connector.
The clean gases are led to the inlet side just before air filter.
Trainer notes
Page 194 (trainer)
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 turbocharger outlet side via connector.
The clean gases are led to the inlet side just before air filter.
Notes
GT120017A v.1.0.01_en
Page 195
Trainer notes
Page 195 (trainer)
GT120017A v.1.0.01_en

New Generation Volvo Diesel Engine Fundamentals Classroom Training en

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Service training

Diesel Engine Fundamentals

Diesel Engine Fundamentals

Diesel Engine Fundamentals Classroom training

Diesel Engine Fundamentals Classroom training

Diesel Engine Fundamentals Classroom training

Diesel engine fundamentals. Test 3 ................................................................................... 68

Diesel Engine Fundamentals Classroom training

Oil pump - parts ................................................................................................................ 106

Diesel Engine Fundamentals Classroom training

Air filter ............................................................................................................................. 141

Diesel Engine Fundamentals Classroom training

Engine emission ............................................................................................................... 175

Introduction > Course content

Introduction > Course content

Introduction > Course objectives

Introduction > Course objectives

Engine history > The diesel engine, yesterday and today

The diesel engine, yesterday and today

Engine history > The diesel engine, yesterday and today

Engine history > First diesel engine

First diesel engine

Engine history > First diesel engine

Engine history > Diesel engines in vehicles

Diesel engines in vehicles

Engine history > Diesel engines in vehicles

Engine history > Engines for heavier vehicles

Engines for heavier vehicles

Engine history > Engines for heavier vehicles

Engine history > Diesel engines in Volvo vehicles

Diesel engines in Volvo vehicles

Engine history > Diesel engines in Volvo vehicles

Engine range > Engine range

Engine range > Engine range

Her it is time to run the movie AN INTRO TO DIESEL ENGINE chapter

The diesel engine is an internal combustion engine

Power from crankshaft

Diesel engine - petrol engine

Diesel engine - another approach

Sturdy engine components in the diesel engine

Four strokes for a complete cycle

Four stroke - six cylinder

Her it is time to run the movie AN INTRO TO DIESEL ENGINE chapter

The diesel engine is miserly with its fuel

Three diesel engine types

Precombustion indirect-injection engines

Diesel engine fundamentals. Test 1

Introduction to diesel engines. Test 1 Key

Peak pressure in a diesel engine can approach 20 MPa (200 bar).

The main engine components

Cylinder block - inside

Camshaft in cylinder block

Cylinder liner design

Diesel engine fundamentals. Test 2

Introduction to diesel engines. Test 2 Key

Which of these figures shows a wet cylinder liner?

as space for coolant fluid

Cylinder head - Inlet and exhaust ducts

Cylinder head - Copper sleeve

Cylinder head - Details

Cylinder head and cylinder liner seals

Cylinder head and cylinder liner seals

A few facts about loads