CATERPILLARENGINE SYSTEM

Fuel System Air Intake & Exhaust System Lubrication System Cooling System Electrical Starting System AGENDA Caterpillar Engine System,

Engine Operation ENGINE STROKE

ENGINE STROKE

FUEL SYSTEM

Pump & Lines Fuel System Sleeve meteringScroll typeNew scroll type

Unit Injector Fuel SystemMUI (Actuator)MEUI / EUIHEUI Two categories of fuel system, FUEL SYSTEM

Pump & Lines Fuel System 1. Fuel tank 2. Fuel filter 3. Transfer pump 4. Low pressure lines 5. Timing advance 6. Injection pump, Governor and Fuel Ratio Control 7. High pressure lines 8. Nozzles 9. Return lines

FUEL SYSTEMFilter

MEUI / EUI (Mechanical Electronic Unit Injector)Fuel controlled electronically by means of a solenoid operated poppet valve, still require mechanical valve train to actuate the plungerUnit Injector Fuel System FUEL SYSTEM

FUEL SYSTEMFuel delivery, FUEL INJECTION SYSTEMCOMBUSTION SYSTEM

Fuel System Inspection,Dynamic Timing ProcedureTiming advance adjustment Timing pin procedures FUEL SYSTEMTiming AdvanceDynamic Timing Timing Pin Engine

Fuel System Inspection, Continuo's.4. Nozzle or injector test 5. Fuel pressure test 6. Fuel specific gravity test

FUEL SYSTEMNozzle Test

AIR INTAKE, EXHAUST SYSTEM

AIR INTAKE & EXHAUST

Natural Aspirated, AIR INTAKE & EXHAUST

Turbocharger, AIR INTAKE & EXHAUST

1. Precleaner2. Air filter3. Turbocharger4. Intake manifold5. After cooler6. Exhaust manifold7. Exhaust stack8. Muffler

Turbocharger Aftercooler, AIR INTAKE & EXHAUST12346578

Air to Air Aftercooler,

AIR INTAKE & EXHAUST

Air System Inspection,1. Inspect air filter indicator.(Visual check Reading or color)

2. Checking air inlet restriction (Engine pressure gauge tool)

AIR INTAKE & EXHAUST

Air System Inspection, Continuo's.3. Checking boost pressure (Engine pressure gauge)

4. Smoke density test (Gauge sensing tool)

AIR INTAKE & EXHAUST

Engine: OLD Vs MODERN AIR INTAKE & EXHAUST

LUBRICATION SYSTEM

Lubrication Functions Lubricate Reduce wear Remove heat Clean surfaces Sealant LUBRICATION SYSTEM Transmit power / Hyd. Prevent corrosions Dampen shock at gear Disperse contaminants Prevent foaming

1. Oil pan2. Suction bell3. Oil pump4. Relief valve

5. Oil filter with bypass valve

6. Oil cooler with bypass valve7. Main oil gallery8. Piston cooling jets9. Crankcase breather

LUBRICATION SYSTEM

Substance of Additive CAT Oils LUBRICATION SYSTEM

Jam Pemakaian Oli (lamanya oli dipakai sejak diganti)Service Meter Reading (lamanya jam operasi unit)Kondisi Operasi Mesin / unit yang informasinya diperoleh dari labelMelihat kondisi oli dan type oli yang dipakai Adanya kontaminasi Bahan Bakar dan air pada oli engine dan non engineMeningkatnya kandungan logam yang tidak normalBagaimana aplikasi & perawatan praktis dilapanganFaktor penggantian oli, LUBRICATION SYSTEM

SOOT : Jelaga yang dapat menyumbat filter oli disebabkan kualitas bahan bakar, perawatan mesin & pengoperasian mesin yang tidak baik Oxidation : Reaksi kimia antara oli dan oksigen, menyebabkan oli mengental, membentuk asam organik, menyumbat filter, deposit pistonNitration : Masalah hanya terjadi pada Mesin Natural GasSulfur : Indikasi adanya korosi pada semua bagian mesin, berasal dari bahan bakan yang kurang baik dan menyebabkan korosi pada valve guides, ring dan linerWater : Campuran Air dan oli membentuk emulsi yang dapat menyumbat filter, juga dapat membentuk asam, kemungkinan adanya kondensasi dalam crankcaseFuel : Menurunkan karakteristik oliContaminant oli & penyebabnya LUBRICATION SYSTEM

Lubrication System Inspection,1. Inspect engine oil level

Engine oil pressure test

Schedule Oil Sampling

LUBRICATION SYSTEM

Schedule Oil Sampling,Pemeriksaan contoh oli bekas secara berkala,guna mencegah masalah kecil menjadi besar,

Analisa Keausan Analisa Fisik & Kimiawi Analisa kondisi Oli ( Infra Red test) Test kandungan TBN. Menghitung Partikel besar (10 -15 ) mikro per ml LUBRICATION SYSTEM

COOLING SYSTEM

50% kerusakan dini dari Engine dapat di-akibatkan oleh Problem-problem pada Cooling System COOLING SYSTEMCATERPILLAR SURVEY,

Pentingnya cooling system,Pabrik Diesel Engine Dunia telah meningkatkan standar Temperature Operasi Engine utk meningkatkan efisiensi Engine.

Perawatan Cooling System yg baik sama pentingnya dengan kualitas dari Oli maupun Bahan bakar

Overheating, Overcooling, Pitting, Cavitation, Erosion, Cracked Heads, Piston Seizures & Radiator Buntu adalah problem klasik dari Cooling System Failures

Effective Preventative Maintenance (PM) dapat mencegah pemborosan biaya dari hal2 diatas

COOLING SYSTEM

Flow of system,1. Radiator2. Water pump3. Cooler4. Engine block5. Cylinder head6. Bypass valve Water Temperature Regulator

COOLING SYSTEM

COOLING SYSTEM

Membuang panas hasil pembakaran Temperature pembakaran dpt mencapai 1,937 Deg. C

Transfer panas dari,Transmission Oil CoolersHydraulic Oil CoolersWater Cooled Exhaust ManifoldsWater Cooled Turbocharger Shields / HousingsMarine Gear Oil CoolersTorque Converter / Retarder CoolersJacket Water After Coolers

Fungsi cooling system, COOLING SYSTEM

Perbandingan panas yang dilepaskan engine, COOLING SYSTEM

Cooling system Inspection, Check coolant level

Test antifreeze concentration

Coolant test kit

Adjusting coolant mix

Radiator cap test

Water temperature regulator test

COOLING SYSTEM

OVERHEATING

OVERCOOLING

LOSS OF COOLANT Cooling system problem, COOLING SYSTEM

Low Coolant LevelPlugged Radiator CoreLoose Fan BeltsReduced Air flow Through RadiatorInsufficient Cooling System PressureCoolant OverflowHigh Inlet Air Temperature Or RestrictionExhaust RestrictionExcessive Engine LoadWater Pump Or Temperature Regulator Failure

Typical penyebab Overheating COOLING SYSTEM

Cracked Or Warped Cylinder HeadsOverheating effects, COOLING SYSTEM

Low Ambient Air Temperatures Water Temperature Regulators Stuck Open or RemovedDefective Temperature Gauge Typical penyebab OvercoolingOvercooling effects, Jika temperatur dibawah 80 derajat Celcius akan mengakibatkan peningkatan sulfur pada fuel dan keausan pada komponen engine

Engine tidak mencapai temperatur operasi yang memadai sehingga performance tidak maksimal COOLING SYSTEM

Transfer panas dari komponen engine yang panas ke Radiator atau heat exchanger untuk dibuang.Coolant function,Karakteristik yg dihasilkan, High Boiling Temperature Freeze Protection Corrosion Resistance Deposit Prevention Non Foaming Minimum Sediment Maintain pH

Rust, (karatan)

Iron Oxidation, (oksidasi metal)

Scale and Deposit Formation, (jumlah dan formasi deposit)

Aeration, (kemasukan udara)

Acid Alcalinity Imbalance, (tidak seimbangnya tingkat keasaman dalam cooling system

Pitting,

Cavitation Corrosion / ErosionCoolant effects, COOLING SYSTEM

Cooling system problem, COOLING SYSTEM

Supplemental Coolant Additive Test Kit - 8T5296Checks Concentration SCAChecks Ethylene Glycol RangeOnly Takes A Few Minutes To Perform Coolant Testers - 5P3514Accurate Reading Of Freezing Temperature Blowby / Air Flow Indicator Group - 8T2700Hand Held Digital Indicator And Remote PickupMeasure Air Velocity Through Radiators

COOLING SYSTEM

OBJECTIVE

Improve PM To Prevent Overheating ProblemsLower Operating Costs Through Good System MaintenanceLower Cost Per Hour

COOLING SYSTEM

10 Hour / Daily CheckInspect Coolant LevelClean Radiator Core 250 Hour / Monthly CheckPerform 10 Hours / daily checkInspect Condition & Tension Of Fan Belts - Adjust / Replace As RequiredIf not Using Cat ELC, Add Supplemental Coolant AdditiveTest Coolant For Freeze Protection If necessaryInspect Radiator Cap & GasketInspect Hoses, Engine Electrical GroundsCheck Function Of Water Temperature Regulator COOLING SYSTEM

3,000 SMU /24 MonthsPerform All 250 SMU ChecksAdd Cat Extender If Using Cat Extended Life Coolant Otherwise Drain, Clean & Refill The Cooling SystemInspect Condition Of Fan Blades & Guards, Hoses & ClampsTighten All ClampsPerform A Coolant Analysis 6,000 SMU Or 6 Years Whichever Comes FirstIf Using Cat Extended Life Coolant, Drain, Flush With Clean Water And RefillOtherwise Repeat The 3,000 SMU PM COOLING SYSTEM

STARTING SYSTEM

Electric Starting, - Battery- Cranking motor- Cable/Wires2. Air Starting, - Air tank- Push Button Valve- Relay Valve- Cranking motor- Pinion 3. Hydraulic Starting,Three types engine starting : STARTING SYSTEM

Starting System circuit Battery

2. Solenoid cranking motor

3. Starter switch

4. Wires & cable

COOLING SYSTEM

Starting System circuit (switch on) COOLING SYSTEM

There are three types:

Conventional Low maintenance Maintenance-free.

Battery, COOLING SYSTEM

1. Check conventional batteries every 100 operating hours

2. Check Low Maintenance / High Output batteries every 250 operating hours

3. Make sure all vent caps are clean

4. Never remove caps while charging the battery

5. Never need to check the electrolyte levelBattery electrolyte, COOLING SYSTEM