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D5 Engine Training

Road machine
Engine
g Identification - 010102

Engine identification plate


Also on engine cover
Engine serial number
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168 2012-12-20
Engine
g Identification plate
p - 010103

Engine Type plate:


• Engine model
• Engine spec No
• Engine serial number (8 digits)
• Rated engine speed
• Injection timing and type of cam shaft
• Injection pump code
• Piston class

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Engine
g view from right
g

1. Crank case breather


2. Lubricating oil filling
3
3. Injection pump
4. Lubricating oil stick
5. Lube oil cooler
6. Lube oil replacement
p filter
7. Lubricating oil drain plug
8. Exchangeable fuel filter N/A
9. V-belts
10. Generator

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170 2012-12-20
Engine
g view from left

1.
1 Combustion
C b ti air i iinlet
l t
2. Coolant out let
3. Coolant inlet
4
4. Connection charge air cooler
5. Exhaust outlet
6. Starter

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Engine
g Ignition
g order - 010104

Direction
Di ti off rotation:
t ti C
Counter
t clockwise
l k i
As seen from the fly wheel

Engine
g Ignition
g order : 1 – 3 – 4 - 2

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Cylinder
y head valves - 010202

Valves:

• There are some difference in valve guide

• The valve springs of D5D / D7D have no


special direction of installation and are
replaceable

• D5D / D7D valve guide are seal with ‘O” rings

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Crank mechanism - 010301

• Crank mechanism

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Crank mechanism - 010302

D5D & D7D: Wet liner replaceable

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Crank mechanism - 010303

Connecting rod:

• The connecting rod is made of forged


steel and the bearing cap (1) is guided
using two guide pin (3)

• Locating lug (2) are provided in


bearing shells

• Connecting rod and bearing are


marked
a ed ((4))

• Marking (5) on the piston is to face


the fly wheel

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Piston - 010304

Max injection pressure 1500 bar

• The ppistons are made of special


p aluminum alloy.
y The p
piston is slightly
g y off – Centre
(A) in relation to the piston guide pin

• The piston must be installed with fly wheel symbol on the piston top facing the
fly wheel
• There are three piston rings. The top ring has a ring carrier made of cast iron

• 6h
hole
l nozzle
l
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Selecting
g gasket
g - 010305

Gasket holes
1, 2 & 3

Piston crown clearance:


• To obtain the power, fuel consumption and exhaust gas emission specified
for engine the piston height above the block face has to me measured and
correct thickness for the cylinder head gasket has to be determined
• The piston height is measured using a dial gauge (1) fixture (2) and spacer (3)
• The procedure is described in service manual

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Engine
g Timing
g gear
g - 010401

1. Governor gear
g
2. Transfer gear
3. Cam shaft gear

4. Crank shaft gear

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Lubricating
g oil diagram
g

1. Lubricating oil sump


2
2. Lubricating oil pump
3. Pressure limiting valve TCD2013
4. Lube oil cooler
5. Check valve TCD 2012
6. Bypass valve
7. Bypass valve
8. Pressure control valve
9. Lubricating oil filter
10. Main lube oil channel
11. Piston cooling nozzle
12. Rocker arm
13. Internally switched exhaust gas return
14. Turbo charger
15
15. Air compressor
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Lubrication system
y - 020103

Lubrication system D5D

7. Lube oil filter with integrated by pass


valve 2.5 bar

8. By pass valve oil cooler located in oil


cooler housing 4.0 bar

9
9. Oil pressure valve
l llocated
d iin oilil cooler
l
housing 10 bar

10 Lube oil pump 90 l/min at 2500 rpm


10.

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Oil p
pump
p - 020202

1 Suction
1.

2. Pressure chamber to crank housing

3. Inner Rotor

4. Outer Rotor

5. Driven from crank shaft

6. Safety valve

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Piston Cooling
g Nozzle - 020301

• The piston cooling nozzle made of plastic are fitted in the main bearing
pedestals

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Fuel system
y - 030101

• Change unit injector pump for cylinder number 3 on D5D with injection timer
• Read off EP code for cylinder No 3 on the engine identification plate under
column EP (1)
• Read sequence
Line 1 = cylinder 1
Li 2 = cylinder
Line li d 2 and d so on……
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Fuel system
y - 030104 1 Injection pump
1.

2. Delivery pipe

3. Engine block

4. Shim

5. Roller tappet

6 Cam
6. C shaft
h ft

7. Fuel rack

8. Fuel duct

9 Injector
9.

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Mechanical single
g injection
j pump
p p system
y

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186 2012-12-20
Fuel system
y - 030105

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Fuel schematic

1. Fuel tank
2. Fuel pre-filter
3
3. Fuel pump
4. Exchangeable fuel filter
5. Fuel supply line to the FCU
6. Control block fuel control unit
7. High pressure pump
8. Rail (Not applicable)
9. Injector
10. Fuel return to fuel tank

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Fuel schematic

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Fuel block diagram
g

1. Diesel Tank 2. Water separator 3. Feed pump

4. Fuel filter 5. Fuel supply to fuel control unit / Control block

6. U. I High pressure pump 7. Injector

8. Excess
8 cess leak
ea return
eu 9. Diesel Tank

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Coolant diagram
g (example)
( p )
1. Cooler
2
2. Cooler inlet
3. Coolant pump
4. Coolant partial flow to the lubricating oil cooler
5.
5 Lube oil cooler
6. Coolant supply for engine cooling
7. Cylinder pipe head cooling
8. Connection possibility for cab heating
9. Heat exchanger
10. Return line
11. Coolant return to thermostat
12
12. C l t outt let
Coolant l t
13. Compensation line
14. Venting pipe

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Schematic outlet controlled cooling
g system
y

Expansion Tank

Water out let

Thermostat
Water inlet

Water Pump

Engine oil cooler Radiator

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Coolant block diagram
g (example)
( p )

1. Oil cooler inlet 2. Water pump 3. Engine cooler

4. Engine block / Head / Engine cylinder Head

5. Thermostat cooler out let 6. By pass thru special lines

7. Oil cooler outlet

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Working
g description
p
The coolant pump (“water pump”) draws in the coolant via hose lines directly
from the cooler and delivers it first via the engine-integrated
engine integrated lube oil cooler
cooler,
thereafter enters the engine, flows along the cylinder, upwards into the
cylinder head and to the thermostat at the coolant outlet. From there, the
coolant is directed via special
p lines to the cooler inlet.

When the engine is still cold the coolant is short circuited through the engine
until thermostat response temperature has been reached (starting opening)
according to the volume of hot coolant flowing off, the water pump draws in
cold coolant from the cooler

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Coolant thermostat

Checking the thermostat when removed

1. Measure dimension “a” on thermostat

Note: “a”
a starts of lift at approx
approx. 83+2 (T1)
“b” end of lift at approx. 95+5 (T2)

Lift movement with indicated temp T2,


Min. 8 mm

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195 2012-12-20
Fuel system
y cylinder
y No p
positions -
030113

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Internal exhaust g
gas recirculation

1 Additional cam for exhaust gas recirculation


1.

Inlet valve opens briefly during the outlet cycle


and emits an exhaust gas partial flow to the
suction system.

This p
partial volume is sucked back in the next
suction cycle

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197 2012-12-20
Charging
g g
C
Compressor
Turbine

From filter Turbo charger with charge air cooling

Advantages:
g

¾ Volumetric efficiency of engine increases


¾ Increase Horse Power
¾ Emission improved
¾ Compact in size

To CAC

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Charging
g g piping
p p g connection

Air filter

Compressor

CAC

Engine Inlet manifold

Engine exhaust

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Fuel shut off solenoid

Resistance 4.9 ohms

1. Fuel shut off solenoid operates when


th
there iis iignition
iti supply
l – 2nd position
iti
2. Fuel shut off solenoid + excess fuel
solenoid in 3rd start position

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Excess fuel solenoid

1. Excess fuel solenoid

2. Sensor Not applicable

1. Fuel shut off solenoid operates when


th
there iis iignition
iti supply
l – 2nd position
iti
2. Fuel shut off solenoid + excess fuel
solenoid in 3rd start position

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Engine
g oil pressure
p switch

¾ Engine oil pressure switch

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Engine
g water temperature
p switch

¾ Engine Water temperature switch

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Engine
g glow
g plug
p g

¾ Engine Glow plug

¾ Time - 8 seconds

¾ Temperature 950 0 c

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Diesel tank fuel sender

¾ Fuel sender

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Mechanical governor
g

Governor adjustment screws

Full load “G”


J
Torque maximum “E”

NA based fuel charge “J”


E
G Excess fuel start solenoid

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Engine
g V- belt

Procedure Change Engine V belt

V – belt AVX 11 (Width 11 mm)

Belt tensioning – Automatic tensioning


Spring – loaded clamping roller

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Removing
g the Starter motor

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Installing
g the Starter motor

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EK code - 030114

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A measurement - 030115

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Dimensions, definitions - 030116

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Theoretical shim thickness - 030118

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Actual shim thickness - 030119

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Reinstallation - 030120

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Special
p tools - 030121

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216 2012-12-20
Unit p
pump
p installation - 030122

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Unit p
pump
p installation - 030123

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Assembly
y injection
j p
pump
p

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Unit injection
j pump
p p system
y

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Explanation
p Lo & EP- code for D5D engines
g

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221 2012-12-20
EP-Code on identification plate
p

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Determination compensation
p shim

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From value TS to SS

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F I P installation, step
p1

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F I P installation, step
p2

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Example
p – Lubricating
g oil consumption
p
(at least 100 operating hours) engine in high load operation
Op. h Fuel Lts Lube oil Date Driver Example
9 423 2 15.2 12 Paul
12 551 2 16.2.12
13 523 2 17.2.12
11 600 2 18.2.12 Shashi
13 620 2 19.2.12
14 590 2 20 2 12
20.2.12
10 450 2 21.2.12 Ballal
11 597 2 22.2.12
12 580 2 23.2.12
13 620 2 24.2.12 Ramalu

118 5554 20
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Example
p – Lubricating
g oil consumption
p
(at least 100 operating hours) engine in high load operation

Calculation example:

9 Fuel consumption = 5554 l


9 Lubricating oil consumption = 20 l

¾ Calculation:
20 L
5554 l = 100% X= = 0.36 %
100 %
20 l = x 5554 L

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