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2017(Piling Machinery )Service Training of New product of SANY Heavy Machinery

Production description
2, power system
2.1, structure
2.2, introduction of each system
2.3, special configuration of tier Ⅲ engine

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2017(Piling Machinery )Service Training of New product of SANY Heavy Machinery

2 Power system
Power system provides the power for the whole machine, the
basic composition figure is as follows:

Shock
mitigation
system and
transmission
system

Exhaust
Fuel system
system

Engine

Air inlet Cooling


system system

2
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Power source——
2.1 Power system structure
machine “heart”
Fuel
system

Exhaust
system
Engine

Air inlet
system

Cooling Shock mitigation


system system and
transmission system

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2.1.1 Engine

Type : AH-6HK1X

Description :
This engine is
manufactured by
ISUZU . The power is
212kW/2000rpm ;
Tier III discharge,
level 3 fuel filter, in-
line, water-cooling,
four-stroke,
turbocharger and
EGR

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2.1.2 Exterior structure of engine

Breath EGR
er
Water
High
outlet
pressure
pipe
Hot water Common
return rail
port-air pipe
condition High
Hot er
water pressure
outlet oil pump
port-air
condition Bell
er housin
Fan g

Cylind Oil
er pan
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2.1.3 External structure

Exhaus Air
t port inlet
port
Exhaust
manifol
d
Turboc
harger

Start
motor

Oil Motor
dipstic
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2.1.4 External structure

Engine
water
outlet Inlet
port manifol
d

Engine
water
inlet
port flywhee
l

Bell
housein
g

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2.1.5 Parameters

Item KUBOTA
Model / AH-6HK1X
Manufacture / ISUZU
Emission stage / Tier III
Rated power kw/rpm 212/2000
Max. torque N.m/rpm 1080/1500
Total displacement L 7.79
Cylinder bore ×stroke mm 115×125
Compression ratio / 17.5
/ Electric fitting high
Fuel system pressure common rail
Emission mode / External EGR
Dimension mm 1357×995.4×
(length×width×height) 1162.5
Weight Kg 640

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2.1.1-3 Lubrication system


Main oil
circuit

Bypass valve
Check Turbocharg
Oil cooler
Fuel er
valve
injection
Air Crankcase Camsha Regulating
pump
Alarm condenser valve
bearing ft bush
switch Oil
filter Piston

Connecting Timing Injectin Cylinder


rod bearing gear g plug cover
Reducing Oil Oil
valve pump filter
Rock shaft
Rod sleeve

Oil pan
First primary

Lubrication type : oil pump


Engine oil filter : paper filter, central screw
Engine oil cooler: shell plate

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2.2.1, cooling system

There are three types of


coolant circulation: large
circulation, small circulation
and combination circulation.
Large circulation: thermostat
fully opens, coolant circulates
through radiator;
Small circulation: thermostat
closes, coolant circulates
between water pump and
water jacket;
Combination circulation:
thermostat opens partly, a
part of coolant performs
large circulation; the other
part performs small
circulation.

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2.2.2 Oil supply system

1. Common rail 5. Fuel tank


2. Fuel filter 6. Fuel feed pump
3. Solenoid pump 7. Fuel injector
4. Fuel prefilter 8. Oil return pipe

Engine oil flows through water oil separator and fuel filter, the water and impurities are filtered
from the fuel.

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2.2.3 , damping and transmission system


Vibration
reduction
Connection
Power output
Pressure
plate

Anti-
vibration
pad

Engine Coupling
outrigger flange

Socket Coupler

Bolt M20×200GB5782
Torque : 549±59Nm

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2.2.3 Emission system

Reduce noise

U bolt
Guard cover

Silencer seat
Exhaust
pipe
Silencer
drain pipe Silencer

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2.2.5 Cooling system

Sponge seal EGR degassing


tube
Radiator
degassing Water outlet
tube pipe

Support rod

Water
supply pipe

Water inlet
pipe

Clip and
Radiator
pipe
Cooling
drain

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The structure of radiator on small machine:


Water radiator and oil radiator in parallel
The structure of radiator on large machine:
Water radiator and oil radiator in parallel
Water radiator and intercooler in parallel; oil radiator
is independent.

Intercooler

Air
conditioner Fuel
condenser condenser

Hydraulic oil Coolant


radiator radiator

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2.2.6 Air intake system


Air filter Turbocharger
outlet pipe outlet hose
Filter air
Rain shield

Air filter
support
Engine inlet
pipe

Main filter
Oil-bath air
filter
Air inlet
steel pipe
Intercooling
Air inlet outlet pipe
hose

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2.2.7 Fuel system


Reserve,
filter and
Fuel supply fuel
Fuel Solenoid condenser
tank pump Engine oil
inlet pipe

Engine oil
Primary filter
fuel filter
Secondary Tertiary Engine oil
fuel filter fuel filter return pipe

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2.3, special configuration of tier III engine

Description

The major differences between tier III engine and traditional engine:

1. Emission control —exhaust gas recirculation ( EGR )

2. Electronic control high pressure common rail fuel system

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2.3.1, EGR (exhaust gas recycling system)

Internal combustion engine separates a part of air and leads this part of air to the air inlet side
and make the air burn again to reduce the exhaust Nox and increase combustion efficiency.
Structure : external EGR ( other models )
Cycling method: front circulation

To
To
intercooler
intercooler
Turbocharger

From air To
filter muffler

Exhaust Coolant
manifold outlet The left figure is the schematic
Engine EGR cooler
diagram of external high pressure
Coolant
Inlet outlet exhaust gas recycling system.
manifold

EGR valve
From Leaf valve
intercooler Controller

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2.3.2, EGR (exhaust gas recycling system)

EGR Coolant
valv inlet
EGR
e port
cooler

Coolant
outlet
port

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2.3.3, EGR (exhaust gas recycling system)

EGR cooler :
Coolant
(high temperature)
Exhaust gas port
(low temperature)

high temperature
Exhaust gas inlet por
low temperature Coolant (high temperature)
(low temperature)

・ in general, the material of EGR cooler is stainless steel.


・ sulfuric acid corrodes EGR cooler, valve which will lead malfunctions, such as water
entering into cylinder.

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2.3.4, Diesel engine electric system


Introduction : injection system is controlled by diesel engine ECU. ECU ( electrical control
device ) precisely controls the injection amount and injection time of each injector to
achieve an optimum balance between economy and power.
The traditional diesel engine is controlled by mechanical system. The precision is lower
than that controlled by ECU.
Input Output
• Crankshaft position sensor
• Camshaft position sensor Oil injection
• Pedal position sensor amount
• Engine oil pressure sensor
Injection time

• Air inlet temperature sensor Air intake


Senso • Pressure sensor Computer throttle
• Temperature sensor
r • Exhaust gas recycling sensor
ECU
Heater plug

• Self-diagnosis
Coolant temperature sensor
• Fuel temperature sensor
• Common rail sensor
Other
• Other

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2.3.4, The differences between electrical control diesel engine and tradition diesel
engine
The main differences remain in fuel system:
For traditional diesel engine, mechanical oil pump apply pressure on diesel, and the pressurized
diesel injects to cylinder. The injection pressure and timing varies according to different working
conditions, which is uncontrollable.
A key device of electrical control diesel engine is ECU. It analyzes the signal transferred by sensor
and switch, and then send the execution instruction to each executor ( such as injector ) .

Type Tradition diesel engine Electrical control diesel engine


Fuel system type pump-pipe-nozzle High pressure common rail
Decided by ECU, Injection
Injection amount Decided by oil pump
solenoid valve
Decided by ECU, Injection
Injection time Decided by oil pump
solenoid valve
Fuel crowding method By oil pump By high pressure oil pump
Decided by high pressure
Fuel distribution method Decided by oil pump
common rail

Decided by the pressure


Injection pressure Decided by crankshaft speed adjusting valve of high
pressure oil pump

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2.3.5, high pressure common rail system ( CRS system )


Introduction: a separate high-pressure pump generates injection pressure. This pump don't need injection
timing to drive synchronously. Pressure can be set independent of engine speed and jet fuel and it
will be stored within a common pipe. The injection starting point and injection amount are
determined by electronically-controlled injector.
Components: high
pressure pump, pressure limiting valve, common rail, limiter, injectors, sensors, electronic throttle, a
nd ECU

Pressu
Oil rail pressure
High re limit
Oil rail sensor
pressu valve
re
pump Current
Gear
齿轮 Filter limiter
pump
Measure
ment unit Schematic
Other
Other
sensor
diagram of high
executor Injector

Pedal
pressure

Engine common rail


speed
( cranksh
aft )
Oil Engine
Fuel filter High pressure oil
tank speed
Low pressure oil
( camshaf
t)

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2.3.6, electronic control unit ( ECU )

Hardware and software function of ECU


The function of electronic control unit:

2.3.7, output-executor
· protection condition
-over speed protection-
· output control Over load protection
Executor includes: electric indicator-Injection -smoke protection
amount
-high temperature · calibration and
governor, relief control · working condition protection
control detection
· troubleshooting -online calibration
solenoid valve, electric -start
-diagnosis and fault -real-time detection
-idle code
control timing control valve, -speed adjusting -failure safety strategy
·drivability control -balance control of
electric control timing each cylinder
-OBD
device, electromagnetic
relief valve, high-speed
solenoid valve, and etc.

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