Systems Operation Testing And Adjusting - Altorfer Cat
KENR9119-01June 2011Systems OperationTesting and AdjustingC4.4 Industrial Engine4481-Up (Engine)SAFETY.CAT.COM
i03991620Important Safety InformationMost accidents that involve product operation, maintenance and repair are caused by failure to observebasic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardoussituations before an accident occurs. A person must be alert to potential hazards. This person should alsohave the necessary training, skills and tools to perform these functions properly.Improper operation, lubrication, maintenance or repair of this product can be dangerous andcould result in injury or death.Do not operate or perform any lubrication, maintenance or repair on this product, until you haveread and understood the operation, lubrication, maintenance and repair information.Safety precautions and warnings are provided in this manual and on the product. If these hazard warningsare not heeded, bodily injury or death could occur to you or to other persons.The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.The meaning of this safety alert symbol is as follows:Attention! Become Alert! Your Safety is Involved.The message that appears under the warning explains the hazard and can be either written or pictoriallypresented.A non-exhaustive list of operations that may cause product damage are identified by “NOTICE” labelson the product and in this publication.Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.The warnings in this publication and on the product are, therefore, not all inclusive. You mustnot use this product in any manner different from that considered by this manual without firstsatisfying yourself that you have considered all safety rules and precautions applicable to theoperation of the product in the location of use, including site-specific rules and precautionsapplicable to the worksite. If a tool, procedure, work method or operating technique that is notspecifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for youand for others. You should also ensure that the product will not be damaged or become unsafe bythe operation, lubrication, maintenance or repair procedures that you intend to use.The information, specifications, and illustrations in this publication are on the basis of information thatwas available at the time that the publication was written. The specifications, torques, pressures,measurements, adjustments, illustrations, and other items can change at any time. These changes canaffect the service that is given to the product. Obtain the complete and most current information before youstart any job. Cat dealers have the most current information available.When replacement parts are required for thisproduct Caterpillar recommends using Cat replacement parts or parts with equivalent specifications including, but not limited to, physicaldimensions, type, strength and material.Failure to heed this warning can lead to premature failures, product damage, personal injury ordeath.In the United States, the maintenance, replacement, or repair of the emission control devices andsystems may be performed by any repair establishment or individual of the owner's choosing.
KENR9119-013Table of ContentsTable of ContentsSystems Operation SectionGeneral InformationIntroduction . 4Engine OperationBasic Engine .Air Inlet and Exhaust System (SingleTurbocharger) .Air Inlet and Exhaust System (SeriesTurbochargers) .Clean Emissions Module .Cooling System .Lubrication System .Electrical System .Cleanliness of Fuel System Components .Fuel Injection .Electronic Control System .Power Sources .Glossary of Electronic Control Terms .101420252729293131395255Testing and Adjusting SectionFuel SystemFuel System - Inspect .Air in Fuel - Test .Finding Top Center Position for No. 1 Piston .Fuel Injection Timing - Check .Fuel Quality - Test .Fuel System - Prime .Gear Group (Front) - Time .61616364656566Air Inlet and Exhaust SystemAir Inlet and Exhaust System - Inspect .Turbocharger - Inspect (Series Turbochargers) .Turbocharger - Inspect (Single Turbocharger) .Exhaust Cooler (NRS) - Test .Compression - Test .Engine Valve Lash - Inspect .Valve Depth - Inspect .Valve Guide - Inspect .6768717475757778Lubrication SystemEngine Oil Pressure - Test .Engine Oil Pump - Inspect .Excessive Bearing Wear - Inspect .Excessive Engine Oil Consumption - Inspect .Increased Engine Oil Temperature - Inspect .7979808081Cooling SystemCooling System - Check .Cooling System - Inspect .Cooling System - Test .Engine Oil Cooler - Inspect .Water Temperature Regulator - Test .Water Pump - Inspect .828283848585Basic EnginePosition the Valve Mechanism Before MaintenanceProcedures . 86Piston Ring Groove - Inspect . 86Connecting Rod - Inspect . 87Cylinder Block - Inspect . 88Cylinder Head - Inspect . 88Piston Height - Inspect . 89Flywheel - Inspect . 90Flywheel Housing - Inspect . 91Gear Group - Inspect . 92Crankshaft Pulley - Check . 93Electrical SystemAlternator - Test .Battery - Test .Charging System - Test .V-Belt - Test .Electric Starting System - Test .9495969696Index SectionIndex . 99
4Systems Operation SectionKENR9119-01Systems Operation SectionThe crankshaft gear turns the idler gear which thenturns the following gears: the camshaft gearGeneral Information the accessory drive gear (if equipped)i04129192IntroductionSMCS Code: 1000The C4.4 diesel engine is electronically controlled.The C4.4 engine has an Electronic Control Module(ECM) that receives signals from the fuel injectionpump and other sensors in order to control theelectronic unit injector. The fuel injection pumpsupplies fuel to the high-pressure manifold (Rail).The high-pressure manifold (Rail) distributes fuel tothe electronic unit injectors.The four cylinders are arranged in-line. The cylinderhead assembly has two inlet valves and two exhaustvalves for each cylinder. The ports for the exhaustvalves are on the right side of the cylinder head. Theports for the inlet valves are on the left side of thecylinder head. Each cylinder valve has a single valvespring.Each cylinder has a piston cooling jet that is installedin the cylinder block. The piston cooling jet spraysengine oil onto the inner surface of the piston in orderto cool the piston. The pistons have a Quiescentcombustion chamber in the top of the piston in orderto achieve clean exhaust emissions. The piston pin isoff-center in order to reduce the noise level.The pistons have two compression rings and an oilcontrol ring. The groove for the top ring has a hardmetal insert in order to reduce wear of the groove.The skirt has a layer of graphite in order to reducethe risk of seizure when the engine is new. Thecorrect piston height is important in order to ensurethat the piston does not contact the cylinder head.The correct piston height also ensures the efficientcombustion of fuel which is necessary in order toconform to requirements for emissions.The crankshaft has five main bearing journals. Endplay is controlled by thrust washers which are locatedon both sides of the number 3 main bearing.The timing case is made of aluminum or cast iron.The timing gears are stamped with timing marks inorder to ensure the correct assembly of the gears.When the number 1 piston is at the top centerposition of the compression stroke, the marked teethon the idler gear will align with the marks that areon the fuel injection pump gear, the camshaft gear,and the gear on the crankshaft. There are no timingmarks on the rear face of the timing case. the fuel injection pump gear the water pump gearThe camshaft runs at half the rpm of the crankshaft.The fuel injection pump runs at the same rpm as thecrankshaft.The fuel injection pump that is installed on the leftside of the engine is gear-driven from the timingcase. The fuel is transferred to the fuel injectionpump by an external electric transfer pump. Theelectric transfer pump draws fuel across a suctionstrainer that supplies fuel to the primary fuel filterand the secondary fuel filter. The fuel then travels tothe fuel injection pump. A pressure regulator that isinstalled in the low-pressure fuel system controls thefuel pressure to the fuel injection pump. The pressureregulator regulates the fuel at an absolute pressureof 150 kPa (22 psi) when the engine is at idle speed.The fuel injection pump increases the fuel to amaximum pressure of 200 MPa (2900 psi). The fuelinjection pump delivers the fuel to the high-pressuremanifold (Rail). The fuel injection pump is notserviceable. The engine uses speed sensors andthe Electronic Control Module to control the enginespeed.For the specifications of the C4.4 engine, refer to theSpecifications, “Engine Design”.The following model views show a typical C4.4engine. Due to individual applications, your enginemay appear different from the illustrations.
KENR9119-015Systems Operation SectionC4.4 Engine with SeriesTurbochargersg02409511Illustration 1Typical example(1) Front lifting eye(2) Crankcase breather(3) NOx Reduction System (NRS)(4) Primary fuel filter(5) Secondary fuel filter(6) Electronic Control Module (ECM)(7) Fuel priming pump(8) Oil gauge (dipstick)(9) Fuel strainer(10) Oil filter(11) Oil sampling valve(12) Oil filler(13) Fuel injection pump
6Systems Operation SectionKENR9119-01g02409512Illustration 2Typical example(14)(15)(16)(17)Rear lifting eyeHigh-pressure turbochargerLow-pressure turbochargerBack pressure valve(18)(19)(20)(21)Starting motorOil drain plugExhaust outletFlywheel housing(22) Flywheel(23) Exhaust gas cooler (NRS)
KENR9119-017Systems Operation Sectiong02409862Illustration 3Typical example(24) Belt(25) Connection for air inlet(26) Coolant outlet connection(27) Water temperature regulator housing(28) Water pump(29) Inlet connection for the coolant(30) Crankshaft pulley(31) Belt tensioner(32) Alternator
8Systems Operation SectionKENR9119-01C4.4 Engine with SingleTurbochargerg02407436Illustration 4Typical example(1) Front lifting eye(2) Crankcase breather(3) NOx Reduction System (NRS)(4) Secondary fuel filter(5) Primary fuel filter(6) Fuel priming pump(7) Fuel strainer(8) Electronic Control Module (ECM)(9) Oil filter(10) Oil sampling valve(11) Fuel injection pump
KENR9119-019Systems Operation Sectiong02407536Illustration 5Typical example(12)(13)(14)(15)Rear lifting eyeOil gauge (dipstick)TurbochargerStarting motor(16)(17)(18)(19)Oil drain valveOil drain plugBack pressure valveFlywheel housing(20) Flywheel(21) Exhaust outlet(22) Exhaust gas cooler (NRS)
10Systems Operation SectionKENR9119-01g02407537Illustration 6Typical example(23) Oil filler(24) Connection for air inlet(25) Outlet connection for the coolant(26) Water temperature regulator housing(27)(28)(29)(30)Water pumpInlet connection for the coolantCrankshaft pulleyBelt tensionerEngine Operation Connecting rodsi04135810Basic EngineSMCS Code: 1200IntroductionThe eight major mechanical components of the basicengine are the following parts: Cylinder block Cylinder head Pistons(31) Alternator(32) Belt Crankshaft Crankshaft pulley Timing gear case and gears Camshaft
KENR9119-0111Systems Operation SectionCylinder BlockIllustration 7Cylinder Headg02149272Typical exampleThe cast iron cylinder block for the four cylinderengine has four cylinders which are arranged in-line.The cylinder block is made of cast iron. The cylinderblock provides support for the full length of thecylinder bores. The cylinder bores are machined intothe block.The cylinders are honed to a specially controlledfinish in order to ensure long life and low oilconsumption.The cylinder block has five main bearings whichsupport the crankshaft. Thrust washers are installedon both sides of number 3 main bearing in order tocontrol the end play of the crankshaft. The thrustwashers can only be installed one way.Passages supply the lubrication for the crankshaftbearings. These passages are machined into thecylinder block.Cooling passages are cast into the cylinder block inorder to allow the circulation of coolant.The cylinder block has a bush that is installed for thefront camshaft journal. The other camshaft journalsrun directly in the cylinder block.The engine has a cooling jet that is installed in thecylinder block for each cylinder. The piston coolingjet sprays lubricating oil onto the inner surface of thepiston in order to cool the piston.A Multi-Layered Steel (MLS) cylinder head gasket isused between the engine block and the cylinder headin order to seal combustion gases, water, and oil.Illustration 8g02466936Typical example(1) Valve keepers(2) Valve spring retainer(3) Valve springThe engine has a cast iron cylinder head (5). Theinlet manifold is integral within the cylinder head.There are two inlet valves and two exhaust valves foreach cylinder. Each pair of valves (6) are connectedby a valve bridge that is controlled by a pushrod valvesystem. The ports for the inlet valves are on the leftside of the cylinder head. The ports for the exhaustvalves are on the right side of the cylinder head. Thevalve stems move in valve guides that are pressedinto the cylinder head. There is a renewable stemseal (4) that fits over the top of the valve guide. Thevalve seats are replaceable.
12Systems Operation SectionKENR9119-01Pistons, Rings, and ConnectingrodsThe connecting rods (4) are machined from forgedsteel. The connecting rods have bearing caps (6)that are fracture split. Two connecting rod bearings(5) are installed between the connecting rod (4) andthe bearing cap (6). The bearing caps on fracturesplit connecting rods are retained with Torx bolts (7).Connecting rods with bearing caps that are fracturesplit have the following characteristics: The splitting produces an accurately matchedsurface on each side of the fracture for improvedstrength. The correct connecting rod must be installed withthe correct bearing cap. Each connecting rod andbearing cap have an unique serial number. When aconnecting rod is assembled the serial numbers forthe connecting rod and bearing cap must match.CrankshaftIllustration 9g02466938Typical exampleThe pistons (9) have a Quiescent combustionchamber in the top of the piston in order to providean efficient mix of fuel and air. The piston pin (8) isoff-center in order to reduce the noise level. Theposition pin (8) is retained in the correct position bytwo circlips (3).The pistons have two compression rings (1) and anoil control ring (2). The groove for the top ring hasa hard metal insert in order to reduce wear of thegroove. The piston skirt has a low friction coating inorder to reduce the risk of seizure when the engineis new.The correct piston height is important in order toensure that the piston does not contact the cylinderhead. The correct piston height also ensures theefficient combustion of fuel which is necessary inorder to conform to requirements for emissions.Illustration 10g02155439Typical example(1)(2)(3)(4)Crankshaft gearCrankshaftCrankshaft thrust washersCrankshaft timing ringThe crankshaft can be a spheroidal graphite ironcasting or a steel forging.The crankshaft has five main journals. Thrustwashers are installed on both sides of number 3main bearing in order to control the end play of thecrankshaft.The crankshaft changes the linear energy of thepistons and connecting rods into rotary torque inorder to power external equipment.
KENR9119-0113Systems Operation SectionA gear at the front of the crankshaft drives the timinggears. The crankshaft gear turns the idler gear whichthen turns the following gears:Camshaft Camshaft gear Fuel injection pump and fuel transfer pump The idler gear is driven by the crankshaft gearwhich turns the gear of the lubricating oil pump.Lip type seals are used on both the front of thecrankshaft and the rear of the crankshaft.A timing ring is installed to the crankshaft. The timingring is used by the ECM in order to measure theengine speed and the engine position.A ring gear for the balancer can be installed to thecrankshaft. When a balancer is installed, the engineoil pump is an integral part of the balancer assembly.The ring gear for the balancer drives the balancer.Gears and Timing Gear CaseIllustration 11The camshaft rotates at half the engine speed. Thefuel injection pump rotates at engine speed.g02212814Typical example(1) Hole for the water pump gear(3) Position of the accessory drive gearThe crankshaft oil seal is mounted in the cover ofthe timing case. The timing case cover is made fromsound-deadened steel or cast iron.The timing gears are made of steel.The crankshaft gear (5) drives an upper idler gear(4) and a lower idler gear. The upper idler gear (4)drives the camshaft gear (6) and the fuel injectionpump gear (2). The lower idler gear drives the oilpump. The water pump drive gear is driven by thefuel injection pump gear.The engine has a single camshaft. The camshaftis made of cast iron. The camshaft lobes are chillhardened.The camshaft is driven at the front end. As thecamshaft turns, the camshaft lobes move the valvesystem components. The valve system componentsmove the cylinder valves.The camshaft gear must be timed to the crankshaftgear. The relationship between the lobes and thecamshaft gear causes the valves in each cylinder toopen at the correct time. The relationship betweenthe lobes and the camshaft gear also causes thevalves in each cylinder to close at the correct time.
14Systems Operation SectionKENR9119-01i04302990Air Inlet and Exhaust System(Single Turbocharger)SMCS Code: 1050g02469917Illustration 12Air inlet and exhaust system(1) Aftercooler core(2) Air filter(3) Diesel particulate filter(4) Back pressure valve(5) Turbocharger(6) Wastegate actuatorThe components of the air inlet and exhaust systemcontrol the
fuel pressure to the fuel injection pump. The pressure regulator regulates the fuel at an absolute pressure of 150 kPa (22 psi) when the engine is at idle speed. The fuel injection pump increases the fuel to a maximum pressure of 200 MPa (2900 psi). The fuel injection pump delivers the fuel to the high-pressure manifold (Rail). The fuel .
required to bring the systems into compliance with the design. b. The contractor shall use standard forms from AABC's "National Standards for Testing, Adjusting, and Balancing" or NEBB's "Procedural Standards for Testing, Adjusting, and Balancing of Environmental Systems" each time a testing, adjusting, and balancing report is created.
“Testing, Adjusting and Balancing HVAC Systems: An . Testing, adjusting, and balancing (TAB) is a process where air and hydronic flows in a building are measured, adjusted, and documented to meet design specifications and local building codes . operation vs. the actual installation. The need for highly skilled technicians has increased with
building’s HVA and hydronic systems are properly balanced. Three major steps used to achieve the proper operation of the HVA and hydronic sys-tems and a desirable climate are testing, adjusting and balancing (TA). Learning Objectives This three-day seminar provides attendees with an overview of the testing, adjusting and balanc-
A. This Section includes testing, adjusting and balancing HVAC systems to provide design conditions as indicated by the associated drawings. This Section includes, but is not limited to the following: 1. Testing, adjusting and balancing of air and hydronic system fluid flow rates at the system
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