occooecccaanccaocceccecacaccecaecacecaoeccecececeacl Blectro Motive 567, 645 and 710 Diesel Engines ore ol “two stroke” congines. CHAPTER Diesel Engine Theory Introduction In this chapter we will look atthe diesel engine beginning with a review of the four stroke and two stroke operating cycles. In this chapter we will continue with: general engine arrangement; model types (8,12,16, and 20 cylinders); intemal pressure zones (crankcase, airbox, and top deck) serial number locations and system In the next chapter we will cover the individual components in detail. Engine Operating Cycles ‘The General Motors diesel engine utilizes a two stroke operating cycle. ‘This means that for one engine cylinder to generate a power pulse, it requires two strokes of the piston, one upwards stroke and one downwards stroke, The easiest way to present this cycle is by first comparing it to the four stroke cycle used in most other diesel engines. TS Locomotive Tang Sens Student Text 2Four Stroke Engine - Construction ‘Most four stroke diesel engines share a intake similar construction (Figure 2.1) Valve ‘The cylinder is closed on the top by the cylinder head and sealed on the bottom by the moveable piston and piston rings. Intake and exhaust valves located in the ee cylinder head allow the flow of gases into and out ofthe cylinder as required. ‘The crankshaft eccentric and the connecting rod translate the up and down. motion of the piston toa rotary motion on the shaft. Four Stroke Engine - Intake Stroke ‘The four stroke cycle begins with the intake stroke (Figure 2.2). ‘The rotary motion of the crankshaft causes the piston in the cylinder to move downwards, increasing the volume of the cylinder. As the volume of the cylinder increases, the pressure decreases below atmospheric pressure. Fresh air at the higher pressure rushes into the cylinder through the open intake valve to fill the cylinder. This provides a new charge of oxygen for the combustion of the fuel. ‘As the piston approaches the bottom of the stroke (Bottom Dead Center or BDC), the intake valve closes to seal the cylinder. The piston now begins to move upwards on the compression stroke. Figure 2.2 Intake Stroke Blectro- Motive Model 567, 645 & 710 Series Diesel Engines: CCC OR CEE EEC CE ECE CCE CEC CCE CEE CC CE ECC CCEDeccaocceccacaccacccaccacccecceccececcaacccaoaanca Four Stroke Engine - Compression Stroke ‘As the piston moves upwards on the compression stroke (Figure 2.3), the volume of the sealed cylinder is reduced and causes the pressure in the cylinder to rapidly increase. The reduction in cylinder volume is usually expressed as the compression ratio. This ratio is the difference between the cylinder volume with the piston at Bottom Dead Center (BDC) and cylinder volume with the piston at Top Dead Center (TDC). Diesel engines commonly have compression ratios between 16:1 and 20:1. Itis a property of gases, that as the pressure is increased the temperature also increases. Its this rapid increase in temperature that provides the heat necessary to ignite the fuel. Four Stroke Engine - Power Stroke ‘The piston moves upwards on the compression stroke increasing cylinder pressure and temperature. Near the top of this stroke, fuel is sprayed into the eylinder by the fuel injector. The fuel is atomized by the injector so that it will mix easily and completely with the hot air. The high cylinder temperature ignites the fuel and ait mixture and combustion begins. ‘The heat produced by the burning fuel and air mixture causes a further rapid increase in cylinder pressure, As the piston passes through Top Dead Center and begins a downward motion, the increased cylinder pressure pushes the piston down. The force acting downwards on the piston is many times greater than the force required to initially compress the ait. This force is transferred through the connecting rod to the crankshaft. Its through the actions of the cylinder assembly that the latent energy contained in the fuel is released and converted into a useable ‘mechanical force. Figure 2.3 Compression Stroke Fuel enters Cylinder through Injector TTS Locomotive Training Series - Student TextFour Stroke Engine - Exhaust Stroke Before the combustion process can be repeated, the cylinder must be purged of the burnt gases and refilled with a fresh air charge. Just before the piston reaches the bottom of the power stroke, the exhaust valve is opened to vent the pressure contained in the cylinder. The piston passes Bottom Dead Center and moves upwards on the exhaust stroke. The motion of the piston moving upwards reduces the volume of the cylinder and increases the pressure. Since the exhaust valve is open, the burnt gases flow outwards to the atmosphere through the valve. When the piston has reached Top Dead Center, the exhaust valve closes, the intake valve opens, and the cylinder is ready to begin the next intake stroke. Figure 2.5 Exhaust Stroke Four Stroke Engine - Conclusion In order for the four stroke engine to produce one power stroke, four distinct piston movements are required: intake (piston moves downwards) * compression (piston moves upwards) © power (piston moves downwards) © exhaust (piston moves upwards) ‘The crankshaft must turn two cor smplete revolutions to produce these for ‘motions. Therefore each cylinder ofa four stroke engine will produce one power stroke every other revolution of the crankshaft. The valve operating mechanism (usually a camshaft) will operate at one half of crankshaft speed in a four stroke engine. ‘The energy generated on the power stroke is transferred to the crankshaft and then to the devices powered by the engine, Some of the energy produced is absorbed by the heavy flywheel, usually mounted on the rear of the crank. This energy is released as momentum to camry the engine through the exhaust, intake, and compression strokes. Ws Electro-Motive Model 567, 645 & 710 Series Diesel Engines cccecececcecccecececceecC CCC CCC CC COCO OC CCC OCC!BG GOO GCG G.O.6.6.6.6.6 6 6 G66. O1616 61G.0.0.6.0.6.6 © 0.0.0 Go Two Stroke Engine - Construction ‘There are a great many different designs for two stroke (or eyele) engines; this text will deal only with the design similar tothe one used on the General Motors diesel engines. Asin the four stroke engine, the cylinder assembly is sealed at the top by the cylinder head, and at the bottom by the piston and piston rings. Fuel is injected in a similar manner by a fuel injector located in the cylinder head. There are however several very important differences. Instead of utilizing an intake valve located in the cylinder head, a row of ports, or ‘openings, have been located in the lower portion of the cylinder wall, These ports are surrounded by a chamber known commonly asthe airbox. Fresh air is pumped into this chamber by an air pump, or blower, for ‘use in combustion. ‘Two Stroke Engine - Scavenging (Start) ‘The two stroke engine uses a different method of introducing a fresh air charge into the cylinder than the four stroke engine. Rotation of the crankshaft causes the mechanically coupled air ump to force fresh air into the airbox that surrounds the air ports on the lower cylinder walls. With the piston at the bottom of the stroke, this fesh ait enters the cylinder through the ports. As the exhaust valves are also open at this time, the air moves upwards through the cylinder, and exits through the open valves, Figure 2.7 Scavenging (Start) [TS Locomotive Training Series - Student Text‘The air ports are angled slightly from the center line ofthe cylinder causing the air to swirl inthe cylinder as it moves upwards. Thus the cylinder is completely purged and filled with fresh air. This action is called scavenging. Two Stroke Engine - Scavenging Finish) The crankshaft rotates, moving the piston upwards in the cylinder. The upwards piston movement blocks the flow of fresh air through the liner ports, and forces a small amount of ait out the exhaust valves. Any remaining exhaust from the previous power stroke is completely removed from the cylinder by this action ‘The exhaust valves then close to seal the cylinder and allow compression of the air. Two Stroke Engine - Compression ‘After the exhaust valves have closed, the piston moves upwards compressing the air in the cylinder. As in the four stroke engine when the air is compressed, the temperature and pressure rise However, compression in a two stroke engine differs slightly in that the initial cylinder pressure is slightly higher because of the air pump, and the effective stroke is much shorter, Figure 2.8 Scavenging (Finish) ee Figure 2.9. Compression Stroke Ws Electro Motive Mode §67, 645 & 710 Series Diesel Engines: a ccecceccceccecececececeCeCC eC COC CC COCO KCC CCC OC! 7MiGG OFC GGCOGUC TG GCC OCC GG eG GOe TOG CG CHO OGG Two Stroke Engine - Injection ‘The injection of fuel into the cylinder of the two stroke engine is handled in the same manner as the four stroke engine. As the piston nears Top Dead Center (TDC) the fuel injector delivers an atomized spray of fuel into the cylinder. The fuel combines with the air and is ignited by the high temperature. Rotation of, the crankshaft carties the piston past TDC as the fuel begins to combust with the air. Two Stroke Engine - Power Combustion of the fuel and air causes the pressure in the cylinder to rise rapidly. This pressure expands in all directions, pushing the piston downwards with a greater force than it took to initially compress the air, Asin the four stroke engine, this force on the piston is converted into a rotary mo- tion on the crankshaft, providing a useable mechanical force. Fuel injection begins just betora TOC. Figure 2.10 Injection Stroke ofa Figure 2.11 Power Stroke TTS Locomotive Training Series - Student Text 27Two Stroke Engine - Exhaust The piston travels downwards on the power stroke until a point just before the air ports are uncovered. The exhaust valves open to vent cylinder pressure to atmosphere. By opening the exhaust valves slightly before the air ports, a flow of gasses is started through the valves and cylinder pressure is reduced below that of the airbox. By reducing eylinder pressure in this way a back flow of gas (backfire) into the airbox is prevented. Cylinder pressure continues to reduce until the air ports are opened by the piston. At this time the fresh air from the airbox is allowed to enter and scavenge the cylinder to begin the cycle again. Figure 2.12 Exhaust Stroke Two Stroke Engine - Conclusion Conversion of the heat energy contained in the fuel is essentially done the same way in both the two and four stroke engines. However where the four stroke engine requires two revolutions ofthe crankshaft to deliver one power impulse, the two stroke engine will deliver one power impulse every crankshaft revolution, ‘The power impulses in the two stroke engine are of a less magnitude than a four stoke due to the reduced effective compression and power strokes, Electro Motive Model §67, 645 & 710 Series Diesel Engines a Tr cCCOCCCCC KOCK CCC CCC CCC CC OCC CCC CCC COCO COC?RPGGGOG CT CO CCOCEO GCC G GCG CHGCCGOGG HOGG G @ Review ‘The four stroke engine cycle consists of intake, compression, power, and exhaust. Fuel is injected into a closed cylinder containing compressed air at a temperature high enough to ignite the fuel. ‘The pressure increase in the cylinder due to the expanding gases forces the piston downwards inducing a turning motion on the erankshaft ‘The four stroke engine requires two complete revolutions of the crankshaft to produce one power impulse. ‘The two stroke engine uses air ports located around the lower portion of the cylinder liner instead of intake valves to admit fresh air into the cylinder. Fresh air supplied by an air pump is used for combustion and to purge (scavenge) the cylinder of exhaust gases. ‘The two stroke engine requires one complete revolution of the crankshaft to produce one power impulse. TTS Locomotive Trang Series Student Text 2General Engine Arrangement ‘The two stroke General Motors diesel engine is a" Narrow V" type design consisting of two banks (or rows) of engine cylinders arranged with an angle of 45° between them. Opposing cylinders share a common crankshaft eccentric (throw) using a "fork and blade” connecting rod design. This design allows for a close distance between cylinders, and the narrow "V", keeps the overall engine width to a minimum. The engine is available in 8, 12, 16, and 20 cylinder models, depending on the desired horsepower output. The 45° compact nature of this engine makes it particularly Between Banks suited to railroad locomotives and marine installations where size is a major consideration. aN fiywheel end since this is where the main gen- erator is driven from. Depending on equipment and horsepower, it may also be termed the blower ¢ or turbo end because combustion air is supplied through the rear of the engine by either a mec- hanical air blower or a turbocharger. ‘The rear of the engine is usually called the ‘The camshaft gear train and auxiliary generator drive are located on the rear of the engine. Engine rotation is left hand, or anti- Left Hand clockwise as viewed from the rear facing towards Rotation the front. Figure 2.13 GM Engine - Rear View ‘The front end of the engine is commonly referred to as the governor end as this is the mounting location of this device. The water pumps, lube oil pumps, and the pump drive gears are also located on the front of the engine. All oil, fuel, and cooling water connections for the engine are made on the front end, Since the size and type of pumps may vary according to engine horsepower and engine application, the front is sometimes referred to as the accessory end. A drive connection is available on the front end of the crankshaft for accessory items such as air compressors, additional pumps, or mechanically driven blowers. ear End Inet Figure 2.14 Engine Configuration Wa Electro Motive Model 567, 645 & 710 Series Dietol Engines — cceecececceec cece cece ec eceececeeceC CCC OCC COCO COC’PG GG GC GO CQ GGG GG GIOG GGG GGG GGG CCG G 0.0 0 0 GG G - ai Engine orientation is established from the rear of the engine looking forward. ‘The engine banks ae termed left and right as viewed from the rear ofthe engine looking forward. The cylinders are numbered sequentially from front to rear beginning with the right bank. Cylinder number one is always located on the right front comet of the engine. In the illustration of a twelve cylinder engine Figure 2.14, the cylinders on the right bank are numbered one thru si; the cylinders on the left bank are numbered seven thru twelve. On a sixteen cylinder engine the cylinders on the right bank are numbered one thru eight beginning with the right front; the eylinders on the left bank are numbered nine thru sixteen beginning with the left front. Cylinder number one on all engines is at TDC when the flywheel pointer reads 0°. The cylinder mated to number one will be at TDC 45° later because of the layout of the cylinder banks. Therefore, paired engine cylinders, such as number one and seven on the twelve cylinder model, always fire 45° apart On the eight cylinder engine, a power pulse is generated every 45° of crankshaft rotation (360° /8 cyl = 45°). The sixteen cylinder engine generates a power pulse every 22 1/2° of crankshaft rotation (360° / 16 cyl = 22 1/2°). These two engines have a "Balanced" firing order since the pulses are evenly distributed through out one crankshaft revolution, ‘The twelve and twenty cylinder models have an "Unbalanced fring order. ‘To balance these engines is not possible with a 45° vee. For example, the twelve cylinder model would require a power pulse every 30° (360° / 12 cyl = 30°). This is not possible since opposing cylinders are 45° apart. The "Pairs" of cylinders are distributed through ut the revolution based. on experience and computer simulation to give the best performance for the twelve and twenty cylinder models. An Injector Timing tag is located at the rear corner of the engine for use when doing engine adjustments 107 ‘Always consult your Engine Maintenance Manual for the correct firing ‘order and timing for the engine being serviced! ‘The exhaust system is located on the top of the engine between the cylinder banks. For engines equipped with mechanical blowers, the exhaust is collected in the manifold and allowed to vent to atmosphere. On higher horsepower engines equipped with turbochargers, the exhaust is collected in the manifold and sent through the turbine before escaping to atmosphere. TTS Locomotive Taining Series - Student Text 20Review ‘The GM diesel engine is a 45° "narrow V* design. Engine layout is determined from the rear of the engine facing forward ‘The combustion air supply (blower or turbo), camshaft gear train, and generator drives are located on the rear of the engine. ‘The engine consists of two banks (or rows) of cylinders, the left bank and the right bank. ‘The cylinders are numbered from front to rear, beginning with the right front cylinder. Opposing cylinders are always timed 45° apart. ‘The front end of the engine is also called the governor or accessory end. ‘The governor, water pumps, and lube oil pumps are located on the front of the engine. All fuel, oil, and cooling water connections are made at the front of the engine. ‘The exhaust system is mounted to the top of the engine between the cylinder banks. \ Wa Blctto Motive Model 867, 645 & 710 Series Diesel Engines Cccccce CCC CCCCCCCCCCCCCCCCECCCE CECENGO OOO CO GCOCCOO CCC OCGCOGCGGC COO GCGOCOC OO OC GG @ Internal Pressure Divisions ‘The GM diesel engine is divided into two distinct pressure zones; postive pressure (above atmospheric pressure); and negative pressure (below atmospheric pressure). Positive Pressure ‘The airbox area of the engine is always at a positive pressure as compared to atmosphere. The positive pressure is required to force the air into the cylinders through the liner air ports. The in flowing air must have sufficient pressure to push through the cylinder and force the burnt gases out the exhaust valves. Unlike the four stroke engine, there is no intake stroke to draw fresh air into the cylinder, nor an exhaust stroke to expel the burnt gases Figure 2.15. Positive Pressure Zone ‘The positive air pressure in the airbox is sometimes referred to asthe boost pressure, The amount of boost pressure on a mechanical blower equipped engine is directly proportional to the speed of the blower (engine speed). On turbo equipped engines, the boost depends not only on engine speed, but also the amount of fel consumed by the engine, as the turbo relies on waste heat energy in the exhaust to operate, Negative Pressure Most engines use a crankease ventilation system to prevent the buildup of combustible gases in the crankeas The eductor system on the GM engine is Negative designed to keep the crankcase at a Pressure negative pressure whenever the engine is running, Blower equipped engines draw the crankcase vapours through an oil separator into the blower inlet. ‘Turbo equipped engine use an eductor (venturi) tube in the exhaust stack to draw the vapours through the oil separator and expel them to atmosphere. Figure 2.16 Negative Pressure Zone TTS Locomotive Training Series - Student Text 23Wau eter to section 0" of the Engine Maintenance Manu. ‘The oil separator is designed to trap and recover small oil droplets carried out of the engine with the vapours. The top deck area of the engine is common to the engine sump through oil drain tubes, and the entire assembly is kept at the negative pressure. The reduction of pressure is dependant on engine speed and engine condition, As engine speed is increased, the vapour withdrawn is also increased. Leakage on engine covers and seals or excessive piston ring leakage (blowby) will affect the ability of the system to maintain the negative pressure. Serial Numbers To facilitate parts identification most major components and assemblies are stamped with a part number and a unique serial number. In order to maintain the GM engine and ensure correct parts replacement, itis necessary to understand the system used for serial numbers. Section 0 of the Engine Maintenance Manual identifies most parts that carry serial numbers and where the number is located. ‘The following example shows the type of information typically found on the Serial Number & Identification plate found on the right bank of the crankcase, a) model designation b) date of manufacture (or remanufacture) c) location of manufacture 4) production sequence number ELECTRO-MOTIVE DIVISION GENERAL MOTORS CORPORATION LAGRANGE, IL 60526 MODEL NO. ‘SERIAL NO. 16 645E3B e0.a1 1102 (22s 4s | 66 10 Figure 2.17 Engine Identification Plate Electro Motive Model 567, 645 & 710 Series Diesel Engines \ ccececcceccececececececececceceececeCC CCC CCC COCO COCO! .cCccaocaoaoaceccccaoaccacccaccaccecceccecccanaoocaeana ‘The specific breakdown of the data is as follows: a) 2) Number of cylinders (8, 12, 16, or 20) Cubic inch displacement per cylinder ( 567, 645, or 710) (9291.4, 10,569.6, 11,634.5-CM? (3)(4) Application ( 567 A thru E, 645 E th F, 710G) 0) E El E2 E3 E4 ES 56 E7 Es E9 Railroad engine blower equipped Industrial engine blower equipped Marine engine blower equipped (without strainer housing) Railroad engine turbocharged Industrial power generator Marine engine turbocharged (without strainer housing) Marine engine blower equipped (with strainer housing) Marine engine turbocharged (with strainer housing) Drill rig engine blower equipped Drill rig engine turbocharged E10 Industrial engine turbocharged New Generation Fuel Economy Engine (designated B or C) Year produced Month produced (A thru M, I is skipped due to confusion) Engine history pene New manufacture Remanufactured trade in UTEX (unit exchange) Repair and return Location of production MoaMawne LaGrange, Il not used Hazelwood, Mo. (no longer used) Vendor item Halethorpe, Md. (turbo) Commerce, Ca. (turbo) Jacksonville, Fl (10) Production sequence number In addition to the engine itself, all major components and assemblies catty a serial number. While itis possible for two parts to have identical serial numbers, itis not possible for two parts to have both the same serial number and the same part number. For example, while you may have a cylinder head and a cylinder liner with the same serial numbers, itis impossible to have two cylinder heads with the same serial numbers. TTS Locomotive Training Series - Student Text 25Review The diesel engine and all major components and assemblies ate identified with part numbers and unique serial numbers. The serial number provides a history of the engine or component including date and location of manufacture. The diesel engine identification tag is located on the right bank of the engine Itis not possible to have two identical parts with the same serial number. The first two digits ofthe serial number indicate the year of production. Months of manufacture are expressed as A thru M; is excluded due to confusion, The last three digit sequence number. of the serial number indicate the production Wa Electro Motive Model 567, 645 & 710 Saris Diesel Engines ccecccececececccececececccC eC CCC CCC OC CCC CCC OOK!