Foreword

Welcome to value-conscious company. We are proud of the advanced engineering and

quality construction of each equipment we manufacture.

This manual explains the working of equipment. Please read it thoroughly and have all
the occupants follow the instructions carefully. Doing so will help you enjoy many years
of safe and trouble free operation.

When it comes to service, remember that K.C. Engineers knows your equipment best
and is interested in your complete satisfaction. We will provide the quality maintenance
and any other assistance you may require.

All the information and specifications in this manual are correct at the time of printing.
However, Because of K.C. Engineers policy of continual product improvement we
reserve the right to make changes at any time without notice.

Please note that this manual explains all about the equipment including options.
Therefore, you may find some explanations for options not installed on your equipment.

You must follow the instructions and maintenance instructions given in the manual
carefully to avoid possible injury or damage. Proper maintenance will help ensure
maximum performance, greater reliability and longer life for the product.

K.C. Engineers
 Contents

1. Objective 1

2. Aim 1

3. Introduction 1

4. Theory 2

5. Description 3

6. Utilities Required 5

7. Experimental Procedure 5

8. Observation & Calculation 6

9. Nomenclature 8

10. Precautions & Maintenance Instructions 10

11. Troubleshooting 10

12. References 10

4C 4S Diesel Engine with hydraulic brake dynamometer and calorimeter 0

 FOUR CYLINDER, FOUR STROKE, DIESEL ENGINE
TEST RIG
(WITH HYDRAULIC BRAKE DYNAMOMETER AND WITH EXHUST GAS CALORIEMETER)

1. OBJECTIVE:
To study the four cylinder four stroke Diesel engine & its characteristics.

2. AIM:
To determine
Brake Power
Fuel consumption
Specific fuel consumption
Brake thermal efficiency
Heat carried away by engine jacket
Air consumption
Swept volume
Volumetric efficiency

3. INTRODUCTION:
A Diesel engine is almost the same as a petrol engine but it burns a different type of
fuel. Diesel is named after its inventor Rudolf Diesel, a German who first developed
this type of fuel in the early 1900s. Diesel engines have mainly been used in lorries
and buses because of their increased power and their reliability. They tend to be noisy
and smelly compared to a petrol engine but are more economical to run.
In a diesel engine the compression stroke only compresses air and not fuel. On the
ignition stroke the air is compressed to a very high pressure and then fuel is injected
into the engine cylinder with the help of a injector, resulting in generating enormous
heat, which then ignites the fuel that is injected into the combustion chamber at that
precise moment of maximum pressure. There is no need for a spark plug in a diesel
engine. The compressed air is hot enough to cause the fuel to explode. This is because
a diesel engine has a far higher "compression ratio" than does a petrol engine.

4C 4S Diesel Engine with hydraulic brake dynamometer and calorimeter 1

4. THEORY:
The Four-Stroke Cycle
The stroke is simply when the piston moves all the way either up or all the way
down inside the cylinder. As you might guess, in the four-stroke engine each of the
four strokes accomplishes something different. So, lets have a look at the four strokes
and see what happens:
Induction
The first stroke is called Induction. This is when the air is drawn into the cylinder by
the piston going down and producing suction. As the piston travels down the cylinder
it creates a vacuum above it and the air is drawn into the cylinder in the empty space
left by the piston The piston starts at the top, the camshaft turns and pushes on the
tappets which causes the intake valve to open (on the left), and the piston moves down
to let the engine take in a cylinder full of air. This is also sometimes called the intake
stroke.
Compression
Compression is the second of the four strokes. This is the stage when the air is
compressed and forced into the top of the cylinder ready for ignition. The camshaft
has turned, pushed the tappets, which have in turn allowed the inlet valve to return to
the closed position. The piston moves back up and compresses this air. Compressing
the air makes the explosion more powerful. As the valves are both closed, the cylinder
is sealed and the compressed air cant escape from the cylinder.
Ignition
As the piston reaches the top of the compression stroke, the injector injects the fuel
and ignites the highly compressed air. The piston is then forced back down the
cylinder by the resulting explosion, turning the crankshaft and generating the
propulsion for the engine that makes the vehicle to go along the road. The diagram
shows the piston on its way down the cylinder just after the fuel is ignited.
Exhaust
This is when the exhaust gases (after the fuel is burnt) are forced out of the engine.
Once the piston hits the bottom of its stroke, the exhaust valve opens (on the right).
The piston travels back up inside the cylinder and this time it pushes the exhaust
gasses out through the now open exhaust vent. Now the engine is ready for the next
cycle, so it intakes another charge of fresh air and we are back to the intake stroke.

4C 4S Diesel Engine with hydraulic brake dynamometer and calorimeter 2

5. DESCRIPTION:
The diesel engine test rig consists of following arrangements to conduct the
experiment: -
Four Cylinder, Four Stroke, and Diesel Engine Test Rig with Rope Break
dynamometer arrangement mainly consists of:
1. A Four Cylinder, Four Stroke Diesel engine,
2. Loading arrangement,
3. A Fuel Input Measuring Arrangement
4. An Arrangement for measuring the heat carried away by cooling water from
engine jacket.
5. An arrangement for measuring the heat carried away by cooling water from
exhaust gas.
6. Air intake measuring arrangement.
7. A Panel Board Arrangement
MULTICYLINDER PETROL ENGINE:
A medium capacity two cylinder, four strokes, water-cooled, diesel engine is selected
for experimental purposes. The specification for the Engine is as follows:
Engine : 2 cylinder, 4 stroke, water cooled

4C 4S Diesel Engine with hydraulic brake dynamometer and calorimeter 3

 The engine is complete with self-starter, dynamo, lube-oil filter, air cleaner, ignition
coil, Fuel pump, injectors etc.
LOADING ARRANGEMENT:
Hydraulic dynamometer works on the principle of dissipating the power in fluid
friction rather than in dry friction. In principle its construction is similar to that of a
fluid flywheel. It consists of an inner rotating member or impeller coupled to the
output shaft of the engine. This impeller rotates in a casing filled with fluid. This
outer casing, due to centrifugal force developed, tends to revolve with impeller, but is
resisted by a torque arm supporting the balance weight. The frictional forces between
the impeller and the fluid are measured by the spring balance fitted on the casing .the
heat developed due to dissipation of power is carried away by a continuous supply of
the working fluid, usually water. Regulating the sluice gates, which can be moved in
and out to partially or wholly obstructive flow of water between impeller and the
casing, can control the output.
FUEL INPUT MEASURING ARRANGEMENT:
This arrangement consists of a fuel tank of suitable capacity mounted on a stand. The
fuel goes to the engine through a 50 ml burette. The burette facilitates the
measurement of fuel consumption for a definite period with the help of stopwatch.
ARRANGEMENT FOR MEASURING THE HEAT CARRIED BY COOLING
WATER FROM ENGINE COOLING JACKET:
Suitable pipefitting is provided for circulating the cooling water into the engine water
jacket. For measuring the rate of flow of cooling water, a water meter is provided.
With these entire arrangements, one can find the heat carried away by cooling water.
The temperature of inlet and outlet water can be directly read from the Digital
Temperature Indicator.
ARRANGEMENT FOR MEASURING THE HEAT CARRIED AWAY BY
EXHAUST GASES:
It consists of exhaust gas calorimeter to measure the heat carried away by exhaust
gases. Exhaust gas calorimeter consists of a central tube and an outer jacket. Exhaust
gases passes through central tube and water is circulated in outer jacket to get the
maximum Temperature difference of exhaust gases at inlet and outlet of calorimeter.
The volume of water circulation is measured with the help of measuring cylinder and
stopwatch. Thermocouples are provided to get the inlet and outlet temperature of
exhausts gases and water circulated.

4C 4S Diesel Engine with hydraulic brake dynamometer and calorimeter 4

 AIR INTAKE MEASURING ARRANGEMENT:
It consists of an orifice, a diaphragm base manifold and a U- tube manometer. With
the help of orifice and manometer, the volume of the air sucked can be calculated.

6. UTILITIES REQUIRED:
1. Electricity supply; Single phase , 220V AC, 50Hz, 5-15 Amp socket with earth
connection
2. Water Supply: continuous @ 10 LPM at 1 Bar for engine & exhaust gas
calorimeter cooling.
3. Water Supply: continuous @ 10 LPM at 2 Bar for hydraulic brake dynamometer.
4. Drain Required
5. Floor Area Required: 3 m x 2 m.
6. Diesel: 10 Ltrs
7. Engine oil: Multi-grade 20W40.
8. Exhaust Emission.
9. Tachometer: For RPM Measurement.

7. EXPERIMENTAL PROCEDURE:
1. Fill oil in the oil sump of engine. It should be in between the marks provided on
the oil dipstick. If oil level is reduced, add clean oil (SAE40) to the crankcase by
opening the cover of valve provided, at the top of the engine.
2. Fill the diesel in diesel tank.
3. Fill the manometer up to half of the height of manometer with water.
4. Fill the burette with diesel by opening the valve provided at the lower side of
burette. Close the valve after filling the burette.
5. Supply the diesel to the engine by opening the valves provided in the fuel supply
line.
6. Open continuous cold water supply to the engine jacket & calorimeter.
7. Insert the ignition key and turn it in the clockwise direction to ignition on position,
which is indicated by an indicator lamp. Turn the ignition switch key further
clockwise against the spring pressure to start the engine. As soon as the engine
starts, leave the ignition key and it run for 2 minutes under no load condition.
8. When engine start running smoothly, firstly load the engine slightly with the help
of hydraulic brake dynamometer and then gradually increase the load.

4C 4S Diesel Engine with hydraulic brake dynamometer and calorimeter 5

 9. Run the engine for 2 minutes so that it can stabilize.
10. Note the reading of load and note the RPM.
11. Close the diesel supply valve and open the valve of burette. Note down the time to
consume for 10 or 20ml of diesel. It will give fuel consumption.
12. Now open the diesel supply valve, which refill the burette.
13. Note down the reading of manometer to calculate the air intake by the engine.
14. Note the temperature of inlet and outlet of the water circulating through the engine
jacket and calorimeter. Also note the temperature of exhaust gas at inlet and outlet
of calorimeter.
15. Measure the flow rate of water through engine jacket & calorimeter with the help
of water meter and stop watch.
16. Repeat the experiment for different load.
17. When the experiment is over reduce the load on engine and let it run for 2 minutes
then stop the engine.
18. Then close the fuel and cooling water supply to the engine.

8. OBSERVATION & CALCULATION:

DATA:
do = 0.03 m
D = 0.084 m
L = 0.09 m
Nc = 4
n = 2 (for 4 stroke cycle)
Cv = 43500 kJ / kg
Cp = 4.186 kJ / kg oC
Cd = 0.64
a = 1.293 kg/m3
w = 1000 kg / m3
f = 804 kg/m3
g = 9.81 m/s2

4C 4S Diesel Engine with hydraulic brake dynamometer and calorimeter 6

 OBSERVATION TABLE:
Ta =______________0C (Reading of sensor T3/T4 before starting the engine)

Sr. No. 1. 2. 3. 4.
W Kg
N
h1 cm
h2 cm
x ml
t sec.
T1C
T2C
T3C
T4 C
T5 C
T6 C
VC
Tc
VE
tE

CALCULATIONS:
W * N * 0 .746
BP = , kW = -------------- kW
2000
x f
W f = * 06 , kg/sec = -------------- kg/sec.
t 10
Wf
Wsf = , kg/kW-sec = -------------- kg/kW-sec.
BP
H f = W f * C v , kW = -------------- kW

BP
BT = *100 , % = -------------- %
Hf

VE W
mew = * , kg/sec = ------------ kg/sec
t E 10 03

4C 4S Diesel Engine with hydraulic brake dynamometer and calorimeter 7

 H ecw = mew * C P * (T2 T1 ) , kW = ------------------- kW

VC W
mCW = * , kg/sec = ------------ kg/sec
t C 10 03

H CCW = mCW * C P * (T6 T5 ) , kW = ------------------- kW

H exh = mexh * C exh * (T3 Ta ) , kW = ------------- kW.

mCW * CP * (T6 T5 ) = mexh * C exh * (T3 T4 )

mCW * C p * (T6 T5 )
mexh * C exh =
(T3 T4 )

H un = H f ( BP + H ecw + H exh ) , kW = ------------- kW.

a0 = * d 0 , m2 ------------- m2
2
=
4
Qa = Cd * aO 2 gH , m3/sec = ------------- m3/sec

h1 h2 m
H= 1 , m = ------------- m
100 a
* D2 * L * N * Nc
Vs = , m3/sec = ------------- m3/sec
4 * 60 * n
Qa
vol . = * 100 , % = ------------- %
Vs

9. NOMENCLATURE:
ao = Cross-sectional area of orifice, m2
BP = Brake power, kW
Cv = Calorific value of fuel, kJ/ kg
Cd = Co-efficient of discharge for orifice.
Cexh = Specific heat of exhaust gas, kJ/ kg oC
Cp = Specific heat of water, kJ/ kg oC
D = Diameter of cylinder, m
do = Diameter of orifice, m
g = Acceleration due to gravity, m/s2
H = Head causing flow of air through orifice, m
Hf = Heat supplied, kW
h1, h2 = Manometer reading, cm.
Hccw = Heat carried out by water from calorimeter, kW
4C 4S Diesel Engine with hydraulic brake dynamometer and calorimeter 8
 Hexh = Heat carried out by exhaust gas, kW
Hun = Heat lost in radiation and unaccounted heat, kW
Hecw = Heat carried out by water from engine cooling jacket, kW
L = Length of stroke, m
mcw = Mass of water entering the calorimeter, kg/sec
mexh = Mass of exhaust gas, kg/sec
mew = Mass of water entering the engine cooling jacket, kg/sec
Nc = Number of cylinders
n = Number of cycles
N = Revolutions per minute
Qa = Air consumption, m3/sec
Re = Mean effective radius, m
t = Time taken for x ml, sec
T = Torque, N m
tc = Time for Vc, sec
tE = Time for VE, sec
T1 = Temperature of water inlet for Engine jacket, oC
T2 = Temperature of water outlet from Engine jacket, oC
T3 = Temperature of exhaust inlet for calorimeter, oC
T4 = Temperature of exhaust outlet from calorimeter, oC+
T5 = Temperature of water inlet for calorimeter, oC
T6 = Temperature of water outlet from calorimeter, oC
Ta = Ambient air temperature, oC
Vc = Volume of water flows through calorimeter, ltrs.
Vs = Swept volume, m3/sec
VE = Volume of water flows through the engine cooling jacket, ltrs.
W = Spring balance weight, kg
Wf = Fuel consumption, kg/sec
Wsf = Specific fuel consumption, kg/kW sec
x = Volume of the fuel consumed, ml
f = Density of fuel, kg/m3
BT = Brake thermal efficiency
vol = Volumetric efficiency
a = Density of air ,kg/m3

4C 4S Diesel Engine with hydraulic brake dynamometer and calorimeter 9

 w = Density of water, kg/m3

10. PRECAUTIONS & MAINTENANCE INSTRUCTIONS:

1. Always check the oil level in the engine before starting and make sure that
sufficient oil is present in the engine.
2. Change this oil as engine completes 100 hours of total running. (Volume is about
3.5 Ltrs.)
3. Open cold water supply to the engine before starting.
4. Fuel tank and fuel line should cleaned and free from foreign particles.
5. If diesel tank was empty before filling the diesel, remove air trapped in fuel line
by opening the vent screw provided at the right side, top of the fuel pump.

11. TROUBLESHOOTING:
1. If the engine heats up, check the water supply to the engine jacket.
2. If still engine does not start, check the fuel and fuel supply line. If air found in
pipeline, remove it.

12. REFERENCES

1. M.L.Mathur & R.P. Sharma A Course in Internal Combustion Engine7th ed.,

Dhanpat Rai Publication Asian Books ltd., ND, 2000.

4C 4S Diesel Engine with hydraulic brake dynamometer and calorimeter 10