Module 03 major comp enc

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Module 2 7FDL DIESEL ENGINE COMPONENTS INTRODUCTION: Being able to identify the major components and knowing some of the important characteristics about them are essential building blocks for good locomotive maintenance. This module will familiarize students with the major components that make up the 7FDL Diesel Engine.

MODULE SECTIONS: Module sections are as follows: Section 1: Engine Main Frame Section 2: Engine Crankshaft Section 3: Vibration Damper Section 4: Rubber-Bonded Drive Coupling Section 5: Split Gear Section 6: Engine Bearings Section 7: Connecting Rod Arrangement Section 8: Steel Crown Piston Section 9: Engine Camshaft Section 10:Turbocharger Section 11:Exhaust Manifolds Section 12:Unitized Cylinder Section 13:Fuel System Section 14:Summary

OBJECTIVES: By the end of this module you should understand: • •

7FDL Major Components

How to identify the major components of the 7FDL Diesel Engine The importance of proper maintenance and handling of the major components

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Section 1: ENGINE MAIN FRAME INTRODUCTION: See Figure 1. The Main Frame is a ”block” or a base for all the other components to be assembled to. Some of the important characteristics of the main frame are listed below: One piece cast iron construction Oil passages cast in frame to reduce the potential of leaks No cooling water, intake air or exhaust touches frame Serial No. # located on the front right foot 16 Crankcase Inspection openings on a 16 cylinder 7FDL 12 Crankcase Inspection openings on a 12 cylinder 7FDL Main Bearing Caps are serialized to a specific location on the main frame

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Section 2: ENGINE CRANKSHAFT INTRODUCTION: See Figure 2. The crankshaft converts the reciprocating motion of the pistons and rods to radial motion to drive the alternator. Some of the important characteristics of the crankshaft are listed below: 8" diameter main journals 7-7/16" diameter crank pins Nitride hardened journal surfaces Large radius fillets Welded counterweights Diagonally drilled oil passageways provide lubrication from the main bearing journals to the crank pins Nine Main Bearing journals for a 16-cylinder 7FDL Seven Main Bearing journals for a 12-cylinder 7FDL

Figure 2. Engine Crankshaft

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Section 3 VIBRATION DAMPER INTRODUCTION: See Figure 3. Located on the free end of the crankshaft, the vibration damper reduces the shock of each combustion stroke. Without the damper the crankshaft would break. The vibration damper is made up of a flywheel inside the steel shell. The flywheel is surrounded by a thick silicon lubrication that permits it to move independently of the crankshaft.

Figure 3. Vibration Damper

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Section 4 RUBBER-BONDED DRIVE COUPLING INTRODUCTION: See Figure 4. The rubber-bonded coupling located on the free end of the crankshaft provides the interface between the crankshaft and the auxiliary drive gear. In the event that the gear driven oil or water pump would seize the rubber bonded drive is designed to sheer providing crankshaft protection. Some additional information concerning the coupling is listed below: The rubber-bonded drive is bolted to the hot hub, which is a shrink fit to the crankshaft. The auxiliary drive gear is bolted to the outside ring of the rubber-bonded drive. The auxiliary drive gear drives an idler gear, which drives the water and lubricating oil pumps.

Figure 4. Rubber-Bonded Drive Coupling

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Section 5 SPLIT GEAR INTRODUCTION: See Figure 5. The split gear located on the alternator end of the crankshaft drives the camshafts. It is assembled onto the crankshaft in two pieces. The two piece design allows the spit gear to be changed without removing the crankshaft. Some additional features of the split gear are listed below: The split gear is keyed to the crankshaft for proper alignment Timing marks on the split gear line up with timing marks the cam gears

RIGHT CAM GEAR

LEFT CAM GEAR

SPLIT GEAR

Figure 5 Split Gear

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Section 6 ENGINE BEARINGS INTRODUCTION: See Figure 6. The crankshaft main and rod journals are surrounded by precision-made trimetal bearings. See Figure 5. These bearings provide a base that help control the oil film which the crankshaft rides on. Additional features of the bearings include: Grooveless design in lower half crankshaft (loaded bearing) Grooveless design in upper half master rod (loaded bearing) Large surface area, increased load capacity Decreased load per unit area (longer life) Steel shell Copper/lead matrix Nickel barrier Lead/tin overlay

Figure 6. Lower Half of Crankshaft Bearing (Grooveless Design)

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Section 7 CONNECTING ROD ARRANGEMENT INTRODUCTION: See Figure 7. Each pair of cylinders has a master rod and an articulating rod,the master rod is on left and the art rod is on the right side of the engine.

Figure 7. Connecting Rod Arrangement

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SERIAL NUMBERS: See Figure 8. The Serial Number of the Master Rod can be viewed from the right side of the engine through the crankcase inspection door covers. The Main Bearing Cap is serialized to the master rod. Both serial numbers must be visible from the right side of the engine for proper cap installation.

Serial Number

Serial Number

Figure 8. Master Rod Cap Serial Number Must Match Rod Serial Number

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Section 8: STEEL CROWN PISTON INTRODUCTION: See Figure 9. The piston is a 2-piece assembly. The top or crown is contoured to form the combustion chamber. The bottom or skirt has drilled passages for lubrication and cooling. Features of the piston crown include: Forged steel crown High strength and heat resistance in the crown area Excellent cooling through forced high velocity scrubbing of lube oil on inner surfaces Reduced wear in the ring area Cut back design reduces lube oil consumption Cast aluminum skirt Light weight Replaceable bushing Assembled with four high-strength bolts Rings are: Ductile iron or Chrome plated for wear resistance

Figure 9. Steel Crown Piston

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Section 9 ENGINE CAMSHAFT INTRODUCTION: See Figure 10 The camshafts open and close the intake and exhaust valves and operates the high-pressure fuel pump by precision ground lobes or eccentrics. Features of the camshafts include: Fully sectionalized One section per cylinder Each section identical within bank Easy change out through crankcase inspection door. EFI equipped engines have bearing journals independent of the crankshaft Exhaust cam lobe located on right hand side when facing the engine Center cam lobe operates the high pressure fuel pump Left cam lobe when facing the engine operates the intake valves

Figure 10. Engine Camshaft

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Section 10 TURBOCHARGER INTRODUCTION: See Figure 11. Provides oxygen rich compressed air for combustion. The turbocharger is operated by exhaust gasses and increases the efficiency of the engine. Features of the turbocharger include: Exhaust driven over entire speed range. No gear train Lower fuel consumption Matched to engine Water flows from FEC through bottom of turbocharger feet and on to turbocharger water discharge pipe on top of turbocharger.

Figure 11. Turbocharger

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7FDL Major Components

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Section 11 EXHAUST MANIFOLDS INTRODUCTION: See Figure 12. The exhaust manifold channels the combustion gasses to drive the turbocharger. Feature of the exhaust manifolds include: Dual pipe new design used on all 16-cylinder and high horse power 12-cylinder engines. Single pipe design used on older 16-cylinder and high horsepower 12-cylinder engines Superior efficiency at higher power levels Fully sectionalized, minimizes stocking requirements

Figure 12. Exhaust Manifolds

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Section 12 UNITIZED CYLINDER INTRODUCTION: See Figure 13. The components that make up the chamber in which the piston moves are as follows: •

Two major components: Jacket EB Liner

Figure 13. Power Assembly

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CYLINDER JACKET See Figure 14. The features of the cylinder jacket include: Cast iron design Houses all other cylinder components

Figure 14. Cylinder Jacket

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EB CYLINDER LINER See Figure 15. The features of the cylinder liner include: A one-piece steel heavy walled tubing liner is welded to the cylinder head making the EB head and liner. EB stands for the “electron beam” welding process that is used to weld these two components together

Figure 15. EB Cylinder Liner

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CYLINDER HEAD See Figure 16. The features of the cylinder head include: All steel for greater thermal conductivity higher strength The valve seats are welded stainless steel Efficient cooling through water passageways in the cylinder head Two Exhaust and two intake valves in each cylinder head Inconel 751 exhaust valves Silchrome intake valves - Shot peened and chrome plated Rotators on all valves for uniform seating and even wear

Figure 16. Cylinder Head

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Section 13 FUEL SYSTEM INTRODUCTION: The fuel system components deliver clean pressurized diesel fuel to the combustion chamber. Features of this system include: Parallel low pressure system Separate pump and nozzle on each cylinder Low cost changeout Change only part required

Figure 17. Fuel System

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Section 14 SUMMARY The following summarize the major components of the 7FDL diesel engine:

• • • • • • • • • •

7FDL Major Components

Cast main frame - Rugged, long life Crankshaft - Robust design for maximum service life Main bearings - Long life, high load capacity. Sectionalized camshaft - Efficient, convenient Unitized cylinder - Reliable and maintainable Steel crown piston - Excellent strength, long life Connecting rods and bearings - Low unit loading, reduced wear rate Exhaust manifold - Reliable, sectionalized design Turbocharger - Simple, dependable efficient A technically superior product, more efficient, more reliable, and easy to maintain.

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1. The number one left cylinder is on the right side of the locomotive:

a. True b. False 2. On a 7FDL16 engine:

a. b. c. d.

There are eight master connecting rods There are eight articulating connecting rods The articulating (“art” for short) rod is bolted to a pin fitted in the master connecting rod All of the above

3. The water pump and lube oil pump are mounted on the:

a. b. c. d.

Engine room floor Free end cover Generator end of the engine None of the above

4. Camshaft sections:

a. b. c. d.

From the same side of the engine are identical From the Right Bank are identical to those from the left bank Can be rotated to any position and then bolted together All of the above

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5. Upper and lower connecting rod bearings are:

a. Different b. Identical 6. A master rod can be matched to:

a. Any master rod cap b. Only one master rod cap 7. The lower main bearings:

a. b. c. d.

Are “grooveless” Identical to upper main bearings Have a hole in the center All of the above

8. GE turbochargers are driven:

a. By exhaust gases b. Through a clutch from the engines gear train c. Both (a) and (b) depending on the flow of exhaust gases

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