School of Mechanical & Manufacturing Engineering (SMME)

LAB REPORT 02
IC Engines

STUDENT DETAILS:
NAME : FAISAL AMIN
CLASS : ME-12 (A)
CMS ID : 338606
DATED : 21-FEBRUARY-2024
TABLE OF CONTENTS:

Objective: ............................................................................................................................................................ 2
Introduction: ....................................................................................................................................................... 2
Diesel Engines: ................................................................................................................................................... 2
Conceptual Description: ................................................................................................................................... 3
Feed Pump/Primary Pump: ............................................................................................................................. 3
Fuel Injection Pump: ......................................................................................................................................... 3
Fuel Gallery:........................................................................................................................................................ 3
Governor: ............................................................................................................................................................ 3
Fuel injectors: ..................................................................................................................................................... 3
Return Line: ........................................................................................................................................................ 3
Glow plug:........................................................................................................................................................... 3
Oil filter: .............................................................................................................................................................. 3
Alternator: ........................................................................................................................................................... 3
Description of our case: .................................................................................................................................... 3
Feed Pump: ......................................................................................................................................................... 4
Fuel Injection Pump: ......................................................................................................................................... 4
Labelled Diagram: .............................................................................................................................................. 4
Safety Precautions: ............................................................................................................................................. 2
Discussion: .......................................................................................................................................................... 2
Conclusion: ......................................................................................................................................................... 4
................................................................................................................................................................................
OBJECTIVE:

• Study the different accessories and assemblies fitted on a 6- cylinder compression ignition diesel
engine (EC-100 HINO)
• To examine the structure and mechanism of a diesel engine by visual inspection and analysis.

INTRODUCTION:
Internal combustion refers to the controlled burning of fuel within a sealed chamber, releasing heat energy.
This energy is then harnessed to perform mechanical work. ICEs achieve this through a series of precisely
coordinated steps, converting the chemical energy stored in fuel (like gasoline or diesel) into the movement of
pistons, crankshafts, and ultimately, the wheels that propel vehicles and power various equipment. ICEs come
in various forms, each with its own design and operating characteristics. The two most common types are
petrol engines and diesel engines, differentiated primarily by the fuel they use and the ignition process.
However, there are also other engine designs like rotary engines and gas turbines that find application in
specific situations.

This report delves deeper into the world of ICEs, focusing specifically on petrol engines and diesel engines.
We will explore their underlying principles, compare their operation and characteristics, and discuss their
respective strengths and weaknesses for various applications.

DIESEL ENGINES:
A diesel engine is a type of internal combustion engine that operates on the principle of compression ignition,
named after its inventor, Rudolf Diesel. Unlike gasoline engines, which rely on spark plugs to ignite a fuel-air
mixture, diesel engines compress air to such a high degree that the heat generated ignites the injected fuel.
This fundamental difference in ignition method gives diesel engines their distinct characteristics, making them
popular in a variety of applications ranging from automobiles to heavy-duty machinery and power generation.

CONCEPTUAL DESCRIPTION (DIESEL):

The theoretical overview of a diesel engine cycle involves four main stages: intake, compression, power, and
exhaust. During the intake stroke, the piston moves downward, drawing in air into the cylinder. In the
compression stroke, the piston moves upward, compressing the air to a high temperature and pressure. Fuel
is then injected into the hot, compressed air, leading to spontaneous combustion due to the high temperature,
initiating the power stroke. As the ignited fuel-air mixture expands, it forces the piston downward, generating
mechanical work. Finally, in the exhaust stroke, the piston moves upward again, expelling the combustion by-
products, such as carbon dioxide and water vapor, from the cylinder. This cycle, known as the diesel cycle, is
characterized by its high efficiency and ability to produce significant torque, making diesel engines particularly
suitable for heavy-duty applications.

FEED PUMP/PRIMARY PUMP:

A feed pump is an essential component in diesel engines, responsible for drawing fuel from the tank and
delivering it to the fuel injection system. It ensures a steady supply of fuel at the required pressure, crucial for
the engine's optimal performance.

FUEL INJECTION PUMP:

Fuel injection pumps play a vital role in diesel engines by precisely metering and timing the injection of fuel
into the combustion chambers. They ensure efficient combustion by delivering the right amount of fuel at the
right moment, contributing to both power output and fuel efficiency.

FUEL GALLERY:

The fuel gallery serves as a conduit, distributing fuel from the injection pump to individual injectors. This
network of passages ensures uniform fuel delivery to each cylinder, maintaining engine balance and
performance consistency.

GOVERNOR:

Governors are mechanical or electronic devices that regulate engine speed by controlling the amount of fuel
delivered to the injectors. They help maintain engine operation within predetermined speed limits, providing
stability and preventing over speeding or under speeding.

FUEL INJECTORS:

Fuel injectors are critical components that atomize and deliver fuel into the combustion chambers at high
pressure. They play a crucial role in achieving efficient combustion, contributing to power output, fuel
economy, and emissions control.

RETURN LINE:

The return line completes the fuel circulation loop by transporting excess fuel from the injectors back to the
fuel tank. This ensures consistent fuel pressure and prevents fuel from stagnating in the system.

GLOW PLUG:

Glow plugs are electric heating elements installed in the combustion chamber of diesel engines to aid cold
starting. By preheating the air inside the cylinder, glow plugs facilitate easier ignition of the fuel-air mixture,
especially in cold weather conditions.

OIL FILTER:
Oil filters are integral to diesel engines, removing contaminants from the engine oil to maintain lubrication
quality and protect engine components from wear and damage.

ALTERNATOR:

Alternators are essential components that convert mechanical energy from the engine into electrical energy.
They power the vehicle's electrical system, including lights, ignition, and other accessories, while also charging
the battery to ensure continuous operation.

DESCRIPTION OF OUR DIESEL ENGINE (HINO EC-100):

Manufacturer Hino

Model EC-100

Displacement 5 L (5010 CC)

Power 88 KW / 120 Hp

Application Truck (KL-300), Bus (RL-100), Tractor (HL-300)

Number of Cylinder Inline 6 Cylinder

Engine Type Over Head Valve

Camshaft Located inside engine block

Valves Mechanism 2 Overhead valves per cylinder, using pushrod and rockers

FEED PUMP:

Primary pumps are either manually operated or cam-operated, a manually operated one has a lever for manual
operation. Our case is dual, manual for start of operation.
FUEL INJECTION PUMP:

This occurs after the filter, physically it lies right above the feed pump, this one normally has two types,
piston plunger or centrifugal. Our type is piston plunger Fuel injection pump. This is cam-operated which is
visible as Fuel Injection Pump has a pump nearby.
FUEL GALLERY:

This is an array above which lies below the plunger pumps, it itself is horizontal and has fuel awaiting to be
pumped. The plunger pumps are barrel shaped with plungers inside.
GOVERNOR:

The Governor is located to the right of the fuel gallery, it is connected to the accelerator. The more the
accelerator is pressed, the more the governor will expose fuel in the fuel gallery to plunger. It has a wedge
shape for its mechanism.
FUEL INJECTORS:

Above the concealed barrels lie the fuel injectors, these have springs which open at high pressure and close at
lower pressure to regulate the fuel coming form plungers
RETURN LINE:
This line is located next to the fuel injector, it diverts some fuel to the rest of the vehicle.
GLOW PLUG:

This is a plug which helps heat the chamber for combustion. It is visible from the outside and can be
removed easily and safely. Note that in our case, the rocker arm assembly, fuel injection pump and feeder
were all connected via idler gears. In the inside crank, water pump and fan are connected, the oil pump is
internal.
PETROL ENGINE:
Petrol engines are powered by refined petroleum fuel, are the cornerstone of automotive and mechanical
industries globally. Operating on the principle of internal combustion, these engines efficiently convert fuel's
chemical energy into mechanical power, driving vehicles and machinery with agility and reliability. With their
versatility and continual advancements in efficiency and performance, petrol engines play an integral role in
shaping modern transportation and industry.

CONCEPTUAL DESCRIPTION (PETROL ENGINE):

A petrol engine operates through a four-stroke cycle: intake, compression, power, and exhaust. During intake,
air-fuel mixture enters as the piston descends. Compression follows, raising pressure and temperature.
Ignition by the spark plug initiates the power stroke, driving the piston down. Exhaust then expels burnt
gases as the piston rises. This cycle repeats, converting fuel's chemical energy into mechanical power. Engine
components like the crankshaft, camshaft, valves, and pistons work together for efficient operation.
PUSHRODS:

Pushrods are slender metal rods used in some internal combustion engines to transmit motion between the
camshaft and the valve lifters or rocker arms. They play a crucial role in converting the rotational motion of
the camshaft into vertical motion to actuate the opening and closing of the engine's intake and exhaust valves.
INTAKE AND EXHAUST MANIFOLDS:

The intake manifold directs the air-fuel mixture from the carburetor or fuel injectors to the engine's cylinders,
while the exhaust manifold collects the exhaust gases from the cylinders and directs them towards the exhaust
system. These components are essential for efficient engine operation by ensuring proper air and exhaust
flow.
CARBURETOR:

A carburetor is a device found in older internal combustion engines that blends air and fuel for combustion
within the engine. It regulates the air-fuel mixture's ratio to meet the engine's requirements under different
operating conditions, such as idling, acceleration, and cruising, contributing to optimal engine performance.
VENTURI:

A venture is a tapered section of a carburetor where the airflow velocity increases, creating a low-pressure
zone that draws fuel from the carburetor's fuel bowl. This design principle allows for efficient atomization of
fuel and ensures proper mixing with incoming air before entering the engine's cylinders.
CHOKE:
The choke is a mechanism in carbureted engines used to enrich the air-fuel mixture during cold starts or
when the engine is operating under heavy load. By restricting airflow, the choke increases fuel concentration,
aiding in easier starting and smoother engine operation until it reaches optimal operating temperature.

SPARK IGNITOR:
The spark ignitor, commonly known as the spark plug, is a crucial component in the ignition system of
internal combustion engines. It generates an electrical spark across a gap to ignite the air-fuel mixture in the
engine's cylinders, initiating combustion and powering the engine.
PRIMARY COIL:

The primary coil is part of the ignition system in internal combustion engines and is responsible for receiving
low-voltage electrical pulses from the ignition switch or electronic control module. It then transforms these
pulses into high-voltage currents necessary for generating sparks in the spark plugs.
SECONDARY COIL:

The secondary coil, also known as the ignition coil, receives the high-voltage current from the primary coil
and further increases its voltage before delivering it to the spark plugs. This amplified voltage is essential for
producing strong sparks capable of igniting the air-fuel mixture in the engine's cylinders.
CIRCUIT WITH PRIMARY:

The primary circuit in an ignition system includes components such as the ignition switch, ignition coil, and
distributor. It controls the flow of low-voltage electrical current from the battery to the ignition coil, which
then transforms it into high-voltage current for ignition purposes.
ROTOR:

The rotor is a component found in the distributor of some ignition systems, typically in older vehicles. It
rotates within the distributor cap and distributes high-voltage current from the ignition coil to individual
spark plug wires, directing sparks to the appropriate cylinders in the engine's firing order.
TAPPET COVER:

The tappet cover, also known as the valve cover, is a protective casing located on the top of the engine
cylinder head. It covers and seals the valve train components, such as the pushrods, rocker arms, and valves,
while also containing oil to lubricate these moving parts.

LABELLED DIAGRAM:

DIESEL ENGINE:
1. Injection
2. Intake Manifold
3. Fuel Injection Pump
4. Throttle (accelerator Pedal)
5. Hand pump (Primary)
6. Radiator Inlet (Water outlet)
7. Engine Oil Entrance
8. Fuel (Diesel Filter)
9. Connect to Crank Shaft
10. Radiator Outlet (Cold Water)

1. Radiator Inlet (Water outlet)

2. Exhaust Manifold
3. Oil filter
4. Alternator
1. Fuel transportation thin metal pipes
2. Crankshaft flywheel
3. Fan and Water Pump
4. Alternator
5. Connected to crankshaft
PETROL ENGINE:

1. Carburetor
2. Alternator
3. Rocker arm assembly
4. Valves
5. Fan Connected to Crank Shaft
6. Radiator Outlet (Cool water in)
7. Radiator Inlet (Hot water out)
1. Rocker arm assembly
2. Internal Camshaft
3. Plug Connected to distributor
4. Distributor Cup
5. Oil Filter

1. Carburetor
2. Distributor Cup Cover
3. Alternator
4. Exhaust Manifold
5. Intake Manifold
SAFETY PRECAUTIONS:
● Be careful if the engine is connecting to an electric supply and there is gasoline inside.
● Read the manual before pressing or pulling anything.
● Be careful not to tip the heavy engine over.
● Don’t try running the engine without going through the manual.
● Keep hands clear of moving parts: This includes belts, pulleys, fans, and the flywheel.
● Do not run the engine in an enclosed space.
● Be careful when handling fluids: Engine oil, coolant etc.
● Use the correct tools: Only use tools that are specifically designed for working on engines.

DISCUSSION:
The lab offered a valuable hands-on experience with a non-operational diesel engine. However, limitations
existed. We were unable to observe internal components like pistons and valves, hindering understanding of
their movement and interaction during operation. Additionally, the lack of engine operation prevented us
from experiencing real-world aspects like noise, vibrations, and emissions. These factors can offer valuable
insights into engine performance and potential improvements.

Despite these limitations, the lab effectively complemented our theoretical learning. Examining the non-
operational engine provided a tangible representation of its components and their roles. This facilitated a
deeper understanding of their spatial relationships and how they work together to achieve the desired
outcome:

• Observing a disassembled engine model could further explore internal components.

• Witnessing a demonstration of a functional engine could provide insights into real-world operation.

CONCLUSION:

In conclusion, this lab provided a valuable opportunity to bridge the gap between theoretical knowledge and
practical understanding of diesel engines. Although limited by the non-operational nature of the engine, the
firsthand observation of its external components significantly enhanced our comprehension of its core
principles. This experience reinforces the importance of combining theoretical learning with practical
exploration to gain a well-rounded understanding of complex systems like internal combustion engines.