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3412GeneratorSet4BZ00001UP(SEBP278548)Documentation

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Welcome:apache03
Product:GENERATORSET
Model:3412CGENERATORSET4BZ
Configuration:3412GeneratorSet4BZ00001UP

SystemsOperation
3412GeneratorSetEngines
MediaNumberRENR138806

PublicationDate01/08/2015

DateUpdated26/08/2015
i02493482

FuelSystem
SMCS1250

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Illustration1

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Fuelflowschematic
(1)Fuelinletlinefortheinjectionpumphousing
(2)Damper
(3)Adapterwithorifice
(4)Injectionpumphousing
(5)Fuelreturnline
(6)Injectionvalve
(7)Junctionblock
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(8)Fuelprimingpump
(9)Bypassvalve
(10)Fueltank
(11)Fuelsupplyline
(12)Primaryfuelfilter
(13)Fuelpressuregauge
(14)Mainfuelfilters
(15)Pressurereliefvalve
(16)Fueltransferpump

Theseengineshaveapressuretypefuelsystem.Thereisoneinjectionpumpandonefuelinjectornozzlefor
eachcylinder.Theinjectionpumpsareinthepumphousing(4)onthetopfrontoftheengine.Thefuelinjection
nozzlesarelocatedinthefuelinjectionadapters.Thefuelinjectionadaptersareunderthevalvecovers.
Thefueltransferpump(16)pullsthefuelfromthefueltank(10)throughtheprimaryfuelfilter(12).Thefuel
flowsfromtheprimaryfuelfilter(12)tothefuelprimingpump(8)andthroughthemainfuelfilters(14).The
fuelthenflowstothemanifoldoftheinjectionpumphousing.Thefuelinthemanifoldoftheinjectionpump
housingflowstotheinjectionpumps.Theinjectionpumpsareintimewiththeengine.Theinjectionpumps
pushfuelataveryhighpressuretotheinjectionvalves(6).
Adamper(2)islocatedontheinletelbowofthefuelmanifold(19).Thedamper(2)reducestheshockloads
thatarecausedbytheinjectionpumps.Someofthefuelinthefuelmanifoldisconstantlysentthrougha
restrictionorifice(3).Thisremovesairfromthesystem.Thisrestrictionkeepsthefuelpressurehigh.The
restrictionalsocontrolstheamountoffuelthatgoesbacktothefueltankthroughthereturnline(5).

Illustration2

g01246543

Locationofthefuelsystemcomponents
(1)Thefuelinletlinefortheinjectionpumphousing
(2)Damper
(3)Adapterwithorifice
(5)Fuelreturnline
(11)Fuelsupplyline

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(16)Fueltransferpump
(17)Thefueloutletlinefromthetransferpumpandtheinletlinetothemainfilters
(18)Thenutforafuelinjectionlineattheinjectionpump
(19)Thefuelmanifoldacrosstheinjectionpumphousing
(20)Adapterthroughthevalvecoverbase

Thefuelprimingpump(8)isusedtofillthesystemwithfuel.Thefuelprimingpumpalsoremovesairfromthe
lowpressuresideofthefuelsystem.Thelowpressuresideofthefuelsystemconsistofthefuelfilter,thefuel
linesandcomponents.

Illustration3

g01246544

Thelocationofthefuelsystemcomponents
(1)Thefuelinletlinetotheinjectionpumphousing
(5)Thefuelreturnlinetothetank
(7)Junctionblock
(8)Fuelprimingpump
(11)Fuelsupplyline
(14)Mainfuelfilters
(17)Thefueloutletlinefromthetransferpumpandtheinletlinetothemainfilters

Thefueltransferpumphasabypassvalveandacheckvalve.Thebypassvalvecontrolsthemaximumpressure
ofthefuel.Theextrafuelgoestotheinletofthepump.Thecheckvalveallowsthefuelfromthetanktogo
aroundthetransferpumpgearswhentheprimingpumpisused.

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Illustration4

g01246545

Thelocationofthefuelsystemcomponents
(1)Thefuelinletlinefortheinjectionpumphousing
(5)Thefuelreturnline
(7)Junctionblock
(8)Fuelprimingpump
(11)Fuelsupplyline
(14)Mainfuelfilter
(17)Thefueloutletlinefromthetransferpumpandtheinletlinetothemainfilter

FuelInjectionPump

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Illustration5

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Thecrosssectionofthefuelinjectionpumphousing
(1)Fuelmanifold
(2)Inletpassage
(3)Checkvalve
(4)Pressurereliefpassage
(5)Pumpplunger
(6)Spring
(7)Gear
(8)Fuelrack(left)
(9)Lifter
(10)Link
(11)Lever
(12)Camshaft

Therotationofthecamsonthecamshaft(12)causethelifters(9)andthepumpplungers(5)tomoveupand
down.Thestrokeofeachpumpplungerisalwaysthesamestroke.Theforceofthesprings(6)holdthelifters
(9)againstthecamsofthecamshaft.
ThepumphousingisinashapeofaV.Theshapeissimilartotheenginecylinderblock.Thereisthesame
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numberofpumpsoneachside.
Whenthepumpplungermovesdown,thefuelfromthefuelmanifold(1)flowsthroughtheinletpassage(2).
Thefuelthenfillsthechamberthatisabovethepumpplunger(5).Whentheplungermovesup,theplunger
closestheinletpassage.
Thepressureofthefuelinthechamberabovetheplungerincreasesuntilthepressureishighenoughtocause
thecheckvalve(3)toopen.Thehighpressurefuelflowsthroughthecheckvalvetotheinjectionvalveand
throughthefuellineuntiltheinletpassageopensintothepressurereliefpassage(4)intheplunger.Thepressure
inthechamberdecreasesandcheckvalve(3)closes.
Theamountoffuelforcedthroughthecheckvalve(3)isdeterminedbytheamountoftimethattheinletpassage
(2)isclosed.Thepressurereliefpassage(4)willcontroltheamountoftimetheinletpassageisclosed.The
amountoftimetheinletpassageisclosedcanbechangedbecauseofthedesignofthepassage.Thiscanbe
changedbyrotatingtheplunger.Whenthegovernormovesthefuelracks(8),thefuelracksmovethegears(7)
thatarefastenedtotheplungers(5).Thiscausesarotationoftheplungers.
Thegovernorisconnectedtotheleftrack.Thespringload,locatedonthelever(11),removestheplaybetween
theracksandthelink(10).Thefuelracksareconnectedbythelink(10).Thefuelracksmoveinopposite
directions.Whenonerackmovesin,theotherrackmovesout.

FuelInjectionValvesandNozzles
Theinjectionvalvesarelocatedwithinthefuelinjectionadapters.Thefuelinjectionadaptersareinstalledinthe
cylinderhead.
Thefuelinjectionpumpsendsfuelwithhighpressuretothefuelinjectionvalves.Thefuelinjectionvalves
changethefueltothecorrectspraypatternforgoodcombustioninthecylinders.Thefuelinjectionvalveswill
notopenuntilaveryhighpressureisreached.Oncethispressureisreached,thefuelinjectionvalvesopen
quickly.Thefuelisreleaseddirectlyintotheenginecylinderthroughsixorificesinthetipofeachnozzle.

HydramechanicalGovernorwithDashpot
Thegovernorcontrolstheamountoffuelthatisneededbytheenginetomaintainadesiredrpm.Thegovernor
maintainsaconstantrpmforvariableengineloads.
Whentheengineisoperating,thebalancebetweenthecentrifugalforceofthegovernorflyweightsandtheforce
ofthegovernorcontrolonthegovernorspring,controlsthemovementofavalveandindirectly,controlsthe
movementofthefuelrack.Thevalvedirectspressureoiltoeithersideofarackpositioningpiston.Theposition
ofthevalvecontrolstherack.Theamountoffueltotheengineiscontrolledbytherackandloadconditions.

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Illustration6

3412GeneratorSet4BZ00001UP(SEBP278548)Documentation

g01246548

Hydramechanicalgovernorwithdashpot
(1)Collar
(2)Collarbolt
(3)Dashpotchamber
(4)Dashpotpiston
(5)Leverassembly
(6)Dashpotspring
(7)Governorspring
(8)Governorflyweights
(9)Valve
(10)Cylinder
(11)Driveassembly
(12)Pin
(13)Lever

Thegovernorhasgovernorflyweights(8)thataredrivenbytheenginethroughthedriveassembly(11).The
governorhasagovernorspring(7),avalve(9)andapiston.Thevalveandthepistonareconnectedtoonefuel
rackthroughpin(12)andlever(13).
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Thegovernorcontrolisconnectedtothegovernorcontrollever.Thegovernorcontrolcontrolsthecompression
ofthegovernorspring(7).Thecompressionofthespringgivesmorefueltotheengine.Thecentrifugalforceof
thegovernorflyweights(8)alwayspullsup.Thisreducestheamountoffueltotheengine.Whenthesetwo
forcesareinbalance,theenginerunsataconstantrpm.
Thegovernoroilpumpisontopofthefuelinjectionpumphousing.Thegovernoroilpumpsendsengineoil
underpressuretothegovernorcylinder(10)throughpassage(18)aroundsleeve(19).

Illustration7

g01246550

Governorinincreasedloadposition
(7)Governorspring
(8)Governorflyweights
(9)Valve
(10)Cylinder
(12)Pin
(14)Theoildrainpassageforthepiston
(15)Theupperoilpassageinthepiston
(16)Piston
(17)Theloweroilpassageinthepiston
(18)Theoilpassageinthecylinder

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(19)Sleeve

Whentheloadontheengineincreases,theenginerpmdecreases.Thiswillcauseaslowerrotationofthe
governorflyweights(8).Thegovernorflyweightswillmovetowardeachother.Thegovernorspring(7)moves
valve(9).Thiswillopentheoilpassagesinpiston(16).Thiswillalsoclosetheoildrainpassage(14).Thiswill
allowtheoiltoflowfrompassage(17),aroundvalve(9),andthroughpassage(15).Thiswillfillthechamber
abovepiston(16).Thepressureoilpushesdownonpiston(16)andpin(12).Thisgivesmorefueltotheengine.
Enginerpmincreasesuntiltherotationofthegovernorflyweightsisfastenoughtobeinbalancewiththeforce
ofthegovernorspring.

Illustration8

g01246553

Governorindecreasedloadposition
(7)Governorspring
(8)Governorflyweights
(9)Valve
(10)Cylinder
(12)Pin
(14)Theoildrainpassageforthepiston
(15)Theupperoilpassageinthepiston
(16)Piston
(17)Theloweroilpassageinthepiston
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(18)Theoilpassageinthecylinder
(19)Sleeve

Whenthereisareductioninloadontheengine,therewillbeanincreaseinenginerpmandtherotationofthe
governorflyweights(8)willincrease.Thiswillmovevalve(9)toahigherposition.Thisstopstheoilflowfrom
passage(17)andtheoilpressureabovepiston(16)goesoutaroundvalve(9)throughthetopofthepiston(16).
Thepressurebetweensleeve(19)andpiston(16)pushesthepistonandpin(12)toahigherposition.Thiscauses
areductionintheamountoffueltotheengine.Theenginerpmdecreasesuntilthecentrifugalforceofthe
governorflyweightsisinbalancewiththeforceofthegovernorspring.Whenthesetwoforcesareinbalance,
theenginewillrunataconstantrpm.
WhentheenginerpmisatLOWIDLE,aspringloadedplungerintheleverassembly(5)isincontactwitha
shoulderontheadjustmentscrewforlowidle.Tostoptheengine,movetheswitchtothe"OFF"position.This
willcausetheshutoffsolenoidtomovethespringloadedplungerovertheshoulderonthelowidleadjustment
screw.Thiswillmovethefuelrackstothefuelshutoffposition.Withnofueltotheenginecylinders,theengine
willstop.Tostoptheenginemanually,turntheshutoffleveronthegovernorhousingtotheshutoffposition.
Theoilfromthegovernorpumplubricatesthefollowingcomponents:
Thegovernorweightsupportandgear
Thethrustbearingunderthegovernorspring
Thedrivegearbearing
Theotherpartsofthegovernorreceivelubricationfromsplashlubrication.Splashlubricationisoilthatis
thrownbyotherparts.Theoilflowsfromthegovernortothehousingforthefuelinjectionpumps.
Electricsetenginesneedagovernorthathasbettercontrolovertheenginespeedrange.Astandard
hydramechanicalgovernorcannotprovidethisfunction.Thefollowingpartsareaddedtothebasic
hydramechanicalgovernor.
Apiston(4)
Aspring(6)
Abolt(2)
Anoilreservoirintheshutoffhousing
Twoadjustmentscrews(20)and(21)
Thesepartscontroltheflowofoilintothedashpotchamber(3)andoutofthedashpotchamber(3).Thedashpot
chamber(3)isabovethedashpotpiston(4).Theoilflowsthroughinternaloilpassages.Thecorrectoilflowinto
thedashpotchamber(3)andoutofthedashpotchamber(3)causesamoreprecisemovementofthegovernor
springseat.Thisallowsthegovernortoaccuratelycontroltheenginespeed.

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Illustration9

3412GeneratorSet4BZ00001UP(SEBP278548)Documentation

g01246555

Sideviewofgovernor
(20)Theadjustmentscrewforthedashpot
(21)Adjustmentscrewforsupplyoiltothereservoir

Theoilfortheactionofthedashpotcomesfromtheenginelubricationsystem.Theadjustmentscrew(21)
controlstheoilflowfromthelubricationsystemintothereservoir.Thereservoirhasanoiloverflowthatsends
theoilbacktothemechanicalareaofthegovernor.Toomuchoilflowtothereservoirwillfillthegovernorwith
oil.Thiswilldecreasetheengineperformance.Toolittleoilflowdoesnotgiveenoughoiltothereservoir.The
decreaseinoilwillcausethegovernortohunt.Thiswillresultintheconstantincreaseinenginespeedandthe
decreaseinenginespeed.Airgetsintothedashpotchamber(3).Thisaircausesthedashpotpiston(4)andthe
lowergovernorspringseattomovefaster.
Thedashpotadjustmentscrew(20)causesarestrictiontotheoilflowintothedashpotchamber(3)andoutof
thedashpotchamber(3).Toomuchoilflowwillallowthelowergovernorspringseattomovefaster.Thiswill
allowthegovernortohunt.Toolittleoilflowcausesasloweractionbythegovernor.

AutomaticTimingAdvanceUnit

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Illustration10

g01246556

Automatictimingadvanceunit
(1)Flange
(2)Weight
(3)Springs
(4)Slide
(5)Drivegear
(6)Camshaft

Theautomatictimingadvanceunitisinstalledonthefrontofthecamshaft(6)forthefuelinjectionpump.The
timinggearsdrivetheautomatictimingadvanceunit.Thedrivegear(5)forthefuelinjectionpumpisconnected
tothecamshaft(6)bythefollowingcomponents:
Twoweights(2)
Springs(3)
Twoslides(4)
Flange(1)
Eachoneoftheslides(4)isheldonthedrivegear(5)byapin.Theweights(2)inthetimingadvancearedriven
bytwoslides(4).Theseslides(4)fitintonotchesthataremadeonanangleintheweights(2).Whenthe
centrifugalforce(rotation)movestheweights(2)outwardagainstthesprings(3),theguidesintheflangeand
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theslidesonthegearmaketheflangeturninrelationtothegear.Sincetheflangeisconnectedtothecamshaft
forthefuelinjectionpump,thefuelinjectiontimingisalsochanged.
Theunitadvancesthefuelinjectionpumpcamshaft2%betweenapproximatelylowidleand1100rpm.No
adjustmentcanbemadeinthetimingadvanceunit.
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