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MANTENIMIENTO DE EQUIPO PESADO

INGLES TÉCNICO

Saber, Saber hacer, Saber ser


Evaluación de Competencias
INGLES TÉCNICO
(Mantenimiento de Equipo Pesado)

Nombre del estudiante: _____________________________________________________________

El presente documento es una lista de conocimientos, habilidades y destrezas que representa el


estándar de las competencias que debe adquirir un trabajador.
Los niveles de competencia se clasifican de acuerdo al porcentaje de las competencias alcanzadas
(según CETEMIN).

CRITERIOS DE CALIFICACIÓN:

excelente muy bueno/sobresaliente bueno malo deficiente

90 - 100% 80 - 89% 70 - 79% 50 - 69% 0 - 49%

NOTA:
A. Si es necesario, el evaluador puede hacer preguntas durante la evaluación para aclarar cualquier
detalle en relación a los criterios de competencia.
B. El evaluador debe explicar la metodología antes del examen, y recordarles que las acciones
o explicaciones deben ser precisas.

Puntaje Final Total

VALORES Y ACTITUDES:
Responsabilidad, Respeto, Perseverancia y Proactividad. Saber, Saber hacer, Saber ser
MEP - Evaluación por competencia

1. Interpreta manuales técnicos de equipo pesado en ingles.


muy bueno/
excelente sobresaliente bueno malo deficiente

»» Realizar lectura e interpretar textos de inglés técnico referente


a partes de motores diesel
»» Realizar lectura e interpretar textos de inglés técnico referente
a sistemas de motores diesel.
»» Realizar lectura e interpretar textos de inglés técnico referente
a sistemas hidráulicos.
»» Realizar lectura e interpretar textos de inglés técnico referente
a circuitos hidráulicos.
»» Realizar lectura e interpretar textos de sistemas de equipo pe-
sado en inglés.

Puntaje
Observaciones: .....................................................................................................................................
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Ingles Técnico

TABLA DE CONTENIDOS

GENERALIDADES DEL CURSO........................................................................................................ 5

OBJETIVO………............................................................................................................................. 5

1. TECNICA DE LECTURA................................................................................................................... 7

2. DIESEL ENGINE............................................................................................................................ 10

3. HYDRAULIC SYSTEM.................................................................................................................... 31

4. ELECTRIC SYSTEM....................................................................................................................... 49

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Ingles Técnico

Generalidades del Curso:

El curso presenta al estudiante ingles técnico básico necesario, para que pueda interpretar en forma correcta
los nombres técnicos de los componentes de un equipo pesado, para que de esta manera pueda dar
mantenimiento, diagnosticar y reparar correctamente estos usando la información técnica respectiva que se
encuentra en ingles.

Principalmente hablaremos de los Sistemas del motor diesel, los sistemas hidráulicos y sistemas eléctricos de
un equipo pesado.

Objetivos del curso:

Al terminar el curso, el estudiante obtendrá conocimiento práctico de ingles técnico referente a los Sistemas
de Motores Diesel, Sistemas Hidráulicos y Sistemas Eléctricos de equipo pesado. Usando los manuales de
servicio, manuales de números de partes, manuales de operación y mantenimiento, el manual de rendimiento
y otras publicaciones de referencia, el estudiante estará en capacidad de traducir toda la nomenclatura de los
componentes y ubicar cada estos dentro de los sistemas mencionados del equipo pesado.

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1
CAPÍTULO

TÉCNICA DE LECTURA

1.1 ESTRATÉGIAS LECTORAS

La enseñanza del inglés en las carreras técnicas, se basa en la enseñanza de estrategias lectoras.
Anteriormente, lo que se consideraba más importante a la hora de aprender inglés era la gramática. Se
abrumaba al alumno con reglas y estructuras, totalmente opuestas, en este caso a nuestro idioma nativo.
Reglas y conceptos que sólo logran aburrir y confundir.

Sin embargo, no es necesario un manejo perfecto de la gramática para comprender un texto, sino más bien
poder manejar un conocimiento general de las formas idiomáticas, conexiones y similitudes con nuestra
lengua de modo de poder aplicar ese conocimiento al texto de se desea o se necesita leer.

Es necesario comprender y familiarizarse con las “trampas”, los giros y los secretos del idioma, y
fundamentalmente ser conocedor de la materia en la cual aplicaremos ese conocimiento.

1.1.1 FORMA IDIOMÁTICA Y CONECTORES

En un primer paso para la lectura (el dónde comenzar a leer, hasta dónde llegar, y cómo retomarla) se facilita
con el conocimiento de los conectores.

En este grupo se incluyen artículos, preposiciones, conjunciones, pronombres, y verbos, por nombrar algunos, y
los acompañamos con la numeración de las palabras ubicadas entre ellos, y entre las cuales no haya conectores,
siempre de derecha a izquierda, lo que indica cuál debe ser leída primero.

Por ejemplo:

2 1 3 2 1 3 2 1
The hydraulic tank is common to both the pilot hydraulic system and the main hydraulic system.
El tanque hidráulico es común para (ambos) el sistema hidráulico piloto y el sistema hidráulico principal

Este mecanismo nos da cierto orden y control sobre el texto, ayudándonos a determinar dónde comenzar,
cómo enlazar las palabras y dónde terminar a leer. Se toman también como puntos de referencia los puntos
y las comas, pero que como es sabido casi no aparecen en los textos en inglés.

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Manual del Estudiante

1.1.2 SIMILITUDES

Es también útil aprovechar las similitudes entre palabras en inglés y en castellano (muchísimas palabras
tienen la misma raíz y puede reconocerse fácilmente su significado sin recurrir al diccionario).

Ejemplo:
Various, example, dimensions, proportions, problems, symbols, case, statics, products, discrete, form,
elements, forces, process, etc.

También cómo un vocablo en inglés puede funcionar como verbo o como sustantivo, y en conocer ciertas
terminaciones que nos ayudan a conocer la función dada de una palabra.

1. Palabras terminadas en TION (cion): Son verbos a los que cuando se les agrega la terminación TION se
transforman en sustantivos y deben ser leídos como tal.

Verbo Sustantivo
Produce (producir) Production (producción)
Distribute (distribuir) Distribution (distribución)
Simulate (simular) Simulation (simulación)

2. Palabras terminadas en MENT: El mismo caso que el anterior pero con terminación MEN

Verbo Sustantivo
Displace (desplazar) Displacement (desplazamiento
Develop (desarrollar) Development (desarrollo)
Replace (reemplazar) Replacement (reemplazo)

3. Palabras terminadas en ING: También igual a los casos anteriores, con el agregado de que se indica al
estudiante cómo reconocer si la palabra en cuestión está funcionando como sustantivo o en un
determinado tiempo verbal (que podría llevarlo a confusión) denominadores comunes que por supuesto
se presentan a la hora de la lectura.

Verbo Sustantivo
Shear (cortar) Shearing (corte)
Build (construir) Building (edificio)
Bend (doblar) Bending (doblez)

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Ingles Técnico

INGLES ESPAÑOL INGLES ESPAÑOL INGLES ESPAÑOL


A, AN UN, UNA HOLD SOSTENER THE EL , LA
ABOUT A CERCA HOLE AGUJERO THEN ENTONCES
ABOVE ARRIBA HOT CALOR THERE ARE HAY
ACHIEVE ALCANCE IF SI THERE IS HAY

AFTER DESPUES IN EN THESE ESTAS, ESTOS

AGAIN NUEVAMENTE IN ORDER PARA THIS ESTA, ESTO

AIDS AYUDAS INCREASE INCREM ENTO THROUGH A TRAVEZ

ALL TODO INLET INGRESO TO A, PARA

ALLOW PERM ITIR INTO DENTRO TO CALL LLAMAR

ALSO ASI , TAMBIEN IS, ARE IS ESTA, SON , ESTAN TO FILL LLENAR

AMOUNT CANTIDAD, MONTO LEFT IZQUIERDO TO GET COJER

AND Y LOW BAJO TO GIVE DAR

AROUND ENTORNO MAIN PRINCIPAL TO KEEP MANTENER

AS COMO MANY MUCHOS TO MOVE MOVER

AT A , EN MORE MAS TO REDUCE REDUCIR

BACK ATRÁS MOST LA MAYORIA TO REMAIN PERMANECER

BEFORE ANTES MUST DEBE TO SEND ENVIAR

BELOW DEBAJO NEW NUEVO TOO TAMBIEN

BETWEEN ENTRE NEXT PROXIMO TOP LO ALTO

BOTTOM FONDO NOT NO USE USAR

BOTH AMBOS NOW AHORA VERY MUY

BOTH AMBOS OF DE What...? Qué...?

BY POR ON SOBRE Where...? Dónde...?

CAN PUEDE OPEN ABIERTO When...? Cuándo...?

CLOSE CERRADO OR O Who...? Quién...?

COLD FRIO OUT FUERA Whose...? De quién...?

COOLING ENFRIAMIENTO OUTLET SALIDA How...? Cómo...?

DAMAGE DAÑO OUTPUT RENDIMIENTO Why...? Por qué...?

DO HACER PLACE LUGAR Which...? Cuál...?

DRIVES CONDUCE PLAY JUEGO WHILE MIENTRAS

EACH CADA UNO PORTS CONECCIONES WILL BE SERA


EITHER UNO U OTRO PROVIDE SUSMINISTRAR WITH CON
END FI NAL READ LEER WITHIN DENTRO DE
ENOUGH SUFICIENTE REAR POSTERIOR WITHOUT SIN
EVENT EVENTO, CASO RELEASE LIBERAR WRITE ESCRIBIR
EXHAUST DESCARGA REMOVE REMOVER
FAILURE, FAILS FALLA RIGTH DERECHO
FASTENER SUJETADOR SAME MISMO, IGUAL
FIRST PRIMERO SET CONJU NTO
FOLLOW SIGUIENTE SHOULD DEBERIA
FROM DESDE SIDE LADO
FRONT FRENTE SMALL PEQUEÑO
GREAT GRANDE SO ASI
HAS, HAVE TIENE, TIENEN START ARRANQUE
HEAD CABEZA THAN QUE
HIGH ALTO THAT QUE

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2
CAPÍTULO

DIESEL ENGINE

2.1 ENGINE DESIGN

The front of the engine is opposite of the flywheel end of the engine. The left side and the right side of the
engine are viewed from the flywheel end of the engine. The No. 1 cylinder is the front cylinder.

(A) Exhaust valves


(B) Inlet valves
Bore ... 112 mm (4.41 inch)
Stroke ... 149 mm (5.87 inch)
Displacement ... 8.8 L (537 cu in)
Cylinder arrangement ... In-line six cylinder
Valves per cylinder ... 4
Valve lash with engine stopped (cold):
Inlet ... 0.38 ± 0.08 mm (0.015 ± 0.003 inch)
Exhaust ... 0.64 ± 0.08 mm (0.025 ± 0.003 inch)
Type of combustion ... Direct Injection
Firing Order ... 1, 5, 3, 6, 2, 4

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The crankshaft rotation is viewed from the flywheel end of the engine. Crankshaft rotation ... countercloc-
kwise

The engine’s ECM will automatically provide the correct amount of fuel in order to start the engine. Do not
hold the throttle open while the engine is cranking. If the engine fails to start in twenty seconds, release the
starting switch. Allow the starting motor to cool for two
minutes before using the starting motor again.

Starting the engine and operation in cold weather is dependent on the type of fuel that is used, the oil visco-
sity, and other optional starting aids.

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2.2 ENGINE PARTS

2.2.1 Cylinder Block

The cylinder block has seven main bearings. The main bearing caps are fastened to the cylinder block with
two bolts per each cap.
Removal of the oil pan allows access to the following components:

1. Crankshaft
2. Main bearing caps
3. Piston cooling jets
4. Oil pump
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2.2.2 Cylinder Head

The cylinder head is separated from the cylinder block by a nonasbestos fiber gasket with a steel backing.
Coolant flows out of the cylinder block through gasket openings and into the cylinder head. This gasket also
seals the oil supply and drain passages between the cylinder block and the cylinder head. The air inlet ports
are on the left side of the cylinder head, while the exhaust ports are located on the right side of the cylinder
head. There are two inlet valves and two exhaust valves for each cylinder. Each set of inlet valves and each
set of exhaust valves is actuated at the same time by the use of a valve bridge. The valve bridge is actuated
by the pushrod.

Replaceable valve guides are pressed into the cylinder head. The hydraulically actuated electronically
controlled unit injector is located between the four valves. Fuel is injected directly into the cylinders at very
high pressure. A pushrod valve system controls the valves.

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Manual del Estudiante

2.2.3 Piston, Rings and Connecting Rods

(1) Piston
(2) Piston cooling jet
(3) Connecting rod
(4) Compression ring
(5) Intermediate ring
(6) Oil ring
(7) Forged steel crown
(8) Aluminum skirt

High output engines with high cylinder pressures require two-piece articulated pistons. The two pieces
articulated piston consists of a forged steel crown that is connected to an aluminum skirt by the piston pin.

All of the rings are located above the piston pin bore. The compression ring is a Keystone ring. Keystone rings
have a tapered shape. The action of the ring in the piston groove that is tapered helps prevent seizure of the
rings. Seizure of the rings is caused by deposits of carbon. The intermediate ring is rectangular with a sharp
lower edge. The oil ring is a standard type of ring or a conventional type of ring. Oil returns to the crankcase
through holes in the oil ring groove.
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Oil from the piston cooling jets sprays the underside of the pistons. The spray lubricates the pistons and the
spray cools the pistons. The spray also improves the piston’s life and the spray also improves the ring’s life.

The connecting rod has a taper on the pin bore end. Two bolts hold the connecting rod cap to the connecting
rod. The connecting rod can be removed through the cylinder.

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2.2.4 Crankshaft

(1) Crankshaft
(2) Gear

The crankshaft converts the linear motion of the pistons into rotational motion. A vibration damper is used
at the front of the crankshaft to reduce torsional vibrations (twist on the crankshaft) that can cause damage
to the engine.

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Manual del Estudiante

The crankshaft drives a group of gears on the front of the engine. The gear group drives the following devices:
• Oil pump
• Camshaft
• Hydraulic oil pump
• Air compressor
• Steering pump

In addition, belt pulleys on the front of the crankshaft drive the following components:
• Radiator fan
• Water pump
• Alternator
• Refrigerant compressor

(1) Oil gallery


(2) Main bearings
(3) Rod bearings

Hydrodynamic seals are used at both ends of the crankshaft to control oil leakage. The hydrodynamic grooves
in the seal lip move lubrication oil back into the crankcase as the crankshaft turns. The front seal is located in
the front housing. The rear seal is installed in the flywheel housing.
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Pressure oil is supplied to all main bearings through drilled holes in the webs of the cylinder block. The oil
then flows through drilled holes in the crankshaft in order to provide oil to the connecting rod bearings. The
crankshaft is held in place by seven main bearings. A thrust bearing next to the rear main bearing controls the
end play of the crankshaft.

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2.2.5 Vibration Damper

1 2 1 CRANKSHAFT
CRANKSHFT RING
3
RUBBER TING
WEIGHT
2
HUB
4

ALIGNMENT

Rubber Vibration Damper Viscous Vibration Damper

The force from combustion in the cylinders will cause the crankshaft to twist. This is called torsional vibration.
If the vibration is too great, the crankshaft will be damaged. The vibration damper limits the torsional vibra-
tions to an acceptable amount in order to prevent damage to the crankshaft.
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Manual del Estudiante

2.2.6 Camshaft

The camshaft is located in the upper left side of the cylinder block. The camshaft is driven by gears at the front
of the engine. Four bearings are pressed into the cylinder block in order to support the camshaft. A thrust
plate is mounted between the camshaft drive gear and a shoulder of the camshaft in order to control the end
play of the camshaft.

The camshaft is driven by an idler gear which is driven by the crankshaft gear. The camshaft rotates in the
same direction as the crankshaft. The crankshaft rotates in the counterclockwise direction when the engine is
viewed from the flywheel end of the engine. There are timing marks on the crankshaft gear, the idler gear, and
the camshaft gear in order to ensure the correct camshaft timing to the crankshaft for proper valve operation.

As the camshaft turns, each lobe moves a lifter assembly. There are two lifter assemblies
for each cylinder. Each lifter assembly moves a pushrod. Each pushrod moves either the inlet valves or the
exhaust valves. The camshaft must be in time with the crankshaft. The relation of the camshaft lobes to the
crankshaft position causes the valves in each cylinder to operate at the correct time.
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2.3 ENGINE SYSTEMS

2.3.1 Cooling System

This engine has a pressure type cooling system that is equipped with a shunt line. A pressure type cooling
system offers two advantages:
• The cooling system can operate safety at a temperature that is higher than the normal boiling point of
water.
• The cooling system prevents cavitation in the water pump.

COOLING SYSTEM
3
2 EXPEANSION TANK
WATER TEMPERATURE
1 REGULATOR HOUSING
CYLINDER
HEAD

4
BYPASS
CYLINDER
HOSE
BLOCK
5

OIL WATER
COOLER PUMP RADIATOR
6 7 8

Cavitation is the sudden formation of low pressure bubbles in liquids by mechanical forces. The formation of
air or steam pockets is more difficult within a pressure type cooling system.

The shunt line prevents cavitation by the water pump. The shunt line provides a constant flow of coolant to
the water pump.
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Manual del Estudiante

Note: In air-to-air aftercooled systems, a coolant mixture with a minimum of 30 percent ethylene glycol base
antifreeze must be used for efficient water pump performance. This mixture keeps the cavitation temperature
range of the coolant high enough for efficient performance.
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Water pump (7) is located on the right side of the


cylinder block. The water pump is driven by a belt
that is powered by the crankshaft pulley. Coolant can
enter the water pump in three places:

• Inlet at the bottom of the water pump


• Bypass hose (4) which is located on the top of the
water pump
• Shunt line which is located on the top of the wa-
ter pump

Coolant from the bottom of the radiator is pulled into the bottom inlet of the pump by impeller rotation. The
coolant exits the back of the pump directly into the oil cooler cavity of the block.

All of the coolant passes through the core of the oil cooler and the coolant enters the internal water manifold
of the cylinder block. The manifold disperses the coolant to water jackets around the cylinder walls.
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(1) Cylinder head


2 1
(2) Water temperature regulator housing

(4) Bypass hose


10
(10) Water temperature regulator

From the cylinder block, the coolant flows into passages in the cylinder head. The passages send the flow
around the unit injector sleeves and the inlet and the exhaust passages. The coolant now enters water
temperature regulator housing (2) at the front right side of the cylinder head.

Water temperature regulator (10) controls the direction of flow. When the coolant temperature is below the
normal operating temperature, the water temperature regulator is closed. The coolant is directed through
bypass hose (4) and into the top inlet of the water pump. When the coolant temperature reaches the normal
operating temperature, water temperature regulator (10) opens. When the water temperature regulator is
open, the bypass is closed. Most of the coolant goes through bypass inlet (9) to the radiator for cooling. The
remainder flows through bypass hose (4) and into the water pump.

The shunt line extends from the top of the water pump to an expansion tank. The shunt line must be routed
properly in order to avoid trapping any air. By providing a constant flow of coolant to the water pump, the
shunt line keeps the water pump from cavitation.

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Manual del Estudiante

Note: Water temperature regulator (10) is an important part of the cooling system. The water temperature
regulator divides coolant flow between the radiator and the bypass in order to maintain the normal operating
temperature. If the water temperature regulator is not installed in the system, there is no mechanical control,
and most of the coolant will travel the path of least resistance through the bypass. This will cause the engine
to overheat in hot weather and the engine will not reach normal operating temperature in cold weather.

Note: The air vent valve will allow the air to escape past the water temperature regulator from the cooling
system while the radiator is being filled. During normal operation, the air vent valve will be closed in order to
prevent coolant flow past the water temperature regulator.

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2.3.2 Lubrication System

1 2 C-9 LUBRICATION SYSTEM

3 HEVI PUMP 4
5
6

8
7 OIL COOLER
9
12 13
11
10
14
15
16 17
18 20 21
19
OIL FILTER
22

23
24
26 25

(1) Unit injector hydraulic pump


(2) High pressure relief valve
(3) Oil passage to the rocker arms
(4) High pressure oil line
(5) Valve mechanism cover
(6) High pressure oil passage
(7) Oil supply line to the unit injector hydraulic pump
(8) Cylinder head gallery
(9) Oil gallery plug
(10) Piston cooling jets (11) Camshaft bearings (12) Oil filter bypass valve
(13) Oil cooler bypass valve
(14) Main oil gallery
(15) Passage to front housing
(16) Turbocharger oil supply line
(17) Passage to camshaft idler gear bearing
(18) Passage
(19) Passage to oil pump idler gear bearing
(20) Engine oil filter (21) Engine oil cooler (22) Main bearings (23) Engine oil pump
(24) Oil pump bypass valve
(25) Passage to engine oil pan
(26) Engine oil pan

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Manual del Estudiante

2.3.2.1 The engine oil pump

The engine oil pump (23) is mounted to the bottom of the cylinder block. The oil pump is located inside the
oil pan (26). The engine oil pump pulls oil from the engine oil pan. The engine oil pump pushes the oil
through the passage to the engine oil cooler (21). Oil then flows through engine oil filter (20). The filtered oil
then enters the turbocharger oil supply line (16). The filtered oil also enters the main oil gallery (14).

(13) Oil cooler bypass valve


13
(20) Oil filter

21 (12) Oil filter bypass valve

(21) Oil cooler


12

20

The main oil gallery distributes oil to the following areas: main bearings (22) , piston cooling jets (10) and
camshaft bearing (11). Oil exits from the main oil gallery in the front of the block. The oil then enters a groove
that is cast in the front housing.

Oil enters the crankshaft through holes in the bearing surfaces (journals) for the main bearing. Passages connect
the bearing surface (journal) for the main bearing with the bearing surface (journal) for the connecting rod.

The front housing passage sends the oil flow in two directions. At the upper end of the passage, oil is directed
back into the block. The oil then flows up to the cylinder head gallery (8) through passage (3) to the rocker
arm mechanism. A passage (19) sends oil to the oil pump idler gear bearing.

Oil from the front main bearing enters a passage (17) to the camshaft idler gear bearing. Oil passages in the
crankshaft send oil from all the main bearings through the connecting rods to the connecting rod bearings.
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2.3.2.2 Unit injector hydraulic pump

The unit injector hydraulic pump (1) is a gear-driven axial piston pump. The unit injector hydraulic pump raises
the engine oil pressure from the typical operating oil pressure to the actuation pressure that is required by
the unit injectors.

The oil circuit consists of a low pressure circuit and a high pressure circuit. The low pressure circuit typically
operates at a pressure of 240 kPa (35 psi) to 480 kPa (70 psi). The low pressure circuit provides engine oil that
has been filtered to the unit injector hydraulic pump. Also, the low pressure circuit provides engine oil that
has been filtered to the lubricating system of the engine. Oil is drawn from the engine oil pan. Oil is supplied
through the engine oil cooler and the engine oil filter to both the engine and the unit injector hydraulic pump.

The high pressure circuit provides actuation oil to the unit injector. The high pressure circuit operates in a
pressure range typically between 6 MPa (870 psi) and 25 MPa (3626 psi). This high pressure oil flows through
a line into the cylinder head. The cylinder head stores the oil at actuation pressure. The oil is ready to actuate
the unit injector. Oil is discharged from the unit injector under the valve cover so that no return lines are
required.
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Saber, Saber Hacer, Saber Ser 25


Manual del Estudiante

2.3.2.3 The bypass valves

The oil pump bypass valve (24) limits the pressure of the oil that is coming from the engine oil pump. The
engine oil pump can pump more than enough oil into the system. When there is more than enough oil, the
oil pressure increases. When the oil pressure increases, the oil pump bypass valve will open. This allows the
oil that is not needed to go back to the suction side of the engine oil pump

The bypass valves (12) and (13) will open when the engine is cold (starting conditions). Opening the bypass
valves achieves immediate lubrication of all components. Immediate lubrication is critical. Cold oil with high
viscosity causes a restriction to the oil flow through the engine oil cooler and the engine oil filter. The engine
oil pump sends the cold oil through the oil cooler bypass valve. This causes the oil to bypass the engine oil
cooler. The oil filter bypass also allows the oil to bypass the engine oil filter. The oil is then pumped through
the turbocharger oil supply line and the main oil gallery in the cylinder block.

When the oil gets warm, the pressure difference in the bypass valves decreases and the bypass valves close.
After the bypass valves close, there is a normal flow of oil through the engine oil cooler and the engine oil
filter.

The bypass valves will also open when there is a restriction in the engine oil cooler or in the engine oil filter.
This design allows the engine to be lubricated even though the engine oil cooler or the engine oil filter are
restricted.

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2.3.2.4 The high pressure relief valve

The high pressure relief valve regulates high pressure in the system. When the oil pressure is at 695 kPa (100
psi) or more, the high pressure relief valve opens. When the high pressure relief valve opens, oil is returned
to the suction side of the oil pump.

The oil flow continues to the engine oil cooler. Coolant flows through the engine oil cooler in order to cool
the oil.

If the oil pressure differential across the engine oil cooler reaches 155 ± 17 kPa (22 ± 2 psi), then valve will
open. Opening the valve allows the oil flow to bypass the engine oil cooler

Filtered oil flows through the main oil gallery in the cylinder block. Oil is supplied from the main oil gallery to
the following components:
• Piston cooling jets (10)
• Valve mechanism
• Camshaft bearing (11)
• Crankshaft main bearings
• Turbocharger cartridge

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Saber, Saber Hacer, Saber Ser 27


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2.3.2.5 Oil cooling chamber

An oil cooling chamber is formed by the lip that is forged at the top of the skirt of the piston and the cavity
that is behind the ring grooves in the crown. Oil flow for the piston cooling jet enters the cooling chamber
through a drilled passage in the skirt. Oil flow from the piston cooling jet returns to the engine oil pan through
the clearance gap between the crown and the skirt. Four holes that are drilled from the piston oil ring groove
to the interior of the piston drain excess oil from the oil ring.

(29) Breather
(30) Hose
Breather (29) allows engine blowby to escape from the crankcase. The engine blowby is discharged through
hose (30) into the atmosphere. This prevents pressure from building up that could cause seals or gaskets to
leak.
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2.3.3 Air Inlet and Exhaust System

1
3
2

4 5

6 7

8
9

(1) Exhaust manifold


(2) Air inlet heater
(3) Aftercooler core
(4) Exhaust valve
(5) Inlet valve
(6) Air inlet
(7) Exhaust outlet
(8) Compressor side of turbocharger
(9) Turbine side of turbocharger

The components of the air inlet and exhaust system control the quality of air and the amount of air that is
available for combustion. The components of the air inlet and exhaust system are the following components:
• Air cleaner
• Turbocharger
• Aftercooler
• Cylinder head
• Valves and valve system components
• Piston and cylinder
• Exhaust manifold

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Saber, Saber Hacer, Saber Ser 29


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Inlet air is pulled through the air cleaner into air inlet (6) by turbocharger compressor wheel (8). The air is
compressed and heated to about 150 °C (300 °F) before the air is forced to the aftercooler (3). As the air
flows through the aftercooler the temperature of the compressed air lowers to about 43 °C (110 °F). Cooling
of the inlet air increases combustion efficiency. Increased combustion efficiency helps achieve the following
benefits:
• Lower fuel consumption
• Increased horsepower output

From the aftercooler, air is forced into the inlet manifold. Air flow from the inlet chambers into the cylinders
is controlled by inlet valves (5). There are two inlet valves and two exhaust valves (4) for each cylinder. The
inlet valves open when the piston moves down on the intake stroke. When the inlet valves open, cooled
compressed air from the inlet port is pulled into the cylinder. The inlet valves close and the piston begins to
move up on the compression stroke. The air in the cylinder is compressed. When the piston is near the top of
the compression stroke, fuel is injected into the cylinder. The fuel mixes with the air and combustion starts.
During the power stroke, the combustion force pushes the piston downward. The exhaust valves open and
the exhaust gases are pushed through the exhaust port into exhaust manifold (1) as the piston rises on the
exhaust stroke. After the exhaust stroke, the exhaust valves close and the cycle starts again. The complete
cycle consists of four strokes:
• Inlet
• Compression
• Power
• Exhaust

Exhaust gases from exhaust manifold (1) enter the turbine side of the turbocharger in order to turn turbo-
charger turbine wheel (9). The turbine wheel is connected to the shaft that drives the compressor wheel.
Exhaust gases from the turbocharger pass through exhaust outlet (7), a muffler and an exhaust stack.

The air inlet heater (2) is controlled by the ECM. The air inlet heater aids in engine start-up and reducing white
smoke during engine start-up.

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2.3.3.1 Turbocharger

(1) Compressor wheel housing


(2) Oil inlet port
(3) Bearing
(4) Turbine wheel housing
(5) Turbine wheel
(6) Air inlet
(7) Exhaust outlet
(8) Compressor wheel
(9) Bearing
(10) Oil outlet port
(11) Exhaust inlet

The turbocharger is installed on the center section of the exhaust manifold. All the exhaust gases from the
engine go through the turbocharger. The compressor side of the turbocharger is connected to the aftercooler
by pipe.

The exhaust gases enter turbine housing (4) through exhaust inlet (11). The exhaust gases then push the blades of
turbine wheel (5). The turbine wheel is connected by a shaft to compressor wheel (8) .

Clean air from the air cleaners is pulled through compressor housing air inlet (6) by the rotation of compressor
wheel (8). The action of the compressor wheel blades causes a compression of the inlet air. This compressor
allows the engine to burn more fuel. When the engine burns more fuel the engine produces more power.

Bearings (3) and (9) for the turbocharger use engine oil under pressure for lubrication and cooling. The oil comes
in through oil inlet port (2). The oil then goes through passages in the center section in order to lubricate the
bearings. This oil also cools the bearings. Oil from the turbocharger goes out through oil outlet port (10) in
the bottom of the center section. The oil then goes back to the engine oil pan.

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Saber, Saber Hacer, Saber Ser 31


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2.3.3.2 The boost pressure.

(12) Canister

(13) Actuating lever

(14) Line (boost pressure)

The operation of the wastegate is controlled by the boost pressure. At high boost pressures, the wastegate
opens in order to decrease boost pressure. At low boost pressure, the wastegate closes in order to increase
boost pressure.

When the engine is operating under conditions of low boost, a spring pushes on a diaphragm in canister (12).
This action moves actuating lever (13) in order to close the valve of the wastegate. Closing the valve of the
wastegate allows the turbocharger to operate at maximum performance.

As the boost pressure through line (14) increases against the diaphragm in canister (12), the valve of the
wastegate is opened. When the valve of the wastegate is opened, the rpm of the turbocharger is limited by
bypassing a portion of the exhaust gases. The exhaust gases are routed through the wastegate which bypas-
ses the turbine wheel of the turbocharger.

Note: The turbocharger with a wastegate is preset at the factory and no adjustment can be made.

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2.3.3.3 Valve System Components

(1) Rocker arm

(2) Pushrod

(3) Valve bridge

(4) Valve spring

(5) Valve

(6) Lifter

The valve system components control the flow of inlet air into the cylinders during engine operation. The
valve system components also control the flow of exhaust gases out of the cylinders during engine operation.
The crankshaft gear drives the camshaft gear through an idler gear. The camshaft must be timed to the crankshaft
in order to get the correct relation between the piston movement and the valve movement.

The camshaft has two camshaft lobes for each cylinder. The lobes operate the inlet and exhaust valves. As
the camshaft turns, lobes on the camshaft cause lifters (6) to move pushrods (2) up and down. Upward
movement of the pushrods against rocker arms (1) results in downward movement (opening) of valves (5) .

Each cylinder has two inlet valves and two exhaust valves. The valve bridge (3) actuates the valves at the same
time by movement of the pushrod and rocker arm. Valve springs (4) close the valves when the lifters move
down.

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Saber, Saber Hacer, Saber Ser 33


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2.3.3.4 Air Inlet Heater

The engines are equipped with an electric heater that is located behind the air inlet elbow. The electric heater
has two functions:
• Aid in starting
• Aid in white smoke cleanup during start-up

(1) Relay for air inlet heater


(2) Air inlet heater
(3) Stud for the ground strap

Under the proper conditions, the ECM turns on the electric heater.
The system is capable of delivering heat for thirty seconds prior to start-up and during cranking of the engine.
After the engine has started, the system is capable of delivering heat constantly for seven minutes, or the
system can cycle the heat for thirteen minutes. During the heating cycle, the heat is on for ten seconds and
the heat is off for ten seconds.

If the air inlet heater malfunctions, the engine will still start and the engine will still run. There may be a con-
cern regarding the amount of white smoke that is present. Also, there may be a concern regarding the need
for an alternative starting aid.

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The system of the air inlet heater consists of the following basic components:

• Relay of the air inlet heater


• Heater element
• Coolant temperature sensor
• Inlet manifold temperature sensor
• ECM
• Indicator lamp

The relay of the air inlet heater (1) turns the heater ON and OFF in response to signals from the ECM.

The air inlet heater (2) is located between the cover of the air inlet and the air inlet elbow. The heater element
has a stud (3) for the ground strap that must be connected to the engine.

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2.3.4 FUEL SYSTEM

(1) Oil pump


(2) Hydraulic electronic unit injectors
(3) Oil filter
(4) Oil cooler
(5) High pressure oil
(6) Fuel
(7) Connector for the Injection Actuation Pressure Control Valve (IAPCV) (8) Unit injector hydraulic pump
(9) Sensor for the Injection Actuation Pressure (IAP) (10) Fuel filter
(11) Primary fuel filter and water separator
(12) Fuel tank
(13) Camshaft gear
(14) Speed/Timing sensors
(15) ECM (16) Battery
(17) Fuel pressure regulator
(18) Inlet manifold pressure sensor
(19) Oil pressure sensor
(20) Coolant temperature sensor
(21) Accelerator position sensor
(22) Inlet air temperature sensor
(23) Atmospheric pressure sensor
(24) Air inlet heater

36 Saber, Saber Hacer, Saber Ser


3
CAPÍTULO

HYDRAULIC SYSTEMS

3.1 HYDRAULIC SYSTEMS COMPONENTS

Hydraulic systems contain the following key


components:

Fluid - can be almost any liquid. The most common


hydraulic fluids contain specially compounded
petroleum oils that lubricate and protect the system
from corrosion.
Reservoir - acts as a storehouse for the fluid and a
heat dissipater.
Hydraulic pump - converts the mechanical ener-
gy into hydraulic energy by forcing hydraulic fluid,
under pressure, from the reservoir into the system.
Fluid lines - transport the fluid to and from the pump through the hydraulic system. These lines can be rigid
metal tubes, or flexible hose assemblies. Fluid lines can transport fluid under pressure or vacuum (suction).
Hydraulic valves - control pressure, direction and flow rate of the hydraulic fluid.
Actuator- converts hydraulic energy into mechanical energy to do work. Actuators usually take the form of
hydraulic cylinders. Hydraulic cylinders are used on agricultural, construction, and industrial equipment.

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Saber, Saber Hacer, Saber Ser 37


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3.2 HYDRAULIC MACHINERY

Fundamental features of using hydraulics compared to mechanics for force and torque increase/decrease in
a transmission.

Hydraulic machines are machinery and tools that use liquid fluid power to do simple work. Heavy equipment
is a common example.

In this type of machine, hydraulic fluid is transmitted throughout the machine to various hydraulic motors and
hydraulic cylinders and which becomes pressurised according to the resistance present. The fluid is controlled
directly or automatically by control valves and distributed through hoses and tubes.

The popularity of hydraulic machinery is due to the very large amount of power that can be transferred through
small tubes and flexible hoses, and the high power density and wide array of actuators that can make use of
this power.

Hydraulic machinery is operated by the use of hydraulics, where a liquid is the powering medium.

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3.2 FORCE AND TORQUE MULTIPLICATION

A fundamental feature of hydraulic systems is the ability to apply force or torque multiplication in an easy
way, independent of the distance between the input and output, without the need for mechanical gears or
levers, either by altering the effective areas in two connected cylinders or the effective displacement (cc/rev)
between a pump and motor. In normal cases, hydraulic ratios are combined with a mechanical force or torque
ratio for optimum machine designs such as boom movements and trackdrives for an excavator.
Examples

Two hydraulic cylinders interconnected

Cylinder C1 is one inch in radius, and cylinder C2 is ten inches in radius. If the force exerted on C1 is 10 lbf,
the force exerted by C2 is 1000 lbf because C2 is a hundred times larger in area (S = πr²) as C1. The downside
to this is that you have to move C1 a hundred inches to move C2 one inch. The most common use for this is
the classical hydraulic jack where a pumping cylinder with a small diameter is connected to the lifting cylinder
with a large diameter.

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3.4 PUMP AND MOTOR

If a hydraulic rotary pump with the displacement 10 cc/rev is connected to a hydraulic rotary motor with 100
cc/rev, the shaft torque required to drive the pump is 10 times less than the torque available at the motor
shaft, but the shaft speed (rev/min) for the motor is 10 times less than the pump shaft speed. This combination is
actually the same type of force multiplication as the cylinder example (1) just that the linear force in this case
is a rotary force, defined as torque.

Both these examples are usually referred to as a hydraulic transmission or hydrostatic transmission involving
a certain hydraulic “gear ratio”.

Hydraulic circuits

Hydraulic Cylinder

Retract Extend
Reservoir

Control
valve

Filter Pump

A simple open center hydraulic circuit The equivalent circuit schematic

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For the hydraulic fluid to do work, it must flow to the actuator and or motors, then return to a reservoir. The
fluid is then filtered and re-pumped. The path taken by hydraulic fluid is called a hydraulic circuit of which
there are several types. Open center circuits use pumps which supply a continuous flow. The flow is returned
to tank through the control valve’s open center; that is, when the control valve is centered, it provides an
open return path to tank and the fluid is not pumped to a high pressure. Otherwise, if the control valve is
actuated it routes fluid to and from an actuator and tank. The fluid’s pressure will rise to meet any resistance,
since the pump has a constant output. If the pressure rises too high, fluid returns to tank through a pressure
relief valve. Multiple control valves may be stacked in series [1]. This type of circuit can use inexpensive, cons-
tant displacement pumps.

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Saber, Saber Hacer, Saber Ser 41


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3.5 R1600 HYDRAULIC SYSTEM

1 2 3 4 5 6

7 8 9 10 11

The hydraulic system is divided into two basic circuits:


• Pilot circuit
• Main circuit

Pilot Circuit Components:


(8) Bucket positioner valve
(5) Pressure reducing valve
(6) Pilot oil pump
(2) Float sequence valve
(4) Joystick pilot control valve
(10) Selector and pressure control valve

Main Circuit Components:


(1) Tilt cylinder
(3) Hydraulic tank
(11) Main hydraulic pump
(7) Lift cylinders
(9) Main control valve

The pilot system is a closed centre circuit, Pilot pump oil flows to the pilot control valve. The valve blocks
the oil flow until the joystick lever is moved from the HOLD position. The pilot control valve sends pilot oil to
move the main control valve spool. The pilot pressure reducing valve controls the maximum pressure in the
pilot oil system

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SELECTOR ABD PRESSURE CONTROL VALVE


TO BRAKE
SYSTEM LIFT CYLINDER
SELECTOR SPRING INLET VALVE
AND PRESSURE SHIMS ORIFICE 1 SPOOL
PUMP CONTROL VALVE
PILOT
FILTER CONTROL
TILT LIFT VALVES
PILOT CHECK
PRESSURE VALVE
REDUCING PILOT PUMP
VALVE INLET

PILOT SYSTEM
TO STEERING
TANK
TILT LIFT DRAIN
PASSAGE
IMPLEMENT PILOT SYSTEM
ORIFICE 2

MAN VALVE
CONTROL OUTLET
VALVES

The brake and pilot pump is part of the three-section vane-type pump. The brake and pilot pump supplies oil to:
• Implement pilot circuit
• Parking brake circuit
• Service brake circuit
• Steering pilot circuit

Pump oil flows from the pump, through the pressure reducing valve to the pilot control valve. The pressure
reducing valve limits maximum oil pressure in the pilot oil circuit.

The bucket positioner valve allows the operator to lower the bucket to a preset digging
Height. The float sequence valve controls the FLOAT function. In FLOAT, the rod and head end of the lift cylin-
ders are open to tank.

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TILT CYLINDER
SYSTEM RELIEF
VALVE

CONTROL VALVE

TILT TIFT
PUMP

LIFT
FILTER CYLINDER

MAIN HYDRAULIC SYSTEM


TANK HOLD

The main hydraulic system is an open centre circuit. Pump oil flows to the main control valve. The oil flows
through the valve to tank when the valve is in the HOLD position.

In HOLD, the oil in the cylinders is blocked (held). The main system relief valve limits the maximum system
pressure

3.5.1 Implement Hydraulic System

The implement pump is part of the three-section vane-type pump. The implement control valve contains
two valve spools to control the function of the hydraulic cylinders. The implement control valve spools are
moved by pilot oil from the pilot control valve. The main relief valve controls the maximum oil pressure in the
implement oil system.

The tilt cylinder has two relief valves. One for the rod end and one for the head end. The tilt cylinder relief
valves protect the tilt cylinder from excessive pressure caused by external shock.

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ROD END HEAD END


MAKEUP CHECK VALVE
VALVE SUPPLY

PILOT PILOT
VALVE VALVE

TILT & POOL


PILOT PILOT
VALVE VALVE

TILT & POOL


CHECK VALVE
MAKEUP ROD HEAD TANK
VALVE END END
TO FLOTAT
SEQUENCE VALVE

Lift and Tilt Control Valve In HOLD Position, Engine Off. Springs hold the spools in the centred position. The
tilt makeup valve prevents cavitation in the rod end of the tilt cylinder. In FLOAT, the spring chamber of the
lift cylinder rod end makeup valve is connected to tank through the float sequence valve. The two load check
valves allows oil flow from the pump to the cylinders but blocks flow from the cylinders to the pump oil supply
port.

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3.5.2 Hydraulic System Components

Pilot System Components:


• Hydraulic oil tank
• Pilot oil pump section
• Pressure reducing valve
• Selector and pressure control valve
• Bucket positioner valve
• Float sequence valve
• Joystick pilot control valve

Main System Components:


• Hydraulic oil tank
• Implement pump section
• Main relief valve
• Implement control valve
• Tilt cylinder
• Lift cylinders

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3.5.3 Hydraulic System Operation

Hydraulic system in hold with the engine running. Pilot oil is blocked at the pilot control valve. The pressure
reducing valve closes off pilot pump oil flow to maintain a constant pilot system pressure. Implement pump
oil flows through the implement control valve to tank.

Hydraulic system with pilot control lever in the DUMP position. Pilot oil from the pilot control valve moves
the tilt control spool. The tilt control spool directs implement pump oil to the rod end of the tilt cylinders.

Hydraulic system with pilot control lever in the LOWER position. Pilot oil from the pilot control valve moves
the lift control spool. The lift control spool directs implement pump oil to the rod end of the lift cylinders.

Hydraulic system with pilot control lever in the FLOAT position. The pilot control valve is moved past the
LOWER position to the FLOAT position. The increased pilot oil pressure from the pilot control valve opens the
float sequence valve. The spring chamber of the makeup valve is vented to tank. The makeup valve opens
sending implement pump oil to tank. Both the rod end and head ends of the lift cylinders are open to tank.

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4
CAPÍTULO

ELECTRICAL SYSTEM

4.1 ELECTRICAL CIRCUITS AND LAWS

An electrical circuit is a path, or group of interconnecting paths, capable of carrying electrical currents. It is
a closed path that contains a voltage source or sources. There are two basic types of electrical circuits-series
and parallel. The basic series and parallel circuits may be combined to form more complex circuits, but these
combinational circuits may be simplified and analyzed as the two basic types. It is important to understand
the laws needed to analyze and diagnose electrical circuits. They are Kirchoff’s Laws and Ohm’s Law.

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4.1 ELECTRICAL CIRCUITS AND LAWS

Schematics are used by technicians to determine how a system works and to assist in the repair of a system
that has failed.

Schematic symbols present a great deal of information in a small amount of space and the reading of schematic
symbols requires highly developed skills and practice. A logical, step-by-step approach to using schematic
diagrams for troubleshooting begins with the technician’s understanding of the complete system. Although
there are many electrical symbols used in circuit diagrams, next Figure shows the some of the more common
Caterpillar electrical symbols.

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CIRCUIT
SOLENOID MOTOR TRANSISTOR BATTERY BREAKER FUSE LIGHT

DISCONNECT TEMPERATURE PRESSURE SWITCHES TOGGLE SWITCH


SWITCH SWITCH

RESISTORS REOSTAT POTENTIOMETER RESISTOR

RESISTORS

ELECTRICAL COMPONENTS AND SYMBOLS

4.2.1 Connectors

The purpose of a connector is to pass current from one wire to another. In order to accomplish this, the con-
nector must have two mating halves (plug or receptacle). One half houses a pin and the other half houses a
socket. When the two halves are joined, current is allowed to pass.

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Types of Connectors
Several types of connectors are used throughout the electrical and electronic systems on Caterpillar machi-
nes. Each type differs in the manner in which they are serviced or repaired.

Vehicular Environmental (VE) Connectors Sure-Seal Connectors

Deutsch Connectors (HD10, DT, CE and DRC Series)

4.2.2 Switches

A switch is a device used to complete or interrupt a current path. Typically, switches are placed between two
conductors (or wires). There are many different types of switches, such as single-pole single-throw (SPST),
single-pole double throw (SPDT), double-pole Single-throw (DPST) and double-pole double-throw (DPDT).

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4.2.3 Fuses

Fuses are the most common circuit protectors. A fuse is made of a thin metal strip or wire inside a holder
made of glass or plastic. When the current flow becomes higher than the fuse rating, the metal melts and the
circuit opens. A fuse must be replaced after it opens.
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4.2.4 Circuit Breakers

A circuit breaker is similar to a fuse; however, high current will cause the breaker to “trip” thereby opening
the circuit. The breaker can be manually reset after the overcurrent condition has been eliminated.
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4.2.5 Batteries

THERMAL PLATE TRAP


POST CASTING

NEGATIVE
PLATE GROUP

SEPARATOR
ELEMENT

POSITIVE
PLATE GROUP

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A battery stores electrical energy in chemical form to be released as electrical energy for the machine electrical
system. This includes the starting, charging, and accessory circuits. This battery current is produced by a chemical
reaction between the active materials of the battery plates and the sulfuric acid in the electrolyte. The battery
is a voltage stabilizer for the system and acts as an accumulator or reservoir of power.
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4.2.6 Charging System

D.C. CHARGING CIRCUIT D.C. CHARGING CIRCUIT

REGULATOR IGNITION
SWITCH
REGULATOR

AMMETER
AMMETER GENERATOR
ALTERNATOR

GROUND
GROUND
BATTERY

The charging system converts mechanical energy from the engine into electrical energy to charge the battery
and supply current to operate the electrical systems of the machine.

The charging system recharges the battery and generates current during operation. There are two kinds of
charging circuits:
• DC charging circuits that use generators
• AC charging circuits that use alternators

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4.2.7 Starting System

SOLENOID
(MOTOR SWITCH)

STARTING
MOTOR

BATTERY
STARTER
SWITCH
FLYWHEEL

The starting system converts electrical energy from the battery into mechanical energy to start the engine. A
basic starting system has four parts:
• Battery: Supplies energy for the circuit
• Starter switch: Activates the circuit
• Solenoid (motor switch): Engages the starting motor drive with the flywheel
• Starting Motor: Drives the flywheel to crank the engine

When the starter switch is activated a small amount of current flows from the battery to the solenoid and
back to the battery through the ground circuit.

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