Engine Systems 1

Engine Systems Introduction

This topic introduces the five principal engine systems.

Cooling System - What it Does

The primary function of the cooling system is to maintain correct engine temperature by taking
away unwanted heat generated by combustion and friction. The temperature of burning fuel in an
engine can exceed 3,500ºF (1,927ºC).

Even though diesel engines provide the most thermally efficient and cost effective power, only an
estimated 40% of the heat energy developed during combustion is converted into usable
horsepower. Of the remaining 60%, 7% radiates directly off engine surfaces, 23% goes out the
exhaust, and 30% is dissipated by the cooling system.

Coolant circulates through passages in the engine called the water or coolant jacket. The coolant
absorbs heat from the hot engine surfaces and carries it to the radiator where it is dissipated into
the atmosphere.

Cooling System - Heat Exchangers

A radiator is a form of heat exchanger, using air to dissipate heat from the cooling system. In
marine applications, another type of heat exchanger uses seawater to cool the engine. Instead of
using an air-cooled radiator to dissipate heat, seawater is pumped through one side of a heat
exchanger core. Engine coolant circulating in a closed system is pumped through the other side of
the heat exchanger where it is cooled, in later designs, by titanium plates that act like radiator fins.

Cooling System - Oil Coolers & Aftercoolers

The cooling system also helps maintain the correct temperature of the engine oil, transmission oil,
and hydraulic oil through the use of oil coolers. An oil cooler is a type of heat exchanger. With this
device, oil flows through a series of tubes surrounded by engine coolant that dissipates a portion
of the oil’s heat.

On Jacket Water Aftercooling (JWAC) systems, coolant from the engine is routed through the
aftercooler to cool the compressed air between the turbocharger and the intake manifold.

Engine coolant is also used to cool turbochargers.

Cooling System - Functions & Components

The water pump provides continuous circulation of coolant whenever the engine is turning. Water
pumps on most medium and large engines are gear driven; smaller engines use belt driven water
pumps.

A thermostat determines the flow of coolant to the radiator based on coolant temperature. In a
cold engine after start-up, the thermostat remains closed, forcing the coolant to bypass the
radiator or heat exchanger and only circulate within the engine block, cylinder head and oil coolers.
This enables the engine to warm up faster. When the engine reaches operating temperature, the
thermostat opens and coolant is routed through the radiator to be cooled.

The cooling system is a closed system that develops pressure as the coolant heats and expands.
Excess pressure is released through the radiator cap.

Lubrication System - What it Does

The engine lubrication system has three main functions:

To CleanTo CoolTo Seal and Lubricate

Oil cleans parts by carrying away damaging metal particles that materialize during normal engine
operations. Oil also cleans the cylinder walls and carries away carbon and lacquer deposits
produced during combustion. These particles are then removed from the lubricating system by the
engine oil filter.

The second function of oil is to cool parts by absorbing heat and carrying it away. Heat is then
dissipated in the oil pan or, more effectively, by an oil cooler.

Thirdly, oil forms a thin film or layer between the surfaces of moving parts to support and separate
them. This prevents metal-to-metal contact that causes excessive wear. Oil not only lubricates but
forms a dynamic seal that prevents airborne particles from penetrating.