DIFFERENT SYSTEMS OF

IC ENGINE
Different systems available for efficient
functioning of an engine are as follows:
1. Fuel supply system
2. Lubrication system
3. Ignition system
4. Cooling system
5. Governor
Fuel supply system
 Fuel
Fuel is a substance consumed by the engine to
produce energy.
The common fuels for IC engines are:
 Ignition quality of fuel
 Ignition quality refers to ease of burning the oil in the
combustion chamber. Octane number and Cetane number
are the measures of ignition quality of the fuel.
 Octane number: The percentage of iso-octane (C8H18) in
a mixture of iso-octane and normal heptane (C7H16) that
produces the same knocking effect as the fuel under test is
called Octane number of the fuel. Most automobiles use
Petrol of the minimum grade of 91 Octane available in India.
 Cetane number: The percentage of Cetane in a mixture of
Cetane (C16H34) and alphamethyl napthalene (C11H16)
that produces the same knocking effect as the fuel under test
is called Cetane number of the fuel. Commercial diesel fuel
have got cetane number varying from 30 to 60.

 Higher these numbers means better ignition quality and

antiknock quality of the fuel.
Fuel supply system in spark ignition
engine
 The fuel supply system of spark ignition engine consists
of
1. Fuel tank, 2. Fuel filter, 3. Fuel lift pump (Diaphragm
type), 4. Carburetor, 5. Fuel pipes
 Carburetor
 The process of preparing air-fuel mixture away from
the engine cylinder is called carburetion and the device
in which this process takes is called carburetor.
 Functions of carburetor
1. To mix the air and fuel thoroughly
2. To atomize the fuel
3. To regulate the air- fuel ratio at
different speeds and loads on the engine.
4. To supply correct amount of
mixture at different speeds and
loads.
5. 'Stoichiometric' A/F ratio of petrol engine is 14.7:1
 Fuel supply system in diesel engine
 Fuel supply system of diesel engine consists of the
following components:
1. Fuel tank, 2. Fuel lift pump or fuel feed pump, 3.
Fuel filter, 4. Fuel injection pump, 5. High pressure
pipe, 6. Over flow valve, 7. Fuel injector
 Fuel injection pump
 It is a high pressure pump which supplies fuel to the
injectors according to the firing order of the engine.
 It is used to create pressure varying from 120 kg/cm² to
200 kg/cm².
 Fuel injector
 Main parts of injectors are nozzle body, and needle
valve.
 The needle valve is pressed against a conical seat in
the nozzle body by a spring.
 The injection pressure is adjusted by adjusting a screw.
 When fuel pressure exceeds the set spring pressure,
the needle valve lifts off its seat and the fuel is forced
out of the nozzle spray holes into the combustion
chamber.
 Fuel filter
 Usually there are two filters in diesel engine: 1.
Primary filter and Secondary filter.
 Primary filter removes the coarse material, water and
dust. Secondary filter removes the fine dust particles.
 Filters are made of different materials like Metal
element, Felt and cloth element, Paper disc.
 Air cleaner
 Air cleaner is of two types:
1. Dry type Air cleaner
2. Oil bath type air cleaner

(Felt)

Dry type Air cleaner Oil bath type air cleaner

Turbocharger
Lubrication system
 Purpose of lubrication
Lubrication produces the following effects:
1. Reducing frictional effect
2. Cooling effect
3. Sealing effect
4. Cleaning effect
 Types of lubricant
 Lubricants are obtained from animal fat, vegetables
and minerals.
 Lubricants made of animal fat does not stand much
heat. It is not very suitable for machines.
 Vegetable lubricants are obtained from seeds, fruits,
plants. It is used in small simple machines.
 Mineral lubricants are obtained from crude
petroleum. It is most popular for engines and
machines.
 Engine parts require lubrication
1. Cylinder walls and piston
2. Piston pin
3. Crankshaft and connecting rod bearings
4. Camshaft bearings
5. Valve operating mechanism
6. Cooling fan
7. Water pump and
8. Ignition mechanism
 Types of lubricating systems
1. Splash system
2. Forced feed system
3. Combination of splash and forced feed
system
 Splash system
 An Oil trough provided below the connecting rod.
 A dipper is provided at the lower end of the connecting
rod.
 This dipper dips into the oil trough and splashes oil out
of the pan.
 This splashing action lubricates the engine parts like
cylinder walls, pistons, piston pins, timing gears etc.
 Forced feed system
 In this system the oil is pumped directly to the
crankshaft, connecting rod, piston pin, timing gear
and cam shaft of the engine through suitable paths.
 Combination of splash and forced feed
system
 The engine components which are subjected to very
heavy load such as main bearing, connecting rod
bearing and cam shaft bearing are lubricated under
forced feed system.
 The rest of the parts like cylinder liners, cams, tappets
etc. are lubricated by splash system.
 Oil pump
 Gear type oil pump is used to force oil into the oil
pipe.
 The pump is driven by cam shaft.
 Lower end of the pump extends down into the
crankcase.

Gear pump
Oil filter
 It is a type of strainer using cloth, paper, felt, wire
screen or similar elements.
 Oil filters are two types:
1. Full-flow filter
2. By-pass filter
 Full-flow filter
 In this filter the entire quantity of oil is forced to
circulate through it before it enters the engine.
 A spring loaded valve is fitted as a protection
device against oil starvation in case of filter
getting clogged.
 By-pass filter
 Only a part of the oil is filtered through this filter.
The balance oil reaches directly to the engine parts.
 Over a period of operation all the oil in the
crankcase passes through the filter.
Ignition system
 Ignition system
Types of ignition systems:
1. Ignition by heat of compression or
compression ignition
2. Ignition by electric spark or spark ignition
a) Battery ignition
b) Magneto ignition
 Battery ignition
 It includes two circuits:
1. Low voltage (Primary
circuit)
 It consists of:
a)battery, b) ignition
switch, c) primary
winding, d) contact
breaker.
2. High voltage
(Secondary circuit)
 It consists of:
a)Secondary winding,
b) Distributor, c) high
voltage wiring, d)
spark plug.
 Magneto ignition
 Main components are:
a)frame, b)permanent magnet, c)armature, d)spark
plug, e)rotor, f)primary and secondary winding,
g)breaker points, h)condenser.
 Spark plug
 It ignites the air-fuel mixture in combustion chamber.
 It provides insulated and grounded electrode to form a
gap across which the spark jumps and ignites.
 It consists of electrode, insulator and copper gasket.
 Spark gap is kept between 0.5 to 0.85 mm.
 It is two types: a)Hot plug, b)Cold plug
Governor
 Introduction
 Governor is a mechanical device to control the engine
speed within specified limit under different loading by
regulating the intake of fuel.
 It is used on tractor or stationary engines.
 Tractor engine is subjected to rapidly variable loads in
the field and the operator can’t control that. So,
governor is used in tractor.
 Classification of governor system
 Governor system is classified as:
1. Hit and miss system
2. Throttle system
a) Centrifugal governor
b) Pneumatic governor
c) Hydraulic governor
 Hit and miss system
 In this system the frequency of power strokes of engine
are regulated.
 When the engine speed exceeds the rated speed the
exhaust valve gets open for longer period which
prevents air fuel mixture or fuel to enter into the engine
cylinder.
 A detent is provided which prevents the exhaust valve
from closing when the speed is high.
 Throttle system
o This system consists in controlling the amount of fuel
mixture or fuel and thereby changing the explosion
intensity in the cylinder.
o The number of explosions are not reduced, only
intensity of explosion is changed.
o If the speed decreases the throttle remains wide open
and more charge goes to the engine cylinder. When the
speed goes up the throttle comes to nearly closed
position and less charge goes to the engine cylinder.
 Centrifugal governor
 It consists of a) spring loaded centrifugal weights, b)
sliding collar, c) spring, d) throttle valve, e) connecting
rod.
 Centrifugal weights are mounted on the crankshaft or
on another shaft driven by crankshaft.
 At low load the engine speed tends to go high, the
centrifugal weights tend to fly outward against spring
tension, thereby closing the throttle valve and reducing
the entry of charge.
 Centrifugal governor is used in tractors and stationary
engines.

Governor in diesel engine Governor in petrol engine

 Governor regulation:
It is the variation in the engine speed between full
load and no load condition. It is usually expressed as
percentage of rated speed. In normal working , a
variation of about 100 rev/min is observed between
full load and noload conditions for a good governor.
This is given as:
R= (N1-N2)__X 100
(N1+N2)/2
R= % regulation
N1= speed at no load
N2= speed at full load
 Governor hunting
 It is the erratic variation of the speed of governor
when it over compensates for speed changes i.e. too
fast then too slow and so on.
 It may be due to incorrect adjustment of fuel pump or
carburetor, improper adjustment of idling screw and
excessive friction.
Cooling system
 Introduction
 The temperature produce on the power stroke of an
engine can be as high as 1600°C and this is greater
than the melting point of engine parts.
 The best operating temperature of IC engines lie
between 140° F and 200°F and hence cooling of an IC
engine is highly essential.
 It is estimated that about 40% of the total heat
produced is passed to the atmosphere via the exhaust,
30% is removed by cooling system and only about 30%
is used to produce useful power.
Bad effect of high temperature in the
engine
 Cylinder and piston may expand to such an extent that
the piston would seize in the cylinder.
 Lubricating quality of the oil inside the cylinder would
be destroyed.
 Preignition of fuel mixture would take place and would
cause engine knocking and loss of power.
 Purpose of cooling
 To maintain optimum temperature of engine for
efficient operation.
 To dissipate surplus heat for protection of engine
components like cylinder, cylinder head, piston, piston
rings, and valves.
 To maintain lubricating property of the oil inside the
engine cylinder.
Methods of cooling
1. Air cooled system
2. Water cooled system
 Air cooled system
 It has fins to increase the area of contact of air for
speedy cooling.
 The cylinder is normally enclosed in a sheet metal
casing called Cowling.
 The flywheel has blades, acts like a fan drawing air
through a hole in the cowling and directing it around
the finned cylinder.
Advantages:
1. It is more simple in design and construction.
2. Water jackets, radiator, water pump, thermostat,
pipes hoses etc. are not needed.
3. It is more compact.
4. Lighter in weight.
Disadvantages:
1. There is uneven cooling of engine parts
2. Engine temperature is generally high during
working period
 Water cooled system
 Engines using water as cooling medium are called
water cooled engines.
 Water is circulated round the cylinders to absorb
heat from the cylinder walls.
 The heated water is conducted through a radiator to
remove the heat and cool the water.

 Methods of water cooling:

1. Open jacket or hopper method
2. Thermo siphon method
3. Forced circulation method
 Open jacket or hopper method
 There is a hopper or jacket containing water which
surrounds the engine cylinder.
 So long as the hopper contains water the engine
continues to operate satisfactorily. As soon as the water
starts boiling it is replaced by cold water.
 A drain plug is provided in a low accessible position for
draining water as and when required.
 Thermo siphon method
 It consists of a radiator, water jacket, fan, temperature
gauge and hose connections.
 Water which surrounds the cylinder becomes lighter
and it rises upwards in liquid column. Hot water goes
to the radiator where it passes through tubes
surrounded by air.
 Water jacket and radiator are connected at both sides
i.e. at top and bottom.
 A fan is driven with the help of a V belt to suck air
through tubes of the radiator unit, cooling radiator
water.
 Forced circulation method
 The system consists of Water pump, Radiator, Fan, Fan-
belt, Water jacket, Thermostat valve, Temperature
gauge, Hose pipe.
 Water pump (Centrifugal type)forces water from
radiator to the water jacket of the engine.
 After circulating the entire run of water jacket, water
comes back to the radiator where it loses its heat by
the process of radiation.
 To maintain the correct engine temperature, a
thermostat valve is placed at the outer end of cylinder
head.
Forced circulation method
 Thermostat valve
 This valve closes the inlet passage of the water
connected to the radiator.
 It is placed in the water passage between the cylinder
head and the top of radiator.
 Thermostats are designed to start opening at 70°C to
75°C and then fully open at 82°C for petrol engine and
88-90°C for diesel engine.
 It is three types:
1. Wax,2. Bellows and 3. Bimetallic
Bellows type Wax type
 Radiator
 It is a device for cooling the circulating water in the
engine.
 Hot water flows into the radiator at the top and cold
water flows out from the bottom, passing it over a large
metal surface.
 Air flows at right angle to the downward flowing water,
transferring the heat from the water to the atmosphere.
 It is of two types:
1. Tubular type
2. Cellular type

Tubular type Cellular type

Centrifugal type water pump