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2004/11/07 Lubrication System (RENR7597-06)

SMCS - 1300 i02202368

PSP
202 -000A
06: 5/01/0 AF21
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Illustration 1 g01112073
(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 to cylinder block
(19) Passage to oil pump idler gear bearing
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(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
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 (23) pulls oil from the engine oil pan (26). 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).

Illustration 2 g01112096
(13) Oil cooler bypass valve
(20) Oil filter
(12) Oil filter bypass valve
(21) Oil cooler

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Illustration 3 g01112098
(1) Unit injector hydraulic pump

The main oil gallery (14) distributes oil to the following areas: main bearings (22) , piston cooling
jets (10) and camshaft bearing (11). Oil from main oil gallery (14) exits 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 (22).
Passages connect the bearing surface (journal) for the main bearing (22) 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 (22) through the connecting rods to
the connecting rod bearings.

Note: Engines that are equipped with an auxiliary oil filter will receive oil from a port. The filtered oil
will be returned to the engine oil pan (26).

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

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provides engine oil that has been filtered to the unit injector hydraulic pump (1). 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 (26). Oil is supplied through the engine oil cooler (21) and engine
oil filter (20) to both the engine and the unit injector hydraulic pump (1).

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.

After the lubrication oil's work is done, the lubrication oil returns to the engine oil pan.

The oil pump bypass valve (24) limits the pressure of the oil that is coming from the engine oil pump
(23). The engine oil pump (23) 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 (24) will open. This allows the oil that is not needed to go back to the suction side of the
engine oil pump (23).

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 engine oil cooler (21)
and engine oil filter (20). The engine oil pump (23) sends the cold oil through the oil cooler bypass
valve. This causes the oil to bypass the engine oil cooler (21). The oil filter bypass also allows the
oil to bypass the engine oil filter (20). The oil is then pumped through the turbocharger oil supply
line (16) and the main oil gallery (14) 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 (21) or in the
engine oil filter (20). This design allows the engine to be lubricated even though engine oil cooler
(21) or engine oil filter (20) are restricted.

High pressure relief valve (24) regulates high pressure in the system. When the oil pressure is at
695 kPa (100 psi) or more, high pressure relief valve (24) opens. When the high pressure relief
valve opens, oil is returned to engine oil pan (26).

The oil flow continues to the engine oil cooler (21). Coolant flows through engine oil cooler (21) in
order to cool the oil.

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If the oil pressure differential across the engine oil cooler reaches 155 ± 17 kPa (22 ± 2 psi), the
valve will open. Opening the valve allows the oil flow to bypass the engine oil cooler (21).

Approximately five percent of the oil flow is directed through an orificed passage to oil filter bypass
valve (12). The oil then flows to the auxiliary oil filter (if equipped) and to the engine oil pan (26).
The main oil flow now reaches the main engine oil filter (20). When the oil pressure differential
across the oil filter bypass valve (13) reaches 170 kPa (25 psi), the valve opens in order to allow the
oil flow to go around the oil filter (20). The oil flow continues in order to lubricate the engine
components. When the oil is cold, an oil pressure difference in the bypass valve also causes the
valve to open. This bypass valve then provides immediate lubrication to all the engine components
when cold oil with high viscosity causes a restriction to the oil flow through the engine oil filter (20).
The bypass valve will also open when there is a restriction in the engine oil filter (20). This design
allows the engine to be lubricated even though engine oil filter (20) is restricted.

Note: Refer to Specifications, "Engine Oil Filter Base".

Filtered oil flows through the main oil gallery (14) in the cylinder block. Oil is supplied from the main
oil gallery (14) to the following components:

Piston cooling jets (10)

Valve mechanism

Camshaft bearing (11)

Crankshaft main bearings

Turbocharger cartridge

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 (26) 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.

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Illustration 4 g01112104
(27) Breather
(28) Hose

Breather (27) allows engine blowby to escape from the crankcase. The engine blowby is discharged
through hose (28) into the atmosphere. This prevents pressure from building up that could cause
seals or gaskets to leak.

PSP-000AAF21
2025/01/06
06:55:52+03:00
i01817296
© 2025 Caterpillar Inc.

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