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Doosan DE08TIS Series Operation & Maintenance Manual

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950106-063003EN

Operation &

DIESEL INDUSTRIAL ENGINE

DE08TIS

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Summary of Contents for Doosan DE08TIS Series

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    950106-063003EN Operation & Maintenance Manual DIESEL INDUSTRIAL ENGINE DE08TIS…
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    The design of our product may be changed without prior notice and Doosan shall not be held liable for the failure of this manual to contain all the design changes made to improve the product.
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    TABLE OF CONTENTS 1. GENERAL INFORMATION………………………………………………………………1 1.1 General Repair Instructions…………………………………………………………1 1.2 Engine Specific Character……………………………………………………………1 1.3 Engine Specifications…………………………………………………………………3 1.4 Engine Assembly……………………………………………………………………7 2. MAJOR MAINTENANCE…………………………………………………………………10 ……………………………………………………………10 2.1 Preventive Maintenanc 2.2 Diagnosis and Remedy……………………………………………………………17 2.3 Engine Inspection……………………………………………………………………26 3. MAINTENANCE…………………………………………………………………………28 3.1 Engine Disassembly………………………………………………………………28 3.2 Inspection and Measurement………………………………………………………43 3.3 Engine Reassembly…………………………………………………………………61 3.4 Breaking In on Major Parts…………………………………………………………86 4.
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    4. The use of proper tools and special tools where specified is important to efficient and reliable service operation. 5. Use genuine DOOSAN parts necessarily. 6. Used cotter pins, gaskets, O-rings, oil seals, lock washer and self-lock nuts should be discarded and new ones should be prepared for installation as normal function of the parts cannot be maintained if these parts are reused.
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    1. GENERAL INFORMATION 1.2.2 OMEGA combustion bowl The OMEGA combustion bowl is a unit designed to perform high efficiency, low emission combustion. As the rim around the combustion bowl port of the upper of the piston has been machined in a smaller size than the interior of the combustion bowl, strong swirl is produced in the combustion bowl and strong squish flow makes the fuel be mixed more sufficiently with air.
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    1. GENERAL INFORMATION 1.3 Engine Specifications 1.3.1 Specification DE08TIS PBL00 MBE00 4 cycle in-line, water cooled type, Engine type Turbocharged & intercooled Combustion chamber type Direct injection type Cylinder liner type Replaceable dry liner Timing gear system Gear driven type Number of piston rings Compression ring 2, oil ring 1 Number of cylinders — bore x stroke…
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    1. GENERAL INFORMATION 1.3.2 Engine power Production tolerance : ±5% Engine Model Performance Product Power Torque Low Idle High Idle Remark Model (kgf•m/RPM) Code (PS/RPM) (RPM) (RPM) DE08-PBL00 217.6/2,000 92/1,300 2,200 DE08TIS MBE00 212/1,800 85/1,400 1,000 2,000…
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    1. GENERAL INFORMATION 1.3.3 Performance curve (DE08TIS — 225PS) Performance ISO 1585 (SAE J1349) Output (max.) 160 kW (217.6 PS) / 2,000 rpm Torque (max.) 902 N.m (92 kg· m) / 1,300 rpm Fuel consumption (min.) 213 g/kW.h (156 g / PS.h)
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    1. GENERAL INFORMATION 1.3.4 Performance curve (DE08TIS – MBE00 – 195PS) KS – B6537 Performance Output (max.) 143 kW (195 PS) / 1,800 rpm Torque (max.) 833.6 N.m (85 kg.m) / 1,400 rpm Fuel consumption (min.) 214 g/kW.h (158 g / PS.h)
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    1. GENERAL INFORMATION 1.4 Engine Assembly 1.4.1 Engine sectional view (longitudinal) 1. Water pump 10. Intake valve spring 19. Oil seal (Front) 2. Piston 11. Cylinder block 20. Crank shaft pulley 3. Air compressor 12. Push rod 21. Crank shaft gear 4.
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    1. GENERAL INFORMATION 1.4.2 Engine sectional view (cross) 1. Fuel injection pipe 9. Turbo charger 2. Fuel filter 10. Fuel injection pump 3. Fuel injection nozzle 11. Timing gear case 4. Intake manifold 12. Oil filler cap 5. Air heater 13.
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    1. GENERAL INFORMATION 1.4.3 Engine assembly views 1. Flywheel housing 10. Turbocharger 19. Breather 2. Fuel filter 11. Exhaust pipe 20. Thermostat 3. Intake pipe 12. Lifting hook (Rear) 21. Water pump 4. Fuel injection pump 13. Starter 22. Crankshaft pulley 5.
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    ·Since DE08TIS diesel engine cylinder liner is dry type, particularly the cooling water control should be applied thoroughly by the cooling water test kit. (DOOSAN 60.99901-0038) ·The density of antifreezing solution and additive for rust prevention is able to be confirmed by the cooling water test kit.
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    2. MAJOR MAINTENANCE (6) The brown at the middle of test paper and the lower pink color indication represent the additive state for rust prevention, and the proper range is that the meeting numerical value of brown (vertical) and pink color (horizontal) locates in the range of 0.3 to 0.8 at the color list of label on the test paper storage bottle.
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    2. MAJOR MAINTENANCE · The following oils are also recommended. Recommend oil Engine model SAE No. API No. SAE 10W40 API CI-4 DE08TIS 2.1.4 Oil filter · Check for oil pressure and oil leaks, and repair or replace the oil filter if necessary. ·Change the oil filter cartridge simultaneously at every replacement of engine oil.
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    2. MAJOR MAINTENANCE 2.1.7 Intercooler The intercooler is air to air type and has a large cooling fan capacity. The intercooler life and performance depends on the intake air condition greatly. Fouled air pollutes and clogs the air fins of intercooler. As a result of this, the engine output is decreased and engine malfunction is occurred.
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    2. MAJOR MAINTENANCE (1) Rotate the crankshaft to overlap the intake and the exhaust valves of #6, then #1 cylinder become the compression state of top dead center. (2) Therefore adjust the valve clearance corresponding to “ “of lower figure. At this time there are no force on the push rods of #1 cylinder.
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    2. MAJOR MAINTENANCE · Install the special tool (compression gauge adapter) at the nozzle holder hole, and connect the compression pressure gauge there. Standard value 28 kg/cm over Standard value 24 kg/cm Difference Within ±10% between each cylinder * Condition: Water temperature 20°C, Engine rotation 200rpm (10 rotations) 2.1.10 Injection nozzle ·…
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    2. MAJOR MAINTENANCE 2.1.13 Air removal of fuel system The suction room of fuel injection pump has the function of air removal continuously during the operation through a relief valve. In case that the suction room lacks fuel at all, for instance, in case of new installation of injection pump, after loosening the air removing screws of cartridge filter respectively, remove the air by operating the manual pump of fuel supply pump until bubble will disappear.
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    2. MAJOR MAINTENANCE 2.2 Diagnosis and Remedy ·The following description summarizes the probable cause of and remedy for generall failure by item. ·Immediate countermeasures should be taken before a failure is inflamed if any symptom is detected.
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    2. MAJOR MAINTENANCE…
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    2. MAJOR MAINTENANCE 2.3 Engine Inspection 2.3.1 Stopping engine After checking the engine for any unusual condition at the idling speed, then turn the key switch to stop the engine. 2.3.2 General engine inspection cycle ○ : Inspection and adjustment ● : Replacement Inspection interval (hours) Check Points Daily…
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    2. MAJOR MAINTENANCE 2.3.3 Use of original parts for repair and replacement For engine is being mechanically harmonized with many parts, only when the original parts that the manufacture recommends to use is used, the engine trouble would be preventively maintained and capable to keep up the maximum performances.
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    3. MAINTENANCE 3. MAINTENANCE 3.1 Engine Disassembly 3.1.1 Heed at disassembly ·Before disassembly, the part shelf should be prepared for various tools and repair parts. ·When assembling, clean empty hand should be used and clean environment maintained. ·In case of storing the disassembled parts, each part should not touch each other. ·In case of disassembly, the parts should be laid in order.
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    3. MAINTENANCE 3.1.4 Engine oil ·Remove the oil drain plug of oil pan and pour the engine oil into the prepared vessel. 3.1.5 Cooling fan ·Remove the flange fixing bolts, then take off the flange and cooling fan. 3.1.6 Belt ·Loosen the tension adjusting bolts of the alternator and the idle pulley, and take off the belts.
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    3. MAINTENANCE 3.1.8 Starter ·Unscrew the starter fixing nuts and remove the starter being careful not to damage its gears. 3.1.9 Fuel filter ·Remove the hollow screws of filter and tear down fuel supply and discharge rubber hose. ·Remove fuel filter fixing bolts and disassemble the fuel filter.
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    3. MAINTENANCE 3.1.12 Alternator ·Remove the alternator assembling bolt and disassemble the alternator. 3.1.13 Oil cooler ·Loosen the cooling water pump and the rubber hose clamps of connected pipes, and disassemble it. ·Remove the oil cooler fixing bolts and take off the oil cooler.
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    3. MAINTENANCE 3.1.16 Air compressor ·Remove the oil pipe between cylinder block and air compressor. ·Unscrew the air compressor fixing bolts and take off the air compressor. 3.1.17 Idle pulley ·Unscrew the idle pulley fixing bolts and take off the idle pulley.
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    3. MAINTENANCE 3.1.20 Fuel injection nozzle ·Unscrew the fuel injection pipe between the injection pump and nozzle and take off the pipe. ·Install a special jig on the nozzle holder, and then pull out the nozzle as striking the hammer of the jig backwardly.
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    3. MAINTENANCE 3.1.23 Intake manifold ·Unscrew the intake manifold fixing bolts and remove the intake manfold from the cylinder head. ·Disassemble the intake manifold gasket and discard it. 3.1.24 Cooling water pipe ·Unscrew the cooling water pipe fixing bolts and remove the cooling water pipe from the cylinder head.
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    3. MAINTENANCE 3.1.26 Cylinder head ·Remove the cylinder head bolts in the reverse order of tightening but remove it step by step. First step : Loosen 1 ~ 2 threads Second step : Remove by loosening fully. ·However, remove the total bolts simultaneously by the step of 1 and 2.
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    3. MAINTENANCE 3.1.27 Oil pan ·Unscrew the oil pan fixing bolts and remove the oil pan. ·Remove the oil pan gasket and discard it. 3.1.28 Vibration damper ·Unscrew the vibration damper fixing bolts in reverse sequence of installing sequence and remove the vibration damper assembly.
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    3. MAINTENANCE 3.1.31 Piston and connecting rod ·Remove the connecting rod cap bolts in the reverse order of assembling but do same as the cylinder head bolt removal. ·Disassemble the upper/lower of connecting rod caps by tapping lightly with urethane hammer, and remove the bearing.
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    3. MAINTENANCE (3) Remove the piston ring with a plier. (4) Clean the piston thoroughly. 3.1.32 Cylinder liner ·Diassemble the cylinder liner with a special tool or hand but be careful not to generate any damage at cylinder block. 3.1.33 Cam shaft gear and idle gear ·Unscrew the camshaft gear fixing bolts and remove the camshaft gear.
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    3. MAINTENANCE ·Unscrew two bolts fixing the idle gear, then remove the idle gear and its pin. 3.1.34 Fuel injection pump ·Disassembly the oil hose for lubrication. ·Remove the bolts and nuts of injection pump flange. ·Unscrew the injection pump fixing bolts and remove the injection pump by lifting it up.
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    3. MAINTENANCE 3.1.36 Fly wheel ·Remove the flywheel fixing bolts and disassemble it. · The bolt removal is done by the reverse order of assembling and by the steps. 3.1.37 Fly wheel housing · Remove the flywheel housing fixing bolts and disassemble the flywheel housing.
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    3. MAINTENANCE 3.1.40 Bearing cap ·Remove the bearing cap assembling bolts by the step in the reverse order of assembling, and disassemble the bearing cap. (Remove by the same way as the cylinder head bolts’ removal.) ·Disassembled bearing caps are kept laid in order. 3.1.41 Crankshaft ·…
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    3. MAINTENANCE 3.1.43 Oil spray nozzle (D1146TI, DE08TIS only) · Remove the valve screws of oil spray nozzle and disassemble it.
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    3. MAINTENANCE 3.2 Inspection and Measurement on Major Parts 3.2.1 Cylinder block ·Clean the cylinder block thoroughly, and check for any crack or damage. ·If there is any crack or severe damage, replace it and if there is minor one, correct it. ·Check for any clogging or corrosion in the oil passage and water passage.
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    3. MAINTENANCE 2) Inspection of cylinder head (1) Check for the cylinder head. ·Remove carbon from the cylinder head lower surface, and then should be careful not to scratch the surface. ·· Check any crack or damage that can not found by naked eyes through the hydraulic or magnetic particle test.
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    3. MAINTENANCE 3) Inspection of valve and valve guide (1) Valve After cleaning valve with fuel, check it. ·Valve stem outer diameter Measure the valve stem outer diameter at 3 positions (top, middle, and bottom), and check for any wear and if beyond the limit value, replace the valve.
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    3. MAINTENANCE ·Assemble the valve at cylinder head’s valve guide and see if it is centered with the valve seat using a special tool. 3) Valve seat ·Contacting face amount As for the valve seat’s wear, measure the width of the contact surface with intake valve seat and exhaust valve seat.
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    3. MAINTENANCE ·For the disassembling of valve seat, by welding the welding bead to a valve seat rotating tool or valve seat, pull it out with a special tool. ·For the assembling of a new valve seat, by putting it among the dry ices of an ice box previously for about 2 hours for the cold shrinkage, and press it in the cylinder head by a special tool.
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    3. MAINTENANCE ·Valve spring tension Use a spring tester to measure the valve spring tension if the measured value is less than the specified limit, the valve spring must be replaced. 5) Assembling cylinder head ·Clean the cylinder head thoroughly. ·Replace the valve stem seal with new one, and by means of a special tool, press the stem seal into the valve guide of cylinder head.
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    3. MAINTENANCE 2) Inspection of rocker arm assembly (1) Rocker arm shaft ·Rocker arm shaft run-out Place the rocker arm shaft on two V blocks and inspect the shaft for bend using a dial gauge. If the amount of this run-out is small, press the shaft with a bench press to correct the run-out Replace the shaft if the measured value exceeds the limit.
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    3. MAINTENANCE (3) Tappet and push rod ·Clearance Measure the clearance of the tappet and tappet holes of the cylinder block. If the value is beyond the specified limit, replace tappets. Standard Limit 0 .035 ~ 0 .07 7 m m 0 .15 m m ·Visual check of tappet Visually check the face of the tappets in contact with…
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    3. MAINTENANCE ·Be careful not to occur any swap of position and reverse assembly. 3.2.4 Camshaft 1) Camshaft end play ·Push the thrust plate toward the cam gear ·With a feeler gauge, measure the clearance between the thrust plate and camshaft journal. ·If the end play is excessive, replace the thrust plate.
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    3. MAINTENANCE 3) Cam shaft · Clearance between camshaft journal and camshaft bush With an outside micrometer, measure the camshaft journal diameter. Measure the inside diameter of the camshaft bushing on the cylinder block using a cylinder bore indicator, and compare the measured value with the camshaft outside diameter to determine the clearance.
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    3. MAINTENANCE ·If the amount of wear is beyond the limit, have the crankshaft ground and install undersize bearings. However, if the amount of wear is within the limit, you can correct the wear using an oil stone or oiled grinding paper of fine grain size.
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    3. MAINTENANCE 2) Crankshaft bearing and connecting rod (1) Visual check ·Visually check the crankshaft bearing and connecting rod bearing for scores, uneven wear or damage. (2) Oil clearance between crankshaft and bearing (Method 1: dial gauge) ·Main bearing clearance Install the main bearing in the cylinder block, tighten the bearing cap to specified torque, then measure the inside diameter.
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    3. MAINTENANCE (3) Oil clearance between crankshaft and bearing (Method 2: plastic gauge) ·Assemble the crankshaft on the cylinder block and put plastic gauge on the journal and pin of crankshaft and then after assembling bearing cap, tighten the bolts at the specific torque.
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    3. MAINTENANCE ·Connecting rod bearing crush Install the bearing and cap in the connecting rod big end, retighten the bolts to specified torque, unscrew out one bolt completely, then measure the clearance between the bearing cap and connecting rod big end using a feeler gauge.
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    3. MAINTENANCE 3.2.6 Piston assembly 1) Disassemby of piston assembly Disassemble piston according to the disassembly process. 2) Piston inspection (1) Visual check Visually check the pistons for cracks, scuff or wear, paying particular attention to the ring groove. (2) Clearance between the piston and cylinder liner ·With an outside micrometer, measure the piston outside diameter at a point 13mm away from the lower end of piston skirt in a direction at a right…
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    3. MAINTENANCE 3) Piston rings (1) Visual check Replace the piston rings with new ones if detected worn or broken when the engine is overhauled. (2) Piston ring gap ·Insert the piston ring into the upper portion of the cylinder liner bore so that it is held at a right angle to the cylinder liner wall.
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    3. MAINTENANCE 4) Piston pin inspection (1) Wear Measure the amount of wear on the piston pin at the points as shown. The measured values are beyond the limit (0.08 mm or greater), replace the pin. (2) Clearance Measure the clearance between the piston pin and connecting rod bushing, and replace either of them, whichever damaged more, if the measured value is beyond the limit.
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    3. MAINTENANCE (2) Holes alignment (parallelism) Measure the alignment of the connecting rod piston pin bushing holes with connecting rod big end holes. At this time also, use both connecting rod tester and feeler gauge. (3) Wear ·Assemble the connecting rod to the crankshaft and measure connecting rod big end side clearance using a feeler gauge.
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    3. MAINTENANCE 3.3 Engine Reassembly 3.3.1 General precautions ·Clean all the disassembled parts, particularly oil and water ports, using compressed air, then check that they are free from restrictions. ·Arrange the general and special tools in order for engine assembly operation. ·To wet each sliding part, prepare the clean engine oil.
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    3. MAINTENANCE ·Apply engine oil to the entire face of the tappets and slide them into the tappet holes on the cylinder block. ·Wet the cam bush inside diameter and camshaft with oil, and carefully assemble them while turning the camshaft.
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    3. MAINTENANCE ·Heat the crankshaft gear for at least 10 minutes to 120°C, then apply sealant (Loctite # 641) to the inside wall of the heated crankshaft gear evenly before inserting it to the end of crankshaft. ·Semi-tighten a bolt at both sides of the crankshaft, apply engine oil to journals and pins, then assemble the crankshaft with the cylinder block by tightening the fixing bolts.
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    3. MAINTENANCE ·Install the bearing cap by matching the cylinder block No. with the bearing cap No. ·Apply oil to the entire part of the bearing cap bolts, then tighten in tightening sequence to specified torque. ·After semi-tightening both bolts evenly, tighten them diagonally to the specified torque using a torque wrench as follows.
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    3. MAINTENANCE ·The flywheel housing is assembled after the new oil seal was pressed (Coat engine oil over the outside of oil seal) before in the housing by a press. ·If any peripheral scar was generated due to oil seal at the oil seal contact surface of crankshaft, after inserting about 1 mm shim or thereabout in front of oil seal (Direction toward crankshaft.), measure and…
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    3. MAINTENANCE ·Install a guide bar into a bolt hole on the crank shaft, and lift the flywheel to align the dowel pin with the pin hole on the flywheel for temporary assembly operation. ·Coat the adhesive (#271 Loctite) over the assembling bolts and install bolts in the remaining holes.
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    3. MAINTENANCE 3.3.10 Water chamber cover · Coat the adhesive over the water chamber cover (Particular around bolt holes) and after attaching the gasket, assemble it to the cylinder block using the bolts for assembling. ·As for tightening of bolts, after primarily tightening the bolts located at the both ends of cover (4ea at both sides) and middle bolts (Upper, lower 2ea) , tighten the rest.
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    3. MAINTENANCE ·Nothing the direction of the piston, make the longer side(machined with key groove on the bearing) of the connecting rod big end. · On the piston head surface, the longer side connecting rod big end is in opposite direction from the valve seating surface as well as in the same direction with the narrow margin of the combustion chamber.
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    3. MAINTENANCE ·Position the valve seating surface toward the tappet hole and insert the piston with hand. Caution: Use care not to damage the cylinder liner and piston, and slightly lift and insert the piston into the cylinder so that the ring may not be damaged by the fillet of the liner.
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    3. MAINTENANCE · When the connecting rod bearing cap bolts are tightened, check the connecting rod end play to the right and left with hand. If no end play is found, remove and reinstall or replace the connecting rod bearing cap. 3.3.13 Timing gear case ·Mount a new gasket using dowel pin on the cylinder block.
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    3. MAINTENANCE ·With the oil port on the idle gear pin facing the cylinder block, install the idle gear pin. · Idler gear pin with oil hole is assembled toward cylinder block. ·Install the idle gear by coinciding the marks impressed on the crank gear, cam gear, fuel injection pump drive gear, and idle gear.
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    3. MAINTENANCE 3.3.16 Fuel injection pump ·Install the injection pump bracket in the cylinder block. · After measuring the amount of run-out with an alignment setting jig, disassemble the bracket, adjust the shims, then reassemble it. ·Mount the top/bottom adjusting shims in the bracket and then mount the fuel injection pump.
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    3. MAINTENANCE (1) As above adjusting method, Please coincide the indication point at the flywheel housing’s inspection hole with the flywheel’s inspection angle. (2) Loosen the drive gear fixing bolt of injection pump a bit. (3) After turning slowly the coupling of injection pump until the fuel will drop from #1 plunger at the rate of a drop for 6 ~ 8 sec., tighten the driving gear fixing bolt of fuel pump.
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    3. MAINTENANCE 3.3.17 Oil pump and oil pipe · Install a dowel pin in the No.7 bearing cap, then assemble the oil pump by tapping lightly with urethane hammer. ·Tighten the assembling bolts with specified torque. ·Assemble the oil suction pipe with the delivery pipe to oil pump by the bolts.
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    3. MAINTENANCE 3.3.20 Water pump ·Mount a new gasket. · Install the water pump on the cylinder block and tighten the assembling bolts with specified torque. ·Connect water pipes and by-pass pipe to the water pump. ·Connect a water pipe to the expansion tank. 3.3.21 Vibration damper ·…
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    3. MAINTENANCE · Assemble the oil pan by tightening the oil pan assembling bolts, and when tightening bolts, primarily tighten the bolts (4ea) at the both ends, and then tighten the rest bolts to specified torque. Caution: Align the bolt holes with gasket holes to prevent damage to the gasket and tighten.
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    3. MAINTENANCE 3.3.26 Intake and exhaust valves ·Identify the marks of “IN” and “EX” impressed on the valve head before assembling the valve with the valve head. ·With a valve stem seal fitting jig, assemble the valve stem seal on the valve guide. ·After installing valve springs and spring retainer, press the retainer with a jig, then install the cotter pin.
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    3. MAINTENANCE ·Check the inside of combustion chamber for foreign substances, and carefully mount the cylinder head assembly in the block by aligning the dowel pin with the dowel pin hole. Caution: Be careful not to damage the cylinder head gasket. If the dowel pin is not in alignment, lift the cylinder head again and then remount it.
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    3. MAINTENANCE 3.3.28 Rocker arm assembly ·Apply lubricating oil to the rocker arm bush and shaft, and assemble the intermediate bracket with the rockerarm (rocker arm assembly) on the cylinder block using fixing bolts. In tightening the bolts, it must be done at the specified value using zigzag method.
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    3. MAINTENANCE ·To adjust the clearance, loosen the locknuts of rocker arm adjusting screws and push the feeler gauge of specified value between a rocker arm and a valve stem (to measure the clearance of the valve and rocker arm contacting part) and adjust the clearance with adjusting screw respectively and then tighten with the lock nut.
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    3. MAINTENANCE 3.3.30 Exhaust manifold ·Install the exhaust manifold gasket over the stud bolts by aligning the gasket with the exhaust port on the cylinder head so that the face and back of the gasket can be positioned correctly. ·Semi-assemble the exhaust manifold and install the heat resisting plate.
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    3. MAINTENANCE 3.3.33 Idle pulley ·Assemble the air compressor mounting bracket on the timing gear case. ·Install the idle pulley on the air compressor mounting bracket and tightening the fixing bolt. 3.3.34 Air compressor & power steering pump · Couple the power steering oil pump to the air compressor with the driving dog engaged.
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    3. MAINTENANCE 3.3.36 Fuel filter ·Assemble the fuel filter with the intake manifold. ·Assemble the fuel feed hose according to the direction of an arrow impressed on the fuel filter head so that fuel can be fed in the sequence of FUEL FEED PUMP FUEL FILTER FUEL INJECTION PUMP.
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    3. MAINTENANCE 3.3.39 Cylinder head cover ·Attach a new gasket on the cylinder head cover. ·Assemble the cylinder head cover to the cylinder head by tightening the cap bolts for fixing the cylinder head cover. Torque 3.1 kg· m ·Assemble the breather and breather hose. ·Fit the oil filler cap on the cylinder head cover.
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    3. MAINTENANCE 3.3.42 Oil level gauge ·Apply sealant (Locktite #262) to the bottom side of the guide tube. ·Then assemble the guide tube and oil level gauge on the oil pan. 3.3.43 Others ·Assemble by connecting the other oil and fuel hoses.
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    3. MAINTENANCE 3.4 BREAKING IN 3.4.1 Preparations for breaking-in Fill of new engine oil through the oil filler cap. ·When measuring the oil level with the oil level gauge with the engine mounted, the oil level must indicate about 10mm above the max. line. ·Connect water hoses and fill up cooling water.
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    3. MAINTENANCE c) Watch the engine water temperature gauge and be sure there is proper water circulation. The water temperature gauge needle will fluctuate if water level in expansion tank is too low. At the end of the break-in period, remove break-in oil and replace the oil filter. Fill oil pan with recommended engine oil.
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    4. MAINTENANCE OF MAJOR COMPONENTS 4. MAINTENANCE OF MAJOR COMPONENTS 4.1 Cooling System 4.1.1 General information This engine is water-cooling type. Heat from the combustion chamber and engine oil heat are cooled down by coolant and radiated to the outside, resulting in the normal operation of the engine. The water absorbing the oil heat and combustion chamber heat goes on to the thermostat through the water pipe, and circulates to the water pump if water temperature is lower than the valve opening temperature on the thermostat, while circulating to the radiator at water temperature higher than the valve…
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    4. MAINTENANCEOF MAJOR COMPONENTS 4.1.3 Thermostat ·General descriptions and main data The thermostat maintains a constant temperature of coolant and improves thermal efficiency of the engine by preventing heat loss. Namely, when the temperature of coolant is low, the thermostat valve is closed to make the coolant bypass to directly enter the water pump;…
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    4. MAINTENANCE OF MAJOR COMPONENTS ·Replacing thermostat and precautions for handling (1) Precautions for handling The wax pallet type thermostat does not react as quickly as bellows type one to a variation of temperature of coolant. Such relatively slow reaction is mainly due to the large heat capacity of the wax pellet type thermostat.
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    4. MAINTENANCEOF MAJOR COMPONENTS 4.1.4 Diagnostics and troubleshooting…
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    4. MAINTENANCE OF MAJOR COMPONENTS 4.2 Lubricating System 4.2.1 General descriptions and specifications ·General descriptions All the engine oil pumped up from the oil pan by the gear type oil pump is filtrated through the oil cooler and oil filter, and this filtrated oil is forced through the main oil gallery in the cylinder block from where it is distributed to lubricate the various sliding parts, and fuel injection pump in order to ensure normal engine performance.
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    4. MAINTENANCEOF MAJOR COMPONENTS 4.2.2 Oil pump ·Disassembly (1) Disassembly of oil pump drive gear a. Unscrew the screw and disassemble the oil relief valve. b. Unfold the washer for the oil pump drive gear fixing nut and remove the nut. c.
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    4. MAINTENANCE OF MAJOR COMPONENTS (3) Measuring clearance between drive shaft and bushing a. Measure the outside diameters of the drive shaft and driven shaft, and replace if the measured values are less than the limit (N16.95mm) b. Measure the inside diameter of the pump body bushing to determine the clearance between the bushing and shaft, and compare the measured value with the standard value to determine whether to replace or not.
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    4. MAINTENANCEOF MAJOR COMPONENTS 4.3 Fuel Injection Pump 4.3.1 General information of fuel system The fuel system consists of the fuel tank, injection pump, injection nozzle, fuel filter, and fuel lines such as pipes and hoses necessary to connect those components. 4.3.2 Injection pump The components relating to the injection pump should be serviced at regular intervals as the plunger and delivery valve may be worn after a given length of time for use and cause the deterioration of the engine.
  • Page 102
    4. MAINTENANCE OF MAJOR COMPONENTS 1) DE08TIS (225PS)
  • Page 103
    4. MAINTENANCEOF MAJOR COMPONENTS (7) Governor adjustment (DE08TIS-225PS)
  • Page 104
    4. MAINTENANCE OF MAJOR COMPONENTS 2) DE08TIS (240PS)
  • Page 105
    4. MAINTENANCEOF MAJOR COMPONENTS (7) Governor adjustment (DE08TIS-240PS)
  • Page 106
    4. MAINTENANCE OF MAJOR COMPONENTS 4.3.4 Fuel feed pump 1) General descriptions and construction The P-type injection pump is mounted with K-ADS or KP type feed pump. These pumps have the same basic construction and operation, and the general descriptions of the KP type pump are given below: The figures show its construction (right figure) and operation (below figure).
  • Page 107
    4. MAINTENANCEOF MAJOR COMPONENTS This feed pump is mounted with a priming pump designed to permit manual feeding of fuel from the fuel tank with the injection pump mounted in the engine. During the manual feeding operation, air must be bled from the fuel lines.
  • Page 108
    4. MAINTENANCE OF MAJOR COMPONENTS 2) Disassembly ·Clamp the feed pump with a vise and disassemble the hollow screw (30, 32), strainer (31) and seal ring (35, 36). ·Take off the priming pump (25), plug (16), both seal rings (18), spring (15), and check valve (14). ·Take off the plug (7), seal ring (8), spring (6), and piston (5) on the piston side.
  • Page 109
    4. MAINTENANCEOF MAJOR COMPONENTS 5) Testing (1) Suction capacity test Connect one end of a hose to the inlet side of the feed pump and immerse the other end of it into the fuel tank as illustrated. Hold the feed pump in position about 1 m above the level of fuel in the fuel tank.
  • Page 110
    4. MAINTENANCE OF MAJOR COMPONENTS 4.3.5 Injection nozzle 1) General descriptions Pressurized fuel delivered from the fuel injection pump is sprayed into the combustion chamber past the injection nozzle at proper spray pressure and spray angle, then burnt completely to achieve effective engine performance.
  • Page 111
    4. MAINTENANCEOF MAJOR COMPONENTS 6) Adjustment ·After reassembly, install the nozzle on a tester. ·With the adjusting screw loosened, operate the nozzle 2 ~ 3 times to bleed it. ·Operate the nozzle tester lever at the specified rate. ·Adjust the injection pressure to the standard pressure by spring tension shims.
  • Page 112
    4. MAINTENANCE OF MAJOR COMPONENTS 4.3.6 Diagnostics and troubleshooting…
  • Page 113
    4. MAINTENANCEOF MAJOR COMPONENTS…
  • Page 114
    4. MAINTENANCE OF MAJOR COMPONENTS 4.4 Turbocharger (D1146TI, DE08TIS) 4.4.1 Main data and specifications 1) Main data and specifications 2) Construction…
  • Page 115
    4. MAINTENANCEOF MAJOR COMPONENTS 3) Operating principle The turbocharger is a system designed to make use of the engine exhaust gas energy to charge high- density air into the cylinders, thereby to increase the engine output. 4.4.2 General descriptions The engine output is determined by the fuel delivery volume and engine efficiency. To burn the supplied fuel completely to change into effective power for the engine, the volume of air enough to burn the fuel completely should be supplied into the cylinders.
  • Page 116
    4. MAINTENANCE OF MAJOR COMPONENTS 4.4.3 Functions 1) Turbine Exhaust gas discharged from the combustion chamber distributes its own energy to the turbine blades while passing the inside of the turbine housing, with the result that the turbine shaft can get rotating force.
  • Page 117
    4. MAINTENANCEOF MAJOR COMPONENTS 4.4.4 Precautions for operation 1) Precautions for operation of engine The following precautions should be observed when starting, operating, or stopping the engine:…
  • Page 118
    4. MAINTENANCE OF MAJOR COMPONENTS 4.4.5 Walk-around check and servicing As the condition of turbocharger depends greatly on how well the engine is serviced, it is very important to maintain the engine in accordance with the specified maintenance procedure. 1) Intake system Pay particular attention to the air cleaner when servicing the intake system.
  • Page 119
    4. MAINTENANCEOF MAJOR COMPONENTS 4.4.6 Periodical checking and servicing Make it a rule to check the turbocharger assembly for condition and contamination periodically. 1) Guide for checking the rotor for rotating condition The inspection of the rotor assembly for rotating condition should be performed by the degree of unusual sound.
  • Page 120
    4. MAINTENANCE OF MAJOR COMPONENTS (3) If the measured axial and radial plays are beyond the limit of wear, replace or repair the turbocharger. 3) Guide for disassembling/cleaning and checking the turbocharger First, disassemble the turbocharger from the engine and clean/check it with the oil inlet and outlet plugged with tape and so on.
  • Page 121
    4. MAINTENANCEOF MAJOR COMPONENTS 4.4.7. Diagnostics and troubleshooting…
  • Page 122
    APPENDIX APPENDIX ·Tightening torque for major parts 1st : 6 kg m 2nd : 90 3rd : 90 4th : 90 5th : 60 (Angle method) ·Tightening torque for fuel injection pump system…
  • Page 123
    3. Special screws should be tightened to 85% or so of the standard value. For example, a screw coated with MoS2 should be tightened to 60% or so of the standard value. ·Tightening torque for hollow screw (4-hole) *: Adopted in DOOSAN engine…
  • Page 124
    APPENDIX ·Maintenance specification table…
  • Page 125
    APPENDIX…
  • Page 126
    APPENDIX…
  • Page 127
    APPENDIX…
  • Page 128
    APPENDIX…
  • Page 129
    APPENDIX…
  • Page 130
    APPENDIX…
  • Page 131
    APPENDIX…
  • Page 133
    950106-080006 Special Tool List…
  • Page 134
    Special Tool List Engine Model Part Number Figure Part Name FR Oil Seal Assembly Jig ● ● 860104-02047 RR Oil Seal Assembly Jig ● ● 860104-04026 Dust Cover ● ● 860104-04070 RR Oil Seal Holder ● 860104-05075 RR Oil Seal Guide ●…
  • Page 135
    Engine Model Part Number Figure Part Name Valve Stem Seal ● ● ● 860104-06509 FR Oil Seal Assembly Ass’y ● 860104-05435 RR Oil Seal Assembly Ass’y ● 860104-05436 Valve Stem Seal ● 860104-03876 RR Wearing Insert ● 860104-03875 CYL Liner Disassembly ●…
  • Page 136
    Engine Model Part Number Figure Part Name FR Oil Seal Assembly Ass’y ● 860104-05438 RR Oil Seal Assembly Ass’y ● 860104-05437 Valve Stem Seal ● 860104-06347 RR Wearing Insert ● 860104-03871 FR Wearing Insert ● 860104-03872 HP Pump Idle Gear ●…
  • Page 137
    Engine Model Part Number Figure Part Name Oil Spray Nozzle Assembly ● 860104-03892 FR Oil Seal Holder ● 860104-02918 FR Oil Seal Guide ● 860104-02919 Valve Stem Seal ● ● 860104-03881 Valve Spring Jig ● 860104-03921 Valve Stem Seal ● 860104-03880 Compression Adapter…
  • Page 138
    Engine Model Part Number Figure Part Name FR Oil Seal Assembly Ass’y ● ● 860104-06469 Valve Spring Jig ● ● 860104-03391 RR Oil Seal Assembly Jig ● 860104-06471 RR Oil Seal Disassembly ● Ass’y 860104-03923 Nozzle Tube Assembly Jig ● 860104-01429 Nozzle Tube Disassembly Jig…
  • Page 139
    Engine Model Part Number Figure Part Name Wearing Insert ● ● 860104-00885 Wearing Insert ● ● 860104-03874 Valve Stem Seal ● 860104-03877 Valve Spring Jig ● 860104-03920 CYL Liner Disassembly ● 860104-03883 Compression Adapter ● 860104-03885 Valve Spring Jig ● ● ● ● ● ● ● ● ● ● ● ● 860104-03391 — 6 -…
  • Page 140
    Engine Model Part Number Figure Part Name Valve Stem Seal ● 860104-03878 Compression Adapter ● 860104-03888 INJ Pump Fix Jig ● 860104-00261 Camshaft Assembly Guide ● 860104-03893 Wearing Insert ● 860104-03873 Flywheel O-ring Assembly Jig ● 860104-03628 FR Oil Seal Assembly Jig ●…
  • Page 141
    Engine Model Part Number Figure Part Name Compression Adapter ● 860104-03884 Piston Ring Assembly Jig 850322-00177 Injector Assembly ● 860104-01908 HP Connector ● EF.120-277 CYL Liner Disassembly ● EF.123-365 FWH Guide Pin ● 860104-04369 FR Oil Seal Assembly Jig ● 860104-06261 — 8 -…
  • Page 142
    Engine Model Part Number Figure Part Name RR Oil Seal Guide 860104-06293 ● RR Oil Seal Holder 860104-04878 Valve Stem Seal ● 860104-06375 Nozzle Tube Assembly Tool ● ● ● ● 860103-01548 Piston Sleeve Jig ● ● ● ● ● ● ● ● ● 860104-01296 Injector Assembly ●…
  • Page 143
    Engine Model Part Number Figure Part Name Compression Pressure Adaptor ● 860104-07064 — 10 -…

Loading…

65.99897-8056 Feb. 2001

MAINTENANCE MANUAL

Diesel Engine

D1146

D1146TI

DE08TIS

PS-MMA0415-E1A

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

FOREWORD

This maintenance manual is designed to serve as a reference for DAEWOO Heavy Industries Ltd’s (here after DAEWOO’s) customers and distributors who wish to gain basic product knowledge on DAEWOO’s D1146, D1146TI and DE08TIS Diesel engine.

This economical and high-performance diesel engine (6 cylinders, 4 strokes, in-line, direct injection type) has been so designed and manufactured to be used for the overland transport or industrial purpose. That meets all the requirements such as low noise, fuel economy, high engine speed, and durability.

To maintain the engine in optimum condition and retain maximum performance for a long time, CORRECT OPERATION and PROPER MAINTENANCE are essential.

In this manual, the following symbols are used to indicate the type of service operations to be performed.

Removal

Adjustment

Installation

Cleaning

Disassembly

Pay close attention-Important

Reassembly

Tighten to specified torque

Align the marks

Use special tools of manufacturer’s

Directional Indication

Lubricate with oil

Inspection

Lubricate with grease

Measurement

During engine maintenance, please observe following instructions to prevent environmental damage;

zTake old oil to an old oil disposal point only.

zEnsure without fail that oil and diesel fuel will not get into the sea or rivers and canals or the ground.

zTreat undiluted anti-corrosion agents, antifreeze agents, filter element and cartridges as special waste.

Printed in Jan. 2001 PS-MMA0415-E1A

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

zThe regulations of the relevant local authorities are to be observed for the disposal of spent coolants and special waste.

If you have any question or recommendation in connection with this manual, please do not hesitate to contact our head office, dealers or authorized service shops near by your location for any services.

For the last, the content of this maintenance instruction may be changed without notice for some quality improvement. Thank you.

DAEWOO Heavy Industries & Machinery LTD.

Feb. 2001

Printed in Jan. 2001 PS-MMA0415-E1A

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

CONTENTS

1. GENERAL INFORMATION

1.1 General Repair Instructions

1

1.2. Engine Specific Character

2

1.3. Engine Specifications

4

1.4. Engine Assembly

8

2. MAJOR MAINTENANCE

2.1. Preventive Maintenance

13

2.2. Diagnosis and Remedy

22

2.3. Engine Inspection

32

3. MAINTENANCE

3.1. Engine Disassembly

33

3.2. Inspection and Measurement on Major Parts

48

3.3. Reassembly

69

3.4. Breaking in

96

4. MAINTENANCE OF MAJOR COMPONENTS

4.1. Cooling System

98

4.2. Lubrication System

102

4.3. Fuel Injection Pump

106

4.4. Turbocharger

122

5. Special Tool List

132

Appendix

134

WORLDWIDE NETWORK

Printed in Jan. 2001 PS-MMA0415-E1A

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

1. GENERAL INFORMATION

1.1.General Repair Instructions

1.Before performing service operation, disconnect the grounding cable from the battery for reducing the chance of cable damage and burning due to short-circuiting.

2.Use covers for preventing the components from damage or pollution.

3.Engine oil and anti-freeze solution must be handled with reasonable care as they cause paint damage.

4.The use of proper tools and special tools where specified is important to efficient and reliable service operation.

5.Use genuine DAEWOO parts necessarily.

6.Used cotter pins, gaskets, O-rings, oil seals, lock washer and self-lock nuts should be discarded and new ones should be prepared for installation as normal function of the parts can not be maintained if these parts are reused.

7.To facilitate proper and smooth reassemble operation, keep disassembled parts neatly in groups. Keeping fixing bolts and nut separate is very important as they vary in hardness and design depending on position of installation.

8.Clean the parts before inspection or reassembly. Also clean oil ports, etc. using compressed air to make certain they are free from restrictions.

9.Lubricate rotating and sliding faces of parts with oil or grease before installation.

10.When necessary, use a sealer on gaskets to prevent leakage.

11.Carefully observe all specifications for bolts and nuts torques.

12.When service operation is completed, make a final check to be sure service has been done property.

1

Printed in Jan. 2001 PS-MMA0415-E1A

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

1.2. Engine Specific Character

1.2.1.Toroidal combustion mode (D1146)

The D1146 engine is operated in the toroidal combustion mode that was developed by this company with AVL Co. Australia.

The feature of this mode in the fundamental structure is that there are combustion chambers in the centers of piston heads and swirling passages in the cylinder heads. This swirling passages when intake stroke generates the strong swirling motion in the combustion chambers by giving the intake air a big moment, and when compression stroke, the special piston’s shapes causing very complicated and distorted flows by means of eddy current and squashed flows will make the air and fuel mix more smoothly.

Also, when explosion stroke, a considerable output increase came to be expected with the accomplishment of nearly perfect combustion by the more smooth mixing of air and fuel which was injected through multi-nozzles in the combustion chamber.

This engine by means of Toroidal Combustion Mode has the specific character such as quiet and stable revolutional motion, multi-purpose application, economical fuel and oil consumption, etc.

1.2.2.OMEGA combustion bowl (D1146TI, DE08TIS)

The OMEGA combustion bowl is a unit designed

M1041A

to perform high efficiency, low emission

combustion. As the rim around the combustion

bowl port of the upper of the piston has been

machined in a smaller size than the interior of the

combustion bowl, strong swirl is produced in the

combustion bowl and strong squish flow makes

the fuel be mixed more sufficiently with air.

Due to the application of OMEGA combustion

system and optimal utilization of intake and

exhaust port configuration within the cylinder

head, the D1146TI, DE08TIS diesel engines

discharge very low level of hazardous exhaust

gases such as smoke, nitrogen oxide,

hydrocarbon, or carbon monoxide and thus

ensure high performance and low fuel

consumption.

2

Printed in Jan. 2001 PS-MMA0415-E1A

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

1.2.3.Oil gallery cooling type piston (DE08TIS)

Oil gallery cooling is used for the piston of DE08TIS diesel engine.

When thermal loading is high, piston cooling by means of an oil gallery in the crown is normally necessary to prevent crown cracking and ring sticking. The design of the gallery, the design and location of the oil spray nozzle and the quantity of oil flowing in the gallery are critical in order to achieve the desired temperature reduction.

The cross section shape of the gallery should be designed to achieve sufficient oil movement to maximize cooling efficiency.

M1255

3

Printed in Jan. 2001 PS-MMA0415-E1A

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

1.3. Engine Specifications

1.3.1. Specification

Engine Model

D1146

D1146TI

DE08TIS

Items

Engine type

4 cycle in-line,

4 cycle

in-line,

Water-cooled type

Water-cooled type

Naturally aspirated

Turbo charged & intercooled

Combustion chamber type

Direct injection type

Cylinder liner type

Replaceable dry liner

Timing gear system

Gear driven type

No. of piston ring

Compression ring 2, oil ring 1

No. of cylinder-bore x stroke

(mm)

6 – 111 × 139

Total piston displacement

(cc)

8,071

Compression ratio

17.5 : 1

16.8 : 1

18.5 : 1

Engine dimension (length x width x height)

(mm)

1,253×811.5×934.5

1,253×812.5×1,009

1,253×812.5×1,009

Engine weight

(kg)

730

745

745

Rotating direction (viewed from flywheel)

Counter clockwise

Fuel injection order

1 – 5 – 3 – 6 – 2 – 4

Fuel injection timing (B.T.D.C static)

15°

Injection pump type

Zexel in-line “AD” type

Zexel in-line “P” type

Governor type

Mechanical governor

Mechanical

governor

type(RLD)

type(RLD-J)

Injection nozzle type

Multi-hole type (5 hole)

Multi-hole type

(7 hole)

Fuel injection pressure

(kg/cm2)

210

214

160/220

Compression pressure

(kg/cm2)

28 (at 200 rpm)

Intake and exhaust valve clearance (at cold) (mm)

0.3

Intake valve

Open at

16° (B.T.D.C)

Close at

36° (A.B.D.C)

Exhaust valve

Open at

46° (B.B.D.C)

Close at

14° (A.T.D.C)

Lubrication method

Full forced pressure feed type

Oil pump type

Gear type driven by crankshaft

Oil filter type

Paper element type

Cartridge type

Lubricating oil capacity (max./min.)

(lit)

15.5/12 or 20/17

Oil cooler type

Water cooled

Water pump

Centrifugal type driven by belt

Cooling Method

Fresh water forced circulation

Cooling water capacity (engine only)

(lit)

14

Thermostat type

Wax pallet type

(79 94 °C or 83 95 °C )

Air compressor type & capacity

(cc)

Belt driven type, 220 or 300

Alternator voltage – capacity

(V – A)

24 – 45 or 24-150

Starting Motor voltage – output

(V — kW)

24 – 4.5

Air heater capacity

(V – A)

22 – 95 (2.1kW)

Battery capacity

(V — AH)

24 — 150

4

Printed in Jan. 2001 PS-MMA0415-E1A

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

1.3.2. Engine power

Production tolerance : ±5%

Engine model

Performance

Injection

Power

Torque

Low idle

High idle

Model

Suffix

timing

Remark

(PS/rpm)

(kg.m/rpm)

(rpm)

(rpm)

(BTDC°)

EACBA

EACBB

D1146

EACBE

15

182/2,500

57.5/1,600

600-650

2750

EACBH

EACBI

EACBK

2370

EAPBA

9

205/2,200

75/1,400

600-650

2,470

D1146TI

EURO-I

2250

EAPCA

9

215/2,300

82/1,400

600-650

2,350

ECPBA

3

225/2,300

82/1,200

600-650

2,530

ECPCA

DE08TIS

EURO-II

ECPBB

3

240/2,300

90/1,200

600-650

2,530

ECPCB

* Note : All data are based on operation without cooling fan at ISO 1585(SAE J1349).

5

Printed in Jan. 2001 PS-MMA0415-E1A

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

1.3.3. Performance curve (DE08TIS – 225PS)

Performance

ISO 1585(SAE J1349)

Output

(max.)

165 kW (225PS) / 2,300 rpm

Torque

(min)

804 N.m (82 kg.m) / 1,200 rpm

Fuel consumption

(min)

192 g/kW.h (141 g / PS.h)

6

Printed in Jan. 2001 PS-MMA0415-E1A

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

1.3.4. Performance curve (DE08TIS – 240PS)

Performance

ISO 1585(SAE J1349)

Output

(max.)

176 kW (240PS) / 2,300 rpm

Torque

(max.)

882 N.m (90 kg.m) / 1,200 rpm

Fuel consumption

(min.)

192 g/kW.h (141 g / PS.h)

7

Printed in Jan. 2001 PS-MMA0415-E1A

Daewoo D1146, D1146, D1146TI, DE08TIS, D1146TI, DE08TIS Service Manual

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

1.4. Engine Assembly

1.4.1. Engine sectional view (longitudinal)

4

5

6

3

7

8

2

9

1

10

11

12

13

14

19

15

16

17

20

18

21

22

23

24

25

26

1

Water pump

2

Piston

3

Air compressor

4

Intake valve

5

Exhaust valve

6

Breather

7

Cylinder head cover

8

Exhaust valve spring

9

Cylinder head

10

Intake valve spring

11

Cylinder block

12

Push rod

13

Flywheel housing

14

Ring gear

15

Tappet

16

Cam shaft

17

Fly wheel

18

Oil seal (Rear)

19

Oil seal (Front)

20

Crank shaft pulley

21

Crank gear

22

Vibration damper

23

Oil pump

24

Oil suction pipe

25

Oil pan

26

Crank shaft

8

Printed in Jan. 2001 PS-MMA0415-E1A

D1146/D1146TI/DE08TIS MAINTENANCE MANUAL

1.4.2. Engine sectional view (cross)

5

4

3

2

1

10

11

12

13

14

15

1

Fuel injection pipe

9

Turbo charger

2

Fuel filter

10

Fuel injection pump

3

Fuel injection nozzle

11

Timing gear case

4

Intake manifold

12

Oil filler cap

5

Air heater

13

Connecting rod

6

Rocker arm

14

Oil spray nozzle

7

Rocker arm bracket

15

Oil filter

8

Exhaust manifold

16

Oil cooler

9

Printed in Jan. 2001 PS-MMA0415-E1A

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

1.4.3.Engine Assembly Views

(1)D1146 (bus)

2

3

4

5

6

7

14

15

16

8 1

9

1

Flywheel housing

8

Oil filler cap

16

Water pump

2

Intake manifold

9

Oil level gauge

17

Exhaust manifold

3

Breather

10

Oil pan

18

Cylinder head cover

4

Air pipe

11

Oil drain plug

19

Crank shaft pulley

(Air cleaner to intake manifold)

12

Oil filter

20

Vibration damper

5

Fuel filter

13

Fuel injection pump

21

Oil cooler

6

Power steering pump

14

Air compressor pulley

22

Starter

7

Air compressor

15

Thermostat

23

Cooling water pipe

10

Printed in Jan. 2001 PS-MMA0415-E1A

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

(2) DE08TIS (Truck)

3

4

5

6

7

8

14

15

16

2

1

9

10

11

12

13

18

19

20

21

28

29

30

17

31

22

23

24

25

26

27

1

Magnetic pick-up sensor

12

Cooling fan

21

Exhaust elbow

2

Flywheel housing

13

Cooling fan guide

22

Crank shaft pulley

3

Intake manifold

14

Air compressor pulley

23

Vibration damper

4

Fuel filter

15

Thermostat

24

Mounting bracket

5

Air pipe

16

Water pump

25

Oil cooler

(Intercooler to intake manifold)

17

Alternator

26

Starter relay

6

Fuel injection pipe

18

Air pipe

27

Starter

7

Air compressor

(Turbocharger to intercooler)

28

Breather

8

Air con. compressor

19

Air pipe

29

Water delivery pipe

9

Oil pan

(Air cleaner to turbocharger)

30

Air heater relay

10

Fuel injection pump

20

Turbocharger

31

Cooling water pipe

11

Oil filter

11

Printed in Jan. 2001 PS-MMA0415-E1A

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

(3) DE08TIS (Bus)

1

2

3

4

5

6

7

8

18

19

20

9 17

10

11 12 13 14 15 16

22

23

24

25

26

28

29

1

Intake manifold

10

Oil level gauge

20

Water pump

2

breather

11

Flywheel housing

21

Exhaust manifold

3

Air pipe

12

Drain plug

22

Belt

(Intercooler to intake manifold)

13

Oil pan

23

Mounting bracket

4

Fuel injection pipe

14

Oil filter

24

Oil cooler

5

Air pipe

15

Fuel injection pump

25

Turbocharger

(Turbocharger to intercooler)

16

Vibration damper

26

Starter

6

Fuel filter

17

Idle gear pulley

27

Cooling water pipe

7

Power steering pump

18

Air compressor pulley

28

Fly wheel

8

Air compressor

19

Thermostat

29

Pilot bearing

9

Oil filler cap

12

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MAINTENANCE MANUAL

2. Major Maintenance

2.1. Preventive Maintenance

The preventive maintenance means that the operator performs the servicing of engine to obtain long life and best performance from DAEWOO diesel engine.

2.1.1. Cooling Water

zRegarding the cooling water that is to be used for engine, the soft water not the hard water must be used.

zThe engine cooling water can be used diluting it with antifreezing solution 40% and the additive for rust prevention (DCA4) 3 5 %.

zThe density of above solution and additive must be inspected every 500 hours to maintain it properly.

NOTE :

The proper density control of antifreezing solution and rust preventing additive will be able to prevent the rusting effectively and maintain the stable quality of engine. For the improper control might give the fatal damage to the cooling water pump and cylinder liners, detail care is needed.

zSince D1146, D1146TI and DE08TIS (diesel engine of D1146 series) cylinder liner is dry type, particularly the cooling water control should be applied thoroughly.

zThe density of antifreezing solution and additive for rust prevention is able to be confirmed by the cooling water test kit. (Fleetguard CC2602M or DAEWOO 60.99901-0038)

zHow to use the cooling water test kit

(1)When the cooling water temp. of engine is in the range of 10 55 °C, loosen the plug for cooling water discharge and fill the plastic cup about a half.

NOTE :

In taking the cooling water sample, if the water in auxiliary tank were taken, it is hard to measure the accurate density. Take the cooling water sample necessarily loosening the cooling water discharge plug.

(2)At the state of a test paper soaked in the sampled water, after taking the paper out through water agitation, shake off the water.

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(3) Wait for about 45 sec. till the color change of test paper.

NOTE :

However, it should not elapse longer than 75 sec, and if it did, the hue would change.

(4)Make the numerical value by comparing the test paper which hue has changed with the color list of label on storage bottle.

(5)By comparing the hue changed into yellowish green or so with the green color indication of test paper storage bottle, confirm the density. (Then, the density indication must be in the hue range of 33% to 50%).

(6)The brown at the middle of test paper and the lower pink color indication represent the additive state for rust prevention, and the proper range is that the meeting numerical value of brown (vertical) and pink color (horizontal) locates in the range of 0.3 to 0.8 at the color list of label on the test paper storage bottle.

(7)In case of less than 0.3, replenish the additive for rust prevention (DCA4), and in case of more than 0.8, pour out the cooling water about 50% and then readjust the density after refilling with clean fresh water.

zAmount of Anti-freeze in winter

Ambient

Cooling water (%)

Anti-freeze (%)

Temperature (°C)

Over -10

85

15

-10

80

20

-15

73

27

-20

67

33

-25

60

40

-30

56

44

-40

50

50

2.1.2. Fan belt

zUse a fan belt of specified dimensions, and replace if damaged, frayed, or deteriorated.

zCheck the fan belt for belt tension.

If belt tension is lower than the specified limit, adjust the tension by relocating the alternator. (specified deflection: 10 15 mm when pressed down with thumb)

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2.1.3. Engine oil

zCheck oil level with the oil level gauge and replenish if necessary.

z Check the oil level with the engine cooled. If the engine is warm, allow time for 510 minutes for oil drain into the crankcase before checking oil level. The oil level must be between Max and Min. lines on the gauge.

zEngine oil should be changed at the specified intervals. Oil filter cartridge should be changed simultaneously.

— First oil change : 1,000km(50 hr) operating

First oil change

After 1,000km (50hr)

operation

Short-distance operation vehicle

D1146/TI

every 10,000km

(city bus, dump truck)

DE08TIS

every 20,000km

Long-distance operation vehicles

D1146/TI

every 15,000km

(express bus, cargo truck)

DE08TIS

every 30,000km

z The following oils are also recommended

Engine

Recommend oil

Remark

model

SAE No.

API No.

D1146

SAE 15W40

above CD or CE

D1146TI

DE08TIS

SAE15W40

ACEA-E2 or ACEA-E3

SAE10W40

(API CH-4)

*If long oil change intervals are to be used, ACEA-E3 oil must be used.

2.1.4.Oil filter

zCheck for oil pressure and oil leaks, and repair or replace the oil filter if necessary.

zChange the oil filter cartridge simultaneously at every replacement of engine oil.

Oil filter head

Oil filter (Cartridge)

G1081

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2.1.5. Fuel filter

zDrain water in cartridge with loosening the

cock under filter manually (6) from time to time.

G1019

2.1.6. Air cleaner.

zIn case that elements are deformed, damaged or if the air cleaner has a crack, replace it.

zBy the definite interval, the elements must be cleaned and replaced.

2.1.7. Intercooler

The intercooler is air to air type and has a large

cooling fan capacity. The intercooler life and

performance depends on the intake air condition greatly. Fouled air pollutes and clogs the air fins of intercooler. As a result of this, the engine output is decreased and engine malfunction is occurred. So you always check whether the intake air systems like air filter

element are worn or polluted.

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Air/air intercooler with radiator (combined radiator)

Air flow by cooling fan

Hot air by turbo charger compressor

Cooled air to intake manifold (max. 50°C)

2.1.8. Valve clearance adjust procedure

zAfter

letting the #1 cylinder’s piston

come at

the compression top dead center by turning

the crankshaft, adjust the valve clearances.

zLoosen the lock nuts of rocker arm

adjusting screws and push the feeler gauge

of specified value between a rocker arm and

a valve stem and adjust the clearance with

adjusting screw respectively and then tighten

with the lock nut.

z As for the valve clearance, adjust it when in

cold, as follows.

Model

Intake Valve

Exhaust Valve

D1146

D1146TI

0.3 mm

0.3 mm

DE08TIS

1) Rotate the crankshaft to overlap the intake

and the exhaust valves of #6, then #1 cylinder

become the compression state of top dead

center.

2) Therefore

adjust the

valve clearance

corresponding to “

of lower figure.

At this time there are no force on the push rods of #1 cylinder.

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3)Rotating the crankshaft by one revolution, #6 cylinder become the compression state of top dead center.

4)Thereafter adjust the valve clearances corresponding to “ of lower figure.

5)After reinsuring the valve clearances, retighten if necessary.

z No. 1 cylinder is located at the side where flywheel was installed.

Flywheel

Intake Valve

Exhaust Valve Cylinder No.

Cooling Fan

G1048

2.1.9. Cylinder compression pressure

zStop the engine after warming up, and

take out nozzle holder assembly.

G1067

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z Install the special tool (compression gauge adapter) at the nozzle holder hole, and connect the compression pressure gauge there.

Standard value

28kg/cm2 over

Limit value

24kg/cm2

Difference

Within ± 10 %

between each cylinder

♦ Condition : Water temperature 20°C,

G1068

Engine rotation 200rpm (10 rotations)

2.1.10. Injection nozzle

z Install a nozzle on the nozzle tester.

zIf the inspected injection pressure is less than the specified value, adjust using the adjusting shims.

Engine Model

D1146

D1146TI

DE08TIS

Opening pressure

210 kg/cm

2

214 kg/cm

2

1st : 160 kg/cm2

2nd : 220 kg/cm2

zCheck the atomizing state and replace it if abnormal.

2.1.11.Fuel injection pump

zCheck the housing crack, damage etc. and replace it if abnormal.

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zCheck if the idle operation and speed regulating lever’s sealing is removed.

z The adjustment and testing of fuel injection pump should necessarily be done at the test bench.

2.1.12. Battery

zInspect for any leakage of electrolytic solution owing to battery crack, and replace

the battery in case of poor condition.

zInspect for amount of electrolytic solution, and replenish if insufficient.

zMeasure the gravity of electrolytic solution, if less than specified value (1.12 1.28), replenish.

2.1.13. Air removal of fuel system

The suction room of fuel injection pump has the function of air removal continuously during the operation through a relief valve.

In case that the suction room lacks fuel at all, for instance, in case of new installation of injection pump, after loosening the air removing screws of cartridge filter respectively, remove the air by operating the manual pump of fuel supply pump until bubble will disappear.

2.1.14. Fuel supply pump

Every time of engine oil replacement, the fuel strainer installed at the fuel supply pump should be removed and cleaned.

2.1.15. Turbocharger

The turbocharger needs not arty special equipment.

Every time of engine replacement, a leakage or clogging of oil pipes should be inspected. Air cleaner should be maintained carefully for nut or foreign material not to get in. Periodic inspection should be applied on the compressed air and exhaust gas

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pipes, For leaking air will bring the overheat engine, an immediate repair must be done.

During the operation that is surrounded by the dust and oil mixed air, frequent cleaning must be done on the impellers. Tear down the impeller casing (attention: be careful not to bend) and must clean with non-acid solvent solution. If necessary, use plastic scraper If impeller is severely polluted, dip the impeller into solution and may be better to clean it with stiff brush.

Then one thing to beware is to dip only impeller part and so do not support by impeller but bearing housing.

2.1.16. Starting motor

In case of engine maintenance, clean pinion and ring gear thoroughly putting in the fuel, and coat them with grease.

Also, In case of washing engine (room) and so forth, inspect the wiring state being careful for water not to get in.

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2.2. Diagnosis and Remedy

zThe following description summarizes the probable cause of and remedy for generall failure by item.

zImmediate countermeasures should be taken before a failure is inflamed if any symptom is detected.

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Check fresh Radiator tank cap

Operating state

1.Overload

2.Radiator core clogged

3.Continuous over-run

Inspect

Radiator

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Causes according to operating conditions

1.Overload

2.Freqent use of low geae position at high speed

3.Freqent use of high geae position at low speed

4.Clutch slip

5.Too low tire inflation pressure

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Cause according to use conditions

1.Excessive oil infusing

2.continuous operation in low speed or extremely cold state

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Condition

Causes

Remedies

1) Starting difficult

(1) Compression pressure lack

z

Valve’s

poor

shut,

stem

Repair or replace

distortion

z

Valve spring damage

Replace valve spring

z Cylinder head gasket’s leak

Replace gasket

z Wear

of

piston, piston

ring

Adjust

or liner

2) Idle operation abnormal

z

Injection timing incorrect

Adjust

z Air mixing at injection pump

Remove air

3) Engine output insufficient

(1) Continuous output

z

Valve clearance incorrect

Adjust

insufficient

z

Valve tightness poor

Repair

z Cylinder head gasket’s leak

Replace gasket

z Wear,

stick,

damage

of

Replace piston ring

piston ring

z

Injection timing incorrect

Adjust

z

Fuel

injection

amount

Adjust injection pump

insufficient

z

Nozzle

injection

pressure

Adjust or replace

improper or stuck

z

Supply

pump’s

function

Repair or replace

lowered

z Fuel pipe system clogged

Repair

z

Air

suction

amount

Clean or replace air

insufficient

cleaner

(2) Output insufficient

z

Turbocharger poor

Repair or replace

z

Compression pressure

Disassemble engine

when in acceleration

insufficient

z

Injection timing incorrect

Adjust

z

Fuel

injection

amount

Adjust injection pump

insufficient

z

Injection

pump

timer’s

Repair or replace

function insufficient

z

Nozzle

infection

pressure,

Repair, replace

infection angle improper

z

Supply

pump’s

function

Repair or replace

lowered

z

Air intake amount

Clean or

insufficient

replace air cleaner

4) Overheating

z

Engine

oil insufficient

or

Replenish or replace

poor

z

Cooling water insufficient

Replenish or replace

z

Fan

belt

loosened,

worn,

Adjust or replace

damaged

z

Cooling

water

pump’s

Repair or replace

function lowered

z

Water

temp.

regulator’s

Replace

operation poor

z

Valve clearance incorrect

Adjust

z

Exhaust system’s resistance

Clean or replace

increased

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Condition

Causes

Remedies

5) Engine noisy

For

noises

arise

compositely

such as rotating parts, lapping

parts etc., there is necessity to

search the cause of noises

(1) Crankshaft

accurately.

z

As the wear of bearing or

Replace bearing &

crankshaft

progress,

the oil

grind crankshaft

clearances increase.

z

Lopsided wear of crankshaft

Grind or replace

z

Oil supply insufficient due to

Clean oil passage

oil passage clogging

z

Stuck bearing

Replace bearing &

(2) Con.-rod and

Grind

z

Lopsided wear of con rod

Replace bearing

Con.-rod bearing

bearing

z

Lopsided wear of crank pin

Grind crankshaft

z

Connecting rod distortion

Repair or replace

z

Stuck bearing

Replace &

grind crankshaft

z

Oil supply

insufficiency as

Clean oil passage

clogging

at oil

passage

(3) Piston, piston pin &

progresses

z

Piston

clearance

increase

Replace piston &

Piston ring

as the wear of piston and

piston ring

piston ring progresses

z

Wear of piston or piston pin

Replace

z

Piston stuck

Replace piston

z

Piston insertion poor

Replace piston

(4) Others

z

Piston ring damaged

Replace piston

z

Wear of crankshaft,

thrust

Replace thrust bearing

bearing

z

Camshaft

end

play

Replace thrust plate

increased

z

Idle gear end play increased

Replace thrust washer

z

Timing

gear

backlash

Repair or replace

excessive

z

Valve clearance excessive

Adjust valve clearance

z

Abnormal

wear

of tappet,

Replace tappet, cam

cam

z

Supercharger

inner

part

Repair or replace

damaged

6) Fuel Consumption

z

Injection timing incorrect

Adjust

Excessive

z

Fuel

injection

amount

Adjust injection pump

excessive

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Condition

Causes

Remedies

7) Oil Consumption

Excessive

(1) Oil level elevated

z

Clearance between cylinder

Replace

liner & piston

z

Wear of piston ring, ring

Replace piston,

groove

piston ring

z

Piston ring’s damage, stick,

Replace piston ring

wear

z

Piston

ring

opening’s

Correct position

disposition improper

z Piston skirt part damaged or

Replace piston

abnormal wear

z

Oil ring’s oil return hole

Replace piston ring

clogged

(2) Oil level lowered

z Oil ring’s contact poor

Replace piston ring

z

Looseness of valve stem &

Replace in set

guide

z Wear of valve stem seal

Replace seal

(3) Oil leak

z Cylinder head gasket’s leak

Replace gasket

z

Looseness of

connection

Replace gasket, repair

parts

z Various parts’ packing poor

Replace packing

z

Oil seal poor

Replace oil seal

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2.3. Engine Inspection

2.3.1. Stopping engine

After checking the engine for any unusual condition at the idling speed, then turn the key switch to stop the engine.

2.3.2. General engine inspection cycle

О : Check & adjust ● : Replace

Inspection

Daily

Inspection time(km)

Remark

1,000

10,000

15,000

20,000

40,000

Check for leakage(hoses, clamp)

О

Cooling

Check the water level

О

System

Check the V-belt tension

О

Change the coolant water

Check for leakage

О

Lubrication

Check the oil level gauge

О

Change the lubricating oil

(О)

System

1st

Replace the oil filter cartridge

(О)

1st

Intake &

Check the leakage for intercooler

О

(hoses, clamp)

Exhaust

Clean and change

О

System

the air cleaner element

Drain the water in separator

О

Clean the fuel strainer

О

of fuel feed pump

Fuel

Check the fuel line leakage

О

Check fuel Injection timing

When

System

necessary

Replace the fuel filter cartridge

Check the injection nozzles

When

necessary

Check the exhaust gas state

О

Engine

Check the battery charging

О

Check the compression pressure

When

Adjust

О

necessary

Adjust Intake/Exhaust

When

valve clearance

necessary

*(О) The engine oil change interval is determine by engine use and oil grade.

2.3.3.Use of original parts for repair and replacement

For engine is being mechanically harmonized with many parts, only when the original parts that the manufacture recommends to use is used, the engine trouble would be preventively maintained and capable to keep up the maximum performances.

For the analogous parts not the original parts are poor in qualities and gives illl performances, it may rather bring early engine failure.

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3. MAINTENANCE

3.1. Engine Disassembly

3.1.1. Heed at disassembly

zBefore disassembly, the part shelf should be prepared for various tools and repair parts.

zWhen assembling, clean empty hand should be used and clean environment maintained.

zIn case of storing the disassembled parts, each part should not touch each other.

zIn case of disassembly, the parts should be laid in order.

3.1.2.Oil level gauge

zPull out the oil level gauge.

3.1.3.Cooling water

zRemove the radiator cap. Open the drain

valve at the radiator lower part to drain the

coolant as the right figure.

CAUTION:

When removing radiator filler cap while

the engine is still hot, cover the cap with a rag,

then turn it slowly to release the internal Drain valve

P1024a

steam pressure. This will prevent a person from scalding with hot steam spouted out from the filler port.

z Remove the drain plug from the cylinder block and drain out the cooling water into a container.

Drain plug

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3.1.4. Engine oil

zRemove the oil drain plug of oil pan and pour the engine oil into the prepared vessel.

3.1.5. Cooling fan

zRemove the flange fixing bolts, then take off the flange and cooling fan.

3.1.6. Belt

zLoosen the tension adjusting bolts of the alternator and the idle pulley, and take off the belts.

3.1.7. Thermostat

zLoosen the rubber hose connected to the cooling water pipe and remove the thermostat.

zRemove the rubber hose of the by-pass line.

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3.1.8. Starter

zUnscrew the starter fixing nuts and remove the starter being careful not to damage its gears.

3.1.9.Fuel filter

zRemove the hollow screws of filter and tear down fuel supply and discharge rubber hose.

zRemove fuel filter fixing bolts and disassemble the fuel filter.

(If the fuel filter is of cartridge type, disassemble the cartridge element only.)

3.1.10. Breather

zLoosen the clamp screw to remove the rubber hose.

3.1.11.Intercooler (D1146TI, DE08TIS)

zTear down the various hoses and air pipes from the inter cooler.

zRemove the intercooler fixing bolts and tear it down.

P068

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3.1.12. Alternator

zRemove the alternator fixing bolts and take off the alternator.

3.1.13. Oil cooler

zLoosen the cooling water pump and the rubber hose clamps of connected pipes, and disassemble it.

zRemove the oil cooler fixing bolts and take off the oil cooler.

3.1.14.Oil filter

zRemove the oil filter fixing bolts and take off the oil filter.

3.1.15. Power steering pump

zRemove the oil hose between power steering oil pump and control unit of the vehicle.

zUnscrew the power steering oil pump fixing bolts and remove the power steering pump.

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3.1.16. Air compressor

zRemove the oil pipe between cylinder block and air compressor.

zUnscrew the air compressor fixing bolts and take off the air compressor.

3.1.17.Idle pulley

zUnscrew the idle pulley fixing bolts and take off the idle pulley

3.1.18. Water pump

zUnclamp the rubber hose connected to the oil cooler.

zUnscrew the water pump fixing bolts from the cylinder block and take off the water pump.

3.1.19.Cylinder head cover

zRemove the head cover fixing bolts and lift the cylinder head cover.

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3.1.20. Fuel injection nozzle

zUnscrew the fuel injection pipe between the injection pump and nozzle and take off the pipe.

zInstall a special jig on the nozzle holder, and then pull out the nozzle as striking the hammer of the jig backwardly.

Take care not to damage the nozzle at disassembly.

zTake out the seal ring from the nozzle hole of the cylinder head and discard it.

3.1.21.Turbo charger (D1146TI, DE08TIS)

zRemove the oil supply pipe and oil return pipe between the turbo charger and the cylinder block.

zUnclamp the rubber hose connected the intercooler and air cleaner.

zUnscrew the turbo charger fixing nuts and take off the turbo charger from the exahust manifold.

3.1.22.Exhaust manifold

zUnscrew the exhaust manifold fixing nuts and remove the heat shield from the exhaust manifold.

zThen disassemble the exhaust manifold and gasket.

zScrap the used gasket.

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3.1.23. Intake manifold

z

Unscrew the intake manifold fixing bolts

and remove the intake manfold from the

Air heater

Intake manifold

cylinder head.

z

Disassemble the intake manifold gasket

and discard it.

3.1.24. Cooling water pipe

z

Unscrew the cooling water pipe fixing

bolts and remove the cooling water pipe

from the cylinder head.

z

Remove the cooling water pipe gasket

and finish the surface with a scraper.

CAUTION :

Be sure that piece of the gasket do

not come into the cooling water

passage.

3.1.25. Rocker arm

z

Remove the rocker arm bracket fixing

bolts in reverse order (zigzag method) of

assembling and disassemble the rocker

arm.

z Take out the push rod upwards.

z Disassembly of rocker arm assembly

G1088

— Remove the snap ring fron the both

ends of rocker arm shaft by means of a

plier.

— Remove the washer, rocker arm,

bracket and spring from the rocker arm

shaf in sequence.

— Press out the rocker arm bush.

G1056

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CAUTION :

When reassembling the bush, cool the bush in dry ice and press the bush while aligning the bush with the oil hole of the rocker arm.

3.1.26. Cylinder head

zRemove the cylinder head bolts in the reverse order of tightening but remove it

step by step.

First step : Loosen 1 2 threads

Second step : Remove by loosening fully.

However, remove the total bolts G1089 simultaneously by the step of 1 and 2.

zLay the removed bolts orderly not to damage the threads at all and store.

CAUTION :

Prevent a collision between the bolt thread each other.

zTake out the cylinder head gasket and scrap it.

zRemove the foreign residues from the cylinder head surface and block surface.

CAUTION :

Try not to make any damage on the contact surfaces.

zDisassembly of cylinder head

Place the cylinder head on a individual shelf.

As pressing the valve spring with a special tool, remove the cotter pin, valve spring.

Take out the intake and exhaust valves.

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G1102

Compress the spring

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MAINTENANCE MANUAL

For removal of the valve seat, apply arc welding work to two points of valve seat insert, and pull out the valve seat insert with inner extractor.

M1072

3.1.27. Oil pan

zUnscrew the oil pan fixing bolts and remove the oil pan.

zRemove the oil pan gasket and discard it.

3.1.28.Vibration damper

zUnscrew the vibration damper fixing bolts in reverse sequence of installing sequence and remove the vibration damper assembly.

G1090

3.1.29. Timing gear case cover

z Disassemble the oil seal using an oil seal removing jig.

zRemove the cover fixing bolts and disassemble the cover from the timing gear case.

41

Printed in Jan. 2001 PS-MMA0415-E1A

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Diesel industrial engine

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Table Of Contents

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  • Contents

  • Table of Contents

  • Troubleshooting

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Table of Contents

1. GENERAL INFORMATION

1.3.2 Engine power

Engine Model

Product

Model

Code

DE08-PBL00

DE08TIS

MBE00

Performance

Power

Torque

(kgf•m/RPM)

(PS/RPM)

217.6/2,000

92/1,300

212/1,800

85/1,400

4

Production tolerance : ±5%

Low Idle

High Idle

(RPM)

(RPM)

850

2,200

1,000

2,000

Remark

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This manual is also suitable for:

De08tis pbl00De08tis mbe00

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Manual for Doosan DE08TIS Series Engine (143 pages)

Specifications:

1760/1760817-de08tis_series.pdf file (14 Jan 2023)

Doosan DE08TIS Series: Read PDF Manual Online

Accompanying Data:

Doosan DE08TIS Series Engine PDF Operation & Maintenance Manual (Updated: Saturday 14th of January 2023 05:45:09 AM)

Rating: 4.3 (rated by 96 users)

Compatible devices: D110S-5, G424FE, G643E, PU158TI, A2300, DV11, G430 LP, D40S-5.

Recommended Documentation:

Doosan DE08TIS Series: Text of Operation & Maintenance Manual

(Ocr-Read Version Summary of Contents, UPD: 14 January 2023)

  • 77, 3. MAINTENANCE 71 ·With the oil port on the idle gear pin facing the cylinder block, install the idle gear pin. · Idler gear pin with oil hole is assembled toward cylinder block. ·Install the idle gear by coinciding the marks impressed on the crank gear, cam gear, fuel injection pump drive gear, and idle gear. ·Install a…

  • 96, 4. MAINTENANCE OF MAJOR COMPONENTS 90 ·Replacing thermostat and precautions for handling (1) Precautions for handling The wax pallet type thermostat does not react as quickly as bellows type one to a variation of temperature of coolant. Such relatively slow reaction is mainly due to the large heat capacity of the wax pellet type thermo…

  • 14, 1. GENERAL INFORMATION 8 1.4.2 Engine sectional view (cross) 9. Turbo charger 1. Fuel injection pipe 2. Fuel filter 10. Fuel injection pump 3. Fuel injection nozzle 4. Intake manifold 11. Timing gear case 12. Oil filler cap 5. Air heater 6. Rocker…

  • 65, 3. MAINTENANCE 59 4) Piston pin inspection (1) Wear Measure the amount of wear on the piston pin at the points as shown. The measured values are beyond the limit (0.08 mm or greater), replace the pin. (2) Clearance Measure the clearance between the piston pin and connecting rod bushing, and replace either of them, whichever…

  • 38, 3. MAINTENANCE 32 3.1.16 Air compressor ·Remove the oil pipe between cylinder block and air compressor. ·Unscrew the air compressor fixing bolts and take off the air compressor. 3.1.17 Idle pulley ·Unscrew the idle pulley fixing bolts and take off the idle pulley. 3.1.18 Water pump ·Unclamp the rubb…

  • 72, 3. MAINTENANCE 66 ·Install a guide bar into a bolt hole on the crank shaft, and lift the flywheel to align the dowel pin with the pin hole on the flywheel for temporary assembly operation. ·Coat the adhesive (#271 Loctite) over the assembling bolts and install bolts in the remaining holes. After that take out the guide bar, then install a b…

  • 140, — 7 — 43 Valve Stem Seal Jig 86 0104-03878 ● 44 Compression Adapter 86 0104-03888 ● 45 INJ Pump Fix Jig 86 0104-00261 ● 46 Camshaft Ass embly Guide 860104-03893 ● 47 Wearing Insert 86 0104-03873 ● 48 Flywheel O-ring Assembly Jig 860104-03628 ● 49 FR Oil Seal Assembly Jig 860104-00932 ● No. Figure Part Number Part Name Engine Model DB58 DE08 DL01 DL02 DL03…

  • 76, 3. MAINTENANCE 70 · When the connecting rod bearing cap bolts are tightened, check the connecting rod end play to the right and left with hand. If no end play is found, remove and reinstall or replace the connecting rod bearing cap. 3.3.13 Timing gear case ·Mount a new gasket using dowel pin on the …

  • 67, 3. MAINTENANCE 61 3.3 Engine Reassembly 3.3.1 General precautions ·Clean all the disassembled parts, particularly oil and water ports, using compressed air, then check that they are free from restrictions. ·Arrange the general and special tools in order for engine assembly operation. ·To wet each sliding part, prepare the clean engine o…

  • 93, 3. MAINTENANCE 87 c) Watch the engine water temperature gauge and be sure there is proper water circulation. The water temperature gauge needle will fluctuate if water level in expansion tank is too low. At the end of the break-in period, remove break-in oil and replace the oil filter. Fill oil pan with recommended engine oil. Refer to fol…

  • 89, 3. MAINTENANCE 83 3.3.36 Fuel filter ·Assemble the fuel filter with the intake manifold. ·Assemble the fuel feed hose according to the direction of an arrow impressed on the fuel filter head so that fuel can be fed in the sequence of FUEL FEED PUMP FUEL FILTER FUEL INJECTION PUMP. 3.3.37 Injection nozzle ·Install a…

DOC-f52844a7:

Doosan DE08TIS Series: Recommended Instructions

Commercial 1750, PT813, ECLIPSE MATRIX, XC2100 Series

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  • –190-10199Z10135 150 175 OptimaxF PEGB2000  90-10199Z10 400          � …

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  • Operator’s ManualBRIGGSandSTRATTON.comECopyright Briggs & Stratton CorporationMilwaukee, Wisconsin 53201 U.S.A.Form No. 276344-9/06Printed in U.S.A.Models Covered in ThisManual Include Gasoline,Natural Gas and LiquidPropane Gas EnginesModel 210000Power BuiltIntekI/CModel 280000IntekI/CExtended Life SeriesModel 310000IntekI/CExtended Life Series …

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  • CREATING POWER SOLUTIONS.OPERATOR’S MANUALDiesel engineHatz Diesel1B30Vwww.HATZ-DIESEL.comINCLUDES SUPPLEMENTAL INFORMATION TO THE OWNER’S MANUAL FOR MODEL YEAR 2018 EPA CERTIFIED NONROAD COMPRESSION-IG-NITION ENGINES.INCLUDES SUPPLEMENTAL INFORMATION FOR THE USE OF EPA CERTIFIED ENGINES WITHIN CALIFORNIA. …

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  • 24 590 44 Rev. AKohlerEngines.comENOwner’s ManualIMPORTANT: Read all safety precautions and instructions carefully before operating equipment. Refer to operating instruction of equipment that this engine powers. Ensure engine is stopped and level before performing any maintenance or service. Warranty coverage as outlined in the warranty card and on Kohle …

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  • [email protected] OPERATOR’S MANUAL INCLUDING: OPERATION, INSTALLATION & MAINTENANCE Form 49999-055 50 SERIES POWER UNIT Model 8133 3200 R.P.M. Edition 3 April 2000 10589471 WARNING READ THIS MANUAL CAREFULLY BEFORE INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT. FAILURE TO OBSERVE THE FOLLOWING WARNINGS COULD RESULT IN INJURY. Pneumatic too …

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  • Introduction of engine OM 471 andexhaust aftertreatmentIntroduction into Service ManualDaimler AG, GSP/OI, HPC R 822, D-70546 StuttgartBestell-Nr. 6517 1260 02 — HLI 000 000 02 82 – Printed in Germany – 09/11Introduction of engine OM 471 and exhaust aftertreatment– This printout will not be recorded by the update service. Status: 09 / 2011 – …

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  • CH18-CH25, CH620-CH730, CH740, CH750Service Manual2 Safety3 Maintenance5 Specications15 Tools and Aids18 Troubleshooting22 Air Cleaner/Intake23 Fuel System29 Governor System31 Lubrication System33 Electrical System49 Starter System58 Clutch60 Disassembly/Inspection and Service75 ReassemblyIMPORTANT: Read all safety precautions and instructions carefully befor …

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  • BDA SEL-Plus-R 06/2008 1Ergänzungsanleitung SEL Plus-R Wichtige Hinweise für die Erstinbetriebnahme der Funkantriebe SEL Plus-R Funktion: Der SEL Plus-R Antrieb fährt gegen den oberen Anschlag der Anlage, deshalb muss eine Endschiene verbaut sein. Unten muss eine Begrenzung montiert sein (Fensterbank), auf die der Rollladen „aufläuft“. Der SEL Plus-R Antrieb sucht im Automati …

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  • Robert Bosch GmbH72757 ReutlingenGermanywww.bosch-ebike.com0 275 007 3D1 (2021.06) T / 51 WEUde Originalbetriebsanleitungen Original operating instructionsfr Notice d’utilisation d’originees Instrucciones de servicio originalespt Manual de instruções originalit Istruzioni d’uso originalinl Oorspronkelijke gebruiksaanwijzingda Original brugsanvisningsv Originalbruksanvisningno …

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Additional Information:

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Издательство: © «Motorist»

ISBN: 978-039-000-329-4

Количество страниц: 146

Формат: файл PDF

О руководстве

Тип двигателя: Daewoo D1146 / D1146TI / DE08TIS

В руководстве вы найдете

  • Пошаговое руководство по ремонту различных узлов и агрегатов
  • Инструкцию по самостоятельному уходу и обслуживанию
  • Сведения о конструкции двигателя и о том как предупредить неисправность
  • Информацию для поездки на СТО, если самостоятельный ремонт невозможен

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Общая информация

  • Общие инструкции по ремонту
  • Специфика двигателя
  • Технические характеристики двигателя
  • Сборка двигателя

Капитальный ремонт двигателя

  • Профилактика
  • Диагностика и устранение неисправностей
  • Осмотр двигателя

Техническое обслуживание

  • Разборка двигателя
  • Осмотр основных деталей
  • Повторная сборка
  • Обкатка

Обслуживание основных компонентов

  • Система охлаждения
  • Система смазки
  • Топливный насос высокого давления
  • Турбокомпрессор

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