De08tis руководство по ремонту

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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…
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  2. MAJOR MAINTENANCE…
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  2. MAJOR MAINTENANCE…
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  2. MAJOR MAINTENANCE…
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  2. MAJOR MAINTENANCE…
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  2. MAJOR MAINTENANCE…
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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.
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  4. MAINTENANCE OF MAJOR COMPONENTS 1) DE08TIS (225PS)
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  4. MAINTENANCEOF MAJOR COMPONENTS (7) Governor adjustment (DE08TIS-225PS)
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  4. MAINTENANCE OF MAJOR COMPONENTS 2) DE08TIS (240PS)
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  4. MAINTENANCEOF MAJOR COMPONENTS (7) Governor adjustment (DE08TIS-240PS)
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  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).
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  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.
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  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.
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  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.
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  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.
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  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.
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  4. MAINTENANCE OF MAJOR COMPONENTS 4.3.6 Diagnostics and troubleshooting…
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  4. MAINTENANCEOF MAJOR COMPONENTS…
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  4. MAINTENANCE OF MAJOR COMPONENTS 4.4 Turbocharger (D1146TI, DE08TIS) 4.4.1 Main data and specifications 1) Main data and specifications 2) Construction…
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  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.
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  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.
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  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:…
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  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.
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  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.
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  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.
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  4. MAINTENANCEOF MAJOR COMPONENTS 4.4.7. Diagnostics and troubleshooting…
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  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…
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  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…
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  APPENDIX ·Maintenance specification table…
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  APPENDIX…
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  APPENDIX…
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  APPENDIX…
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  APPENDIX…
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  APPENDIX…
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  APPENDIX…
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  APPENDIX…
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  950106-080006 Special Tool List…
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  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 ●…
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  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 ●…
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  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 -…

65.99897-8056 Feb. 2001

MAINTENANCE MANUAL

Diesel Engine

D1146

D1146TI

DE08TIS

1.4.2. Engine sectional view (cross)

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Printed in Jan. 2001 PS-MMA0415-E1A

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

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

z The following oils are also recommended

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

2.1.4.Oil filter

Oil filter head

Oil filter (Cartridge)

G1081

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Printed in Jan. 2001 PS-MMA0415-E1A

Check fresh Radiator tank cap

Inspect

Radiator

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Printed in Jan. 2001 PS-MMA0415-E1A

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

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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Printed in Jan. 2001 PS-MMA0415-E1A

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

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.

1. Manuals
2. Brands
3. Doosan Manuals
4. Engine
5. DE08TIS Series
6. Operation & maintenance manual

Diesel industrial engine

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