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Doosan DE08TS, Manual

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Doosan DE08TS Manual Download Page 77

DE08TS Diesel Engines

Maintenance of Major Components

Fuel Injection Pump

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 com-
ponents.

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.

Make sure that servicing should be performed at the
professional maintenance shop as authorized by
Bosch or Zexel Company.

For adjustment of fuel injection volume, refer to the
‘Specifications of fuel injection pump’ described on the
following pages.

75

2

3

8

9

4

7

12

10

11

5

1

6

1a

1. Fuel filter

1a. Water separater

2. Air bleeding screw (for fuel filter)
3. Injection nozzle
4. Overflow tube 
5. Fuel pipe (filter     injection pump)
6. Overflow valve
7. Fuel injection pipe
8. Fuel pipe (manual pump     filter)
9. Fuel tank

10. Fuel return pipe
11. Suction pipe
12. Feed pump
13. Injection pump

Summary of Contents for DE08TS

Page 1: ...DE08TS Diesel Engine Specification System Operation Testing Adjusting D100 D120 D150 D110S 5 D130S 5 D160S 5 SB4097E02 Sep 2011 ...

Page 2: ......

Page 3: ...llowing symbol Improper operation lubrication maintenance or repair of this product can be dangerous and could result in injury or death Do not operate or perform any lubrication maintenance or repair on this product until you have read and understood the operation lubrication maintenance and repair information Operations that may cause product damage are identified by NOTICE labels on the product...

Page 4: ......

Page 5: ... 29 Water pump 29 Cylinder head cover 30 Fuel injection nozzle 30 Turbo charger 30 Exhaust manifold 30 Intake manifold 31 Cooling water pipe 31 Rocker arm 31 Cylinder head 32 Oil pan 32 Vibration damper 33 Timing gear case cover 33 Oil pump 33 Piston and connecting rod 33 Cylinder liner 34 Camshaft gear and idle gear 34 Fuel injection pump 35 Water chamber cover 35 Fly wheel 35 Fly wheel housing 3...

Page 6: ... points for break in 68 Maintenance of Major Components Cooling System 69 General information 69 Specifications 70 Thermostat 70 Diagnostics and troubleshooting 71 Lubrication System 72 General descriptions and Specifications 72 Oil pump 73 Diagnostics and troubleshooting 74 Fuel Injection Pump 75 General information of fuel system 75 Injection pump 75 Fuel feed pump 80 Injection nozzle 84 Diagnos...

Page 7: ...tion 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 ser...

Page 8: ... D C static 9 Injection pump type Bosch in line AD Type Governor type Mechanical governor pe RSV Injection nozzle type Multi hole type 8 hole Fuel injection pressure kg cm2 180 280 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 Ful...

Page 9: ...Note All data are based on operation without cooling fan at KS R1004 7 Engine model Condition Injection Power Torque Low idle High idle Model Suffix timing Ps rpm kg m rpm rpm rpm Remark BTDC ECDFA 9 140 2 200 55 1 400 750 2 370 TIER II DE08TS ECDFB 9 160 2 200 63 1 400 750 2 370 STAGE II ...

Page 10: ...nce curve DE08TS 140PS 8 50 100 150 1000 1400 1800 2200 150 160 170 180 45 50 55 POWER OUTPUT PS TORQUE kg m FUEL CONSUMPTION g ps h REVOLUTION rpm Standard KS R1004 Rated Power 140 ps 2 200 rpm Max Torque 55 kg m 1 400 rpm Fuel consumption 180 g PS h ...

Page 11: ...ormance curve DE08TS 160PS 9 Standard KS R1004 Rated Power 160 ps 2 200 rpm Max Torque 63 kg m 1 400 rpm Fuel consumption 180 g PS h 100 150 1000 1400 1800 2200 65 60 55 150 160 170 POWER OUTPUT PS TORQUE kg m FUEL CONSUMPTION g ps h REVOLUTION rpm ...

Page 12: ... compressor if equipped 12 Push rod 21 Crank shaft gear 4 Intake valve 13 Flywheel housing 22 Vibration damper 5 Exhaust valve 14 Ring gear 23 Oil pump 6 Breather 15 Tappet 24 Oil suction pipe 7 Cylinder head cover 16 Cam shaft 25 Oil pan 8 Exhaust valve spring 17 Fly wheel 26 Crank shaft 9 Cylinder head 18 Oil seal Rear 10 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 26 25 24 23 22 21 20 19 1 2 3 EB5O1...

Page 13: ...9 Turbo charger 2 Fuel filter 10 Fuel injection pump 3 Fuel injection nozzle 11 Timing gear case 4 Intake manifold 13 Connecting rod 5 Air heater 14 Oil spray nozzle 6 Rocker arm 15 Oil filter 7 Rocker arm bracket 16 Oil cooler 8 Exhaust manifold 11 EB5O1005 5 4 3 2 1 10 11 13 14 15 16 9 8 7 6 ...

Page 14: ...xhaust 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 7 Air compressor if equipped 14 Air compressor pulley 22 Starter 15 Thermostat 12 2 5 8 4 7 15 16 14 13 12 17 18 3 22 9 21 20 19 11 10 1 ...

Page 15: ... 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 mea sure the accurate density Take the cooling water sample necessarily loosening the cooling water discharge plug b A t the state of a test paper soaked in the sam pled water after taking the paper out through water agitation s...

Page 16: ...level gauge and replen ish if necessary 2 Check the oil level with the engine cooled If the engine is warm allow time for 5 10 minutes for oil drain into the crankcase before checking oil level The oil level must be between Max and Min lines on the gauge 3 Engine oil should be changed at the specified intervals Oil filter cartridge should be changed simultane ously a First oil change 50 hr operati...

Page 17: ...dure 1 After letting the 1 cylinder s piston come at the compression top dead center by turning the crank shaft adjust the valve clearances 2 Loosen 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 respec tively and then tighten with the lock nut 3 As for the valve clearance...

Page 18: ... correspond ing to of lower figure e After reinsuring the valve clearances retighten if necessary Cylinder compression pressure 1 Stop the engine after warming up and take out noz zle holder assembly 2 Install the special tool compression gauge adapter at the nozzle holder hole and connect the compression pressure gauge there Condition Water temperature 20 C Engine rotation 200rpm 10 rotations EFM...

Page 19: ...should be removed and cleaned Turbocharger The turbocharger needs not arty special equipment Every time of engine replacement a leakage or clog ging 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 com pressed air and exhaust gas pipes For leaking air will bring the overheat engine an ...

Page 20: ...ent Check compression pressure Normal Too low Inspect of other parts Check valve clearance Normal Adjust Check cylinder head gasket Replace Normal Engine disassembly valve assembly piston cylinder liner etc Fuel Inspect amount of fuel None Replenish Inspect fuel injection No injection Continuous operation after air removal Inspect injection timing Inspect injection nozzle injection pressure inject...

Page 21: ...nspect radiator Repair Replace Repair Replace Repair Replace Repair Replace Replenish Replace Replace Damage Check cooling water pump Engine disassembly Fuel unit Inspect fuel quality Poor Clean and replace with specified fuel Inspect cooling water leakage External Internal Retighten Replace Engine disassembly Operating state 1 Overload 2 Radiator core clogged 3 Continuous over run Fuel excessive ...

Page 22: ... state Adjust Replace Check injection timing Adjustment Disassemble engine or injection pump Inspect injection pipe Check turbocharger Repair Replace Disassemble injection pump or engine Others Inspect air cleaner Clean Relpace Inspect engine control rod link cable etc Adjust Adjust Inspect cylinder head gasket for damage Engine disassembly valve assembly Check valve clearance Installation imprope...

Page 23: ...k oil amount Normal Normal Normal Normal Check cooling temperature Inspect oil quality Check oil relief valve Disassemble engine Too high Refer to engine overheat Water fuel mixed in oil Disassemble engine or injection pump Improper Replace with recommended oil Too low Use recommended oil replenish Retighten Replace ...

Page 24: ...essure Disassemble injection pump Inspect head gasket Disassemble engine valve assembly piston cylinder liner etc Adjust Replace Adjust Adjust Check valve clearance Replace Causes according to Use Conditions 1 Overload 2 Frequent use of low gear position at high speed 3 Frequent use of high gear position at low speed 4 Clutch slip 5 Too low tire inflation pressure Oil leakage Retighten Replace Rep...

Page 25: ...kage External Internal Retighten Replace Check compressed pressure Engine disassembly piston cylinder liner Disassemble cylinderhead valve stem seal Inspect air cleaner Clean Replace 7 Engine Knocking Inspect combustion of fuel oil carbon residue exhaust gas Unconfirmed Inspect compressed pressure Inspect injection pump Adjust Check fuel quality Use specified fuel Too low Check valve clearance and...

Page 26: ...nd loose connections Repair Replace Generator Check fan belt tension damage Normal Normal Electrolytic liquid s standard Replenish Battery room damage Replace Battery self discharge Charging Battery over charging Inspect generator Voltage regulator Check charged stated Discharging Disassemble generator Voltage regulator Abnormal Adjust Replace ...

Page 27: ... stuck Supply pump s function lowered Repair or replace Fuel pipe system clogged Repair Air suction amount insufficient Clean or replace air cleaner Turbocharger poor Repair or replace 2 Output insufficient when Compression pressure insufficient Disassemble engine in acceleration Injection timing incorrect Adjust Fuel injection amount insufficient Adjust injection pump Injection pump timer s funct...

Page 28: ...n ring damaged Replace piston 4 Others Wear of crankshaft thrust bearing Replace thrust bearing Camshaft end play increased Replace thrust plate Idle gear end play increased Replace thrust washer Timing gear backlash excessive Repair or replace Valve clearance excessive Adjust valve clearance Abnormal wear of tappet cam Replace tappet cam Turbocharger inner part damaged Repair or replace 6 Fuel Co...

Page 29: ... disassembly the parts should be laid in order Oil level gauge 1 Pull out the oil level gauge Engine oil 1 Remove the oil drain plug of oil pan and pour the engine oil into the prepared vessel Cooling fan 1 Remove the flange fixing bolts then take off the flange and cooling fan Belt 1 Loosen the tension adjusting bolts of the alternator and the idle pulley and take off the belts Thermostat 1 Loose...

Page 30: ...l filter fixing bolts and disassemble the fuel filter If the fuel filter is of cartridge type disassemble the cartridge element only Breather 1 Loosen the clamp screw to remove the rubber hose Alternator 1 Remove the alternator assembling bolts and dis assemble the alternator Oil cooler 1 Loosen the cooling water pump and the rubber hose clamps of connected pipes and disassemble it 2 Remove the oi...

Page 31: ...il pipe between cylinder block and air compressor 2 Unscrew the air compressor fixing bolts and take off the air compressor Idle pulley 1 Unscrew the idle pulley fixing bolts and take off the idle pulley Water pump 1 Unclamp the rubber hose connected to the oil cooler 2 Unscrew the water pump fixing bolts from the cylinder block and take off the water pump EA9M3006 29 ...

Page 32: ...the nozzle at disassem bly 3 Take out the seal ring from the nozzle hole of the cylinder head and discard it Turbo charger 1 Remove the oil supply pipe and oil return pipe between the turbo charger and the cylinder block 2 Unclamp the rubber hose connected the intercool er and air cleaner 3 Unscrew the turbo charger fixing nuts and take off the turbo charger from the exahust manifold Exhaust manif...

Page 33: ... gasket do not come into the cooling water passage Rocker arm 1 Remove the rocker arm bracket fixing bolts in reverse order zigzag method of assembling and disassemble the rocker arm 2 Take out the push rod upwards 3 Disassembly of rocker arm assembly a Remove the snap ring fron the both ends of rocker arm shaft by means of a plier b Remove the washer rocker arm bracket and spring from the rocker ...

Page 34: ...from the cylinder head surface and block surface Try not to make any damage on the contact sur faces Disassembly of cylinder head a Place the cylinder head on a individual shelf b As pressing the valve spring with a special tool remove the cotter pin valve spring c Take out the intake and exhaust valves d For removal of the valve seat apply arc welding work to two points of valve seat insert and p...

Page 35: ...3 Unscrew the oil pump fixing bolts and disassem ble the oil pump Piston and connecting rod 1 Remove the connecting rod cap bolts in the reverse order of assembling but do same as the cylinder head bolt removal 2 Disassemble the upper lower of connecting rod caps by tapping lightly with urethane hammer and remove the bearing 3 By pushing the connecting rod with wooden bar from the direction of oil...

Page 36: ...round wooden bar 3 Remove the piston ring with a plier 4 Clean the piston thoroughly Cylinder liner 1 Diassemble the cylinder liner with a special tool or hand but be careful not to generate any damage at cylinder block Cam shaft gear and idle gear 1 Unscrew the camshaft gear fixing bolts and remove the camshaft gear 2 Unscrew the camshaft gear fixing bolts and remove the camshaft gear EAMD087I EA...

Page 37: ...r chamber cover 1 Unscrew the fixing bolts and remove the water chamber cover 2 Remove the remnant gasket thoroughly Fly wheel 1 Remove the flywheel fixing bolts and disassemble it 2 The bolt removal is done by the reverse order of assembling and by the steps Fly wheel housing 1 Remove the flywheel housing fixing bolts and dis assemble the flywheel housing 2 Disassemble the oil seal of flywheel ho...

Page 38: ...eful not to give any damage on it 3 In order for the disassembled crankshaft to be pre vented from bends or damage put it on the spe cial lathe and store 4 Disassemble the metal bearings in turn and store them NOTE Do not mingle with the metal bearings and bearing caps randomly To prevent mixing temporari ly assemble the metal bearings to the corresponding bearing caps in turn Camshaft and tappet ...

Page 39: ... any damage on the contact sur faces b Disassemble the cotter pin spring spring seat pushing valve spring by a special tool c Pull out the intake and exhaust valves d The disassembled parts are kept laid in turn e Disassemble the valve stem seal f By means of the special tool punch pull out a valve guide 2 Inspection of cylinder head a Check for the cylinder head Remove carbon from the cylinder he...

Page 40: ... and if beyond the limit value replace the valve Valve seat contacting faces Check the valve seat contact surface for any crack and wear and if necessary correct with grinding paper and if excessive replace it Valve head thickness Measure the thickness of valve head and if beyond the limit value replace the valve EFM2037I EFM2036I End of stem EA9M3020 38 Standard Limit Warpage 0 2 mm or less 0 3 m...

Page 41: ... depression If the amount of depression is beyond the specified limit replace the valve seat 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 ...

Page 42: ...ess the stem seal into the valve guide of cylinder head Coat engine oil to valve stem and valve guide and assemble the valve However be careful for the damage of valve stem seal Install the lower seat of valve spring to the valve guide of cylinder head After putting inner outer springs install the spring upper seat on it Assemble the valve by inserting the valve cotter pressing the valve spring wi...

Page 43: ... diameter at the point where the rocker arms have been installed Replace the rocker arm if the amount of wear is beyond the specified limit b Rocker arm Visual check Visually check the face of the rocker arm in contact with the valve stem end for scores and step wear If the wear is small correct it with an oil stone or grind ing paper of fine grain size Rocker arm with a con siderable amount of st...

Page 44: ... measure the push rod run out Roll the push rod along a smooth flat surface as shown in the figure d Reassembling rocker arm assembly Reassembling can be done in the reverse order of disassembling and following things should be heed ed Check the oil supply hole of rocker arm shaft for any clog and clean thoroughly Be careful not to occur any swap of position and reverse assembly Camshaft 1 Camshaf...

Page 45: ... value with the camshaft outside diameter to determine the clearance Clearance Replace the bushing if the measured value is beyond the specified limit Run out Support the camshaft on two V blocks and check for run out using a dial indicator Correct or replace the cam shaft if the amount of run out is beyond the value indicating need for servicing Crankshaft 1 Inspection of crankshaft a Defect chec...

Page 46: ...aper which has been immersed in oil Undersize bearings available Standard 0 25 Inside diameter is 0 25 mm lesser than the standard size 0 50 Inside diameter is 0 50 mm lesser than the standard size 0 75 Inside diameter is 0 75 mm lesser than the standard size 1 00 Inside diameter is 1 00 mm lesser than the standard size Undersize bearings are available in 4 different sizes as indicated above and t...

Page 47: ...ankshaft journals to determine the oil clearance Main bearing oil clearance Connecting rod bearing clearance Install the connecting rod bearing in the connecting rod bearing cap tighten the connecting rod cap bolts to the specified torque then measure the inside diameter Compare the two values obtained through measure ment of connecting rod bearing inside diameter with the outside diameters of cra...

Page 48: ...haft bearing crush Install the bearing and cap in the cylinder block retighten the bolts to specified torque unscrew out one bolt completely then measure the clearance between the bearing cap and cylinder block using a feeler gauge 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 meas...

Page 49: ... the largest and small est values excepted The clearance is computed by subtracting the pis ton outside diameter from the cylinder liner inside diameter Replace either piston or cylinder liner whichever damaged more if the clearance is beyond the specified limit Clearance between piston and liner 3 Piston rings a Visual check Replace the piston rings with new ones if detected worn or broken when t...

Page 50: ...hem whichever damaged more if the measured value is beyond the limit c Condition check Check the engaged condition of the piston and piston pin If it is possible to force the pin into the piston heated with piston heater the piston is normal When replacing the piston be sure to replace the piston pin together 5 Connecting rod inspection a Distorsion Check the connecting rod for distortion As shown...

Page 51: ...nd special tools in order for engine assembly operation 3 To wet each sliding part prepare the clean engine oil 4 Prepare service materials such as sealant gaskets etc 5 Discard used gaskets seal rings and consumable parts and replace with new ones 6 Apply only the specified torque for bolts in the spec ified tightening order and avoid over tightening 7 Be sure to check that all the engine parts o...

Page 52: ...nd carefully assemble them while turning the camshaft Be careful not to generate a damage to camshaft and bush 4 Check to see that the camshaft rotates smoothly Crankshaft 1 Install the main bearing refer to assemble sequence right figure machined with two holes in the cylinder block so that the key is aligned with the key groove then apply oil to the bearing surface 2 Heat the crankshaft gear for...

Page 53: ...the entire part of the bearing cap bolts then tighten in tightening sequence to specified torque 8 After semi tightening both bolts evenly tighten them diagonally to the specified torque using a torque wrench as follows Tightening order a First stage Coat the cap bolts with engine oil b Second stage Temporary bolt screwing about 1 2 threads c Third stage With impact wrench tighten up to about 15 k...

Page 54: ...ontact surface of crankshaft after inserting about 1 mm shim or thereabout in front of oil seal Direction toward crankshaft measure and adjust Oil seal Rear side 1 Apply lubricating oil to the outside of the oil seal and flywheel housing inside diameter and fit them over the crank shaft then assemble the oil seal using an oil seal fitting jig Flywheel Installation of flywheel ring gear With a gas ...

Page 55: ...e the pick up sensor for 270 gap 1 0 mm and fix lock nut 10 Tolerance limit is 27 gap L 0 1 mm Water chamber cover 1 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 2 As for tightening of bolts after primarily tightening the bolts located at the both ends of cover 4ea at both...

Page 56: ...amber 5 Install the snap rings and check to see that it is securely assembled 6 Install the piston ring in the piston using piston ring pliers 7 Identify the mark Y or TOP on the ring end to prevent the top and bottom of the piston ring from being interchanged and make the marked portion face upward The surface marked as Y is upper surface 8 Adjust the angle among individual piston ring gaps to 90...

Page 57: ...rd stage With torque wrench tighten up to about 10 kg m 4 Fourth stage With torque wrench tighten up to about 15 kg m 5 Fifth stage By means of torque wrench tighten finally in the specified torque 18 kg m 13 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 con necti...

Page 58: ...he amount of backlash between gears using a feeler gauge Injection pump flange 1 After assembling the fuel injection pump gear to the idle gear tighten the assembling bolts of the injection pump flange 2 Mount gasket by aligning the bolt holes with the pin holes on the bearing housing 3 Turning the flywheel adjust the pointer to the posi tion of the engraved scale 4 After adjusting the injection t...

Page 59: ...the valve and valve spring again assemble the valve holder and then on it assemble the pipe of U shape on it 8 Operating the priming pump of supply pump turn the crankshaft slowly in the direction of engine rotation until the fuel will drop at the rate of a drop for 6 8 sec 9 Confirm then whether the indication point at the flywheel housing inspection hole and the engraved specified injection angl...

Page 60: ...ht tap 4 Tighten the fixing bolts beginning with the oil pan fitting face In the assembling be careful not to be damaged by the crankshaft Front oil seal 1 Apply lubricating oil to the outside of the oil seal and the oil seal hole of the timing gear case cover 2 Put the new oil seal on the oil seal hole of timing gear case cover aligning the center of them then assemble the oil seal using an oil s...

Page 61: ...k 2 Coat the silicone at the gasket part that was removed Contacting part and attach the new oil pan gasket 3 Assemble the oil pan by tightening the oil pan assembling bolts and when tightening bolts pri marily tighten the bolts 4ea at the both ends and then tighten the rest bolts to specified torque Align the bolt holes with gasket holes to prevent damage to the gasket and tighten Oil filter 1 In...

Page 62: ...heel housing Intake and exhaust valves 1 Identify the marks of IN and EX impressed on the valve head before assembling the valve with the valve head 2 With a valve stem seal fitting jig assemble the valve stem seal on the valve guide 3 After installing valve springs and spring retainer press the retainer with a jig then install the cotter pin 4 Tap the valve stem lightly with a rubber hammer to ch...

Page 63: ... the cylinder head gasket should be changed a new one 5 Coat the cylinder head bolts with engine oil and tighten in proper sequence to the specified torque according to bolt tightening order refer to the fig ure Cylinder head bolts 6 However before tightening bolts the side parallel degree between cylinder heads should be adjust ed Tightening order of bolts by steps 1 First stage Coat the bolts wi...

Page 64: ...s In tightening the bolts it must be done at the specified value using zigzag method 2 Semi install valve clearance adjusting bolts onto the rocker arm 3 Install the spring rocker arm bracket rocker arm spring washer and snap ring in the described sequence 4 Install the rocker arm and bracket in the same direction 5 Adjust the valve clearance as following guide EA8M3008 EB1M3026 62 Torque M10 B 1 ...

Page 65: ...f 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 d As for the valve clearance adjust it when in cold a Crankshaft revolution is done by hands with out using a starting motor b Turn it to the direction of engine rotation but do not...

Page 66: ...ositioned correctly 2 Semi assemble the exhaust manifold and install the heat resisting plate 3 Assemble them by tightening the assembling bolts The tightening order of bolts is from the mid dle to left and right alternately For upper and lower bolts differ in the length so use the correct bolts Turbocharger 1 Fit a new gasket over the stud bolts of the exhaust manifold before tightening those tur...

Page 67: ... compressor if equipped power steering pump 1 Couple the power steering oil pump to the air compressor with the driving dog engaged 2 Insert the O ring coated with grease into the oil outlet of the air compressor 3 Place the air compressor on the mounting bracket carefully and tighten the fixing bolts to the speci fied torque Carefully damage the O ring 4 Assemble the oil feed pipe Alternator 1 In...

Page 68: ...n the nozzle Fuel injection pipe 1 Semi assemble a nut at both ends of the fuel injection pipe and tighten them up one by one to specified torque 2 Assemble the fuel return pipe on the nozzle hold er 3 Connect the injection pump lubricating oil pipe with a hollow screw Be sure not to damage the connection part due to over tightening the hollow screw Cylinder head cover 1 Attach a new gasket on the...

Page 69: ...Poly belt will be properly tensioned if the deflection force F is applied midway between the belt s tan gent points with the pulley T 0 015 X S about 1 5 mm per 100 mm Oil level gauge 1 Apply sealant Locktite 262 to the bottom side of the guide tube 2 Then assemble the guide tube and oil level gauge on the oil pan Others 1 Assemble by connecting the other oil and fuel hoses EQM3005I S SPAN d T F C...

Page 70: ...ished thoroughly Check points for break in During the break in the initial running of the engine period be particularly observant as follows a Check engine oil level frequently Maintain oil level in the safe range between the min and max marks on dipstick NOTE If you have a problem getting a good oil level reading on dipstick rotate the level gauge 180 and re insert for check b Watch the oil press...

Page 71: ...t 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 temper ature on the thermostat while circulating to the radi ator at water temperature higher than the valve opening temperature At the radiator the heat absorbed in the coolant is radiated to cool down and the coolant recirculates to ...

Page 72: ...The wax pallet type thermostat does not react as quickly as bellows type one to a variation of tem perature of coolant Such relatively slow reaction is mainly due to the large heat capacity of the wax pellet type thermostat Therefore to avoid a sharp rise of coolant temperature it is essential to idle the engine sufficiently before running it In cold weather do not run the engine at overload or ov...

Page 73: ... of radiator Gases leaking into water jacket Replace cylinder head gasket due to broken cylinder head gasket 2 Engine overcooling Thermostat inoperative Replace thermostat Ambient temperature too low Install radiator curtain 3 Lack of coolant Radiator leaky Correct or replace Radiator hoses loosely Retighten clamps or replace connected or damaged hoses Radiator cap valve spring Replace cap weakene...

Page 74: ...pe Bypass for filter element Relief valve opening pressure 10L1 5 kg cm2 Valve opening pressure 1 8 2 3 kg cm2 Bypass for oil cooler Bypass for entire oil filter Opening pressure 5 1 kg cm2 Valve opening pressure 4 0 4 8 kg cm2 Adjusting valve for spray nozzle Opening pressure 1 5 1 8 kg cm2 메인 오일 통로 실린더 헤드 록커암 축 록커암 부쉬 캠 축 베어링 크랭크 축 베어링 컨넥팅 로드 베어링 아이들 기어 부쉬 피스톤 스프레이 노즐 과 급 기 연료분사 펌프 공기 압축기 오일 여과기...

Page 75: ...nd the limit b With a feeler gauge measure the amount of back lash between the oil pump drive gear and driven gear Replace if the measured value is beyond the limit c Measuring clearance between drive shaft and bushing Measure the outside diameters of the drive shaft and driven shaft and replace if the measured val ues are less than the limit N16 95mm Measure the inside diameter of the pump body b...

Page 76: ...tons and or piston rings Valve guide oil seals or valve Replace guides or valve stem worn 2 Oil pressure too low Poor oil Use suggested oil Relief valve sticking Replace Restrictions in oil pump strainer Clean strainer Oil pump gear worn Replace Oil pump feed pipe cracked Replace Oil pump defective Correct or replace Oil pressure gauge defective Correct or replace Various bearings worn Replace 3 O...

Page 77: ...n length of time for use and cause the deterioration of the engine Make sure that servicing should be performed at the professional maintenance shop as authorized by Bosch or Zexel Company For adjustment of fuel injection volume refer to the Specifications of fuel injection pump described on the following pages 75 2 3 8 9 4 7 12 10 11 5 1 6 1a 1 Fuel filter 1a Water separater 2 Air bleeding screw ...

Page 78: ...jection pump Test oil ISO4113 Temperature 40 L 5C Nozzle holder Ass y 65 10102 6058 Nozzle 7 x N 0 22 B Engine standard parts 65 10101 7088 1st 180 kg cm2 2st 280 kg cm2 Injection pipe ID x OD L 65 10301 6048C N 2 x N 6 650 mm Rack diagram and setting valve at each point Rack Pump Injection Q ty VARIATION Check position speed on RIG mm3 st RATE Press point mm rpm mmHg A 10 2 1100 95 L 2 250 Power ...

Page 79: ... 0 R1 0 7 R1 10 2 0 7 3 7 6 8 4 10 2 11 4 14 400 Injection pump speed rpm Boost pressure mmHg Rack position mm Rack position mm 1190 1220 1170 20 0 1 0 1 0 1 0 1 E C D B A BOO COM STRDKE 0 7 IDLE SUB SPRING 2 Governor adjustment D100 120 Boost adjustment DE08TS N 550rpm ...

Page 80: ...tion pump Test oil ISO4113 Temperature 40 L 5C Nozzle holder Ass y 65 10102 6026 Nozzle 5 x N 0 22 B Engine standard parts 65 10101 7050 1st 180 kg cm2 2st 280 kg cm2 Injection pipe ID x OD L 65 10301 6036A N 2 x N 6 650 mm Rack diagram and setting valve at each point Rack Pump Injection Q ty VARIATION Check position speed on RIG mm3 st RATE Press point mm rpm mmHg A 11 4 1100 104 L 2 250 Power B ...

Page 81: ...00 240 100 0 R1 0 7 R1 11 4 0 7 3 7 6 8 4 11 4 12 7 14 400 Injection pump speed rpm Boost pressure mmHg Rack position mm Rack position mm 1190 1120 1170 20 0 1 0 1 0 1 0 1 E C D B A BOO COM STRDKE 0 4 Governor adjustment D150 2 Boost adjustment DE08TS N 550rpm ...

Page 82: ...iven by the push rod and tappet via the camshaft of injection pump and performs reciprocat ing operation to control the suction and delivery of fuel When the cam reaches the Bottom Dead Center as shown in the figure the fuel is drawn in through the check valve on the inlet side The fuel pressurized as the cam rotates on flows through the check valve on the outlet side as shown in B If the feeding ...

Page 83: ...he manual feeding operation air must be bled from the fuel lines When using the priming pump fix it securely to pre vent the possible entry of moisture or other foreign substances in the inside of feed pump In addition a strainer is fitted into joint bolt on the inlet side of the fuel feed pump to filtrate any foreign substances possibly mixed in fuel 81 A Inlet side B Outlet side C Interruption E...

Page 84: ... tappet 10 e Disassemble the snap ring then take off the tap pet 10 and push rod 1 3 Inspection a If the check valve is damaged or scored on its seat face replace it with a new one b Inspect the piston and tappet for damage c Replace the push rod if excessively worn and replace together with the pump housing if required The inspection for wear should be per formed in the same procedure as for suct...

Page 85: ...fuel is drawn in and delivered for 40 seconds or so b Delivery test Make a test with the feed pump mounted on a pump tester as illustrated Operate the pump at the rate of 1 000 rpm and check to see if the pump delivery is more than 405 cc 15 seconds c Sealing test Plug up the delivery port on the feed pump and apply compressed air of 2 kg cm2 into the inlet side Submerge the feed pump in a contain...

Page 86: ...p the nozzle assembly and remove the noz zle holder b Remove the nozzle nut and components inside 4 Inspection a Visually inspect the disassembled components for damage 5 Reassembly a After removing carbon deposit submerge the nozzle in diesel oil and clean it b Replace all the seal rings with new ones c Assemble the parts and tighten them to speci fied torque 84 1 밸브 닫힘 2 밸브 열림 EQM4024I 1 2 4 5 7...

Page 87: ...tandard pressure by spring tension shims e After adjusting the injection pressure tighten the cap nut to specified torque f Re check the injection pressure and see if the spray pattern is normal Spray pattern should be uniform and free of spattering 7 Testing With the nozzle assembled to a nozzle tester and specified pressure applied check the nozzle for fuel leakage EAMC022I EFM2057I Abnormal Nor...

Page 88: ...arance Correct or replace between nozzle and needle valve injection pressure incorrect Adjust 2 Engine starts but stalls Pipe from feed pump to injection Clean immediately pump clogged or filter clogged Air in fuel Bleed Feed pump delivery insufficient Disassemble correct Fuel delivery insufficient due to Replace breather clogging of fuel tank air breather 3 Engine lacks power Plunger worn excessi...

Page 89: ...mble correct sluggish Nozzles defective Disassemble correct Injection starting pressure of Adjust each barrel incorrect Automatic timer defective Disassemble correct 7 Engine does not reach Nozzles not working normally Disassemble correct maximum speed Governor defective Disassemble correct 8 Engine idling unstable Movement of control rod Disassemble correct sluggish Operation of plungers unsmooth...

Page 90: ...t 4 Impeller D Oil supply 5 Turbine E Oil return 88 Specification DE08TS Turbocharger model ALLIED SIGNAL 466721 7 Air pressure at compressor outlet 1 26 kg cm2 At maximum Air suction volume 16 8 m3 min output Speed of turbine revolution 102 800 rpm Maximum allowable speed 126 150 rpm Max allowable temperature of exhaust gas at turbine inlet 750 C Lubricating system External oil supply Weight 9 5 ...

Page 91: ...r enough to burn the fuel completely should be supplied into the cylinders Therefore the engine output is determined substan tially by the cylinder capacity and a greater volume of compressed air is charged into cylinders of given capacity the greater engine output can be obtained as a greater volume of air charged into the cylinders burns so much more fuel As explained the compressing of air to s...

Page 92: ...the turbine shaft Then the compressed air is delivered to the intake stake This is the operating principle of the com pressor 3 Bearings a Thrust bearing The turbine wheel creates thrust force Therefore exercise care so that the shaft is not deviated from its the original position due to this thrust b Journal bearing This journal bearing of floating type forms a dual oil film on both the inside an...

Page 93: ...or extended time or in a cold place oil fluidi ty within the pipes can be deteriorated Immediately after starting 1 Run the engine at idle for 5 minutes after starting off 2 Check each part for leakage of oil gas and air and take proper measure 1 Applying load abruptly If load is abruptly applied with the engine and turbocharger rotating unsmoothly such parts that a suf ficient amount of oil has n...

Page 94: ...t system because leakage of exhaust gas from discharge pipes turbocharger fixing portions etc lowers charging effect As such components as turbine chamber that becomes red hot during operation use heat resist ing steel nuts do not interchange these nuts with ordinary steel nuts In addition apply anti seizure coating to fixing nuts on the portions as designated 3 Fuel system If the full load stoppe...

Page 95: ...l bearing and rotor are like ly to be in abnormal conditions the turbocharger should be replaced or repaired b Rotor radial play c If the measured axial and radial plays are beyond the limit of wear replace or repair the tur bocharger 2 Guide for checking rotor end play Disassemble the turbocharger from the engine then check the rotor axial play and radial play When disassembling the turbocharger ...

Page 96: ...ct new oil in the oil inlet port and lubricate the journal and thrust bearings by rotating them with hand Clean not only the pipes installed between the engine and oil inlet port but also the oil outlet pipe and check them for damage or foreign matters Assemble each joint on oil pipes securely to prevent oil leaks b Intake system Check the inside of the intake system for for eign matters Assemble ...

Page 97: ...r clogged Check and correct 2 Excessive white smoke 1 Oil leak into turbine and compressor Disassemble repair or replace 2 Worn or damaged seal ring due to excessive Disassemble repair wear of bearing or replace 3 Low engine output 1 Gas leak at each part of exhaust system Check and correct 2 Air cleaner element restricted Replace or clean 3 Turbocharger fouled or damaged Disassemble repair or rep...

Page 98: ... ass y Front 5 EF 123 048 Oil seal puller ass y Rear 6 EU 2 0530 Cylinder pressure tester adapter 7 EU 123 086 Cylinder liner puller ass y 8 EF 123 179 Valve stem seal punch 9 EU 2 0131 Valve clearance adjust ass y EB1M70 D1146 TI EF 123 014 EF 123 015 EF 123 127 EF 123 173 EF 123 043 EF 123 184 DE08TIS CR made USA up to 2000 Apr NOK made Japan From 2000 may CR made USA up to 2000 Apr NOK made Jap...

Page 99: ... No Figure Tool Name Remark 10 EF 123 065 Valve spring press 11 EU 2 0647 Crankshaft gear punch 12 Piston sleeve 13 60 99901 0027 Feeler gauge 14 T7610001E Snap ring plier 15 T7621010E Piston ring plier D1146 TI DE08TIS All engine EF 123 064 EF 120 208 ...

Page 100: ...2nd 25 kg m 3rd 30 kg m Balance weight fixing bolt M12 B 1 5 10 9T 9 0 kg m Flywheel housing fixing bolt M14 B 1 5 10 9T 8 0 kg m Flywheel fixing bolt M14 B 1 5 10 9T 21 5 kg m Crankshaft pulley fixing bolt M12 B 1 5 10 9T 13 4 kg m Oil spray nozzle M14 B 1 5 7 0 kg m Major Parts Screw Strength Tightening Torque Remarks Diameter x pitch grade Injection nozzle nut M28 B 1 5 7 0 L 0 5 kg m Injection...

Page 101: ... 0 7 0 63 0 83 0 78 1 2 1 3 1 4 1 95 2 35 M8 0 7 0 75 1 1 1 1 4 1 25 1 9 2 1 2 2 3 1 3 8 M8 B 1 0 73 0 8 1 2 1 1 1 5 1 34 2 1 2 3 2 4 3 35 4 1 M10 1 35 1 4 2 2 1 9 2 7 2 35 3 7 4 2 4 4 6 2 7 4 M10 B 1 1 5 1 6 2 5 2 1 3 1 2 8 4 3 4 9 5 7 8 4 M12 2 4 2 5 3 7 3 3 4 7 4 2 6 3 7 2 7 5 10 5 12 5 M12 B 1 5 2 55 2 7 4 3 5 5 4 6 6 8 7 7 8 11 2 13 4 M14 3 7 3 9 6 5 2 7 5 7 10 11 5 12 17 20 M14 B 1 5 4 1 4 3...

Page 102: ...te kg cm2 Measure at 13mm Outer dia piston N 110 883 Replace liner away from lower N 110 897 surface of piston Clearance between 0 103 0 139 0 3 Replace one worn piston and liner more Width of Top ring Replace piston if Piston piston ring 2nd ring 3 06 3 08 groove width is beyond grooves Oil ring 4 04 4 06 specified value Piston projection from Measure unworn cylinder block upper 0 0 12 Must exist...

Page 103: ...pm Torque valve journal Coat the bolt with Clean out foreign bearing cap bolt 30 engine oil objects on joining kg m surface Crush height of journal Measure after bearing 0 08 0 110 tightening metal cap and releasing one stud Oil seal for wear crank Replace oil seal Major shaft rear if oil leaking moving End play of con rod 0 170 0 248 0 50 Replace con rod parts Clearance between con rod bearing an...

Page 104: ...ickness Intake 2 7 Max 1 Replace valve of valve head Exhaust 2 2 Clearance between valve Intake 2 0 guide and valve Exhaust 2 0 spring seat Clearance between valve 0 039 0 010 Spread oil over guide and cyl head Press fit valve guide and installing hole press it into the hole Concentricity between valve stem and valve 0 05 Without spring seat head Valve Free length mm Approx 64 system Valve Tension...

Page 105: ...e in contact Replace with cam if severely worn or deformed Oil pressure at Check oil leakage normal speed kg cm 2 4 8 or less 3 5 and clearance Oil between each part pressure Oil pressure 0 8 1 4 0 6 Use recommended idling kg cm 2 oil Max permissible 105 Oil oil temperature C Must not exceed this tempera Permissible valve ture oil temperature 120 in short time C Axial play 0 055 0 105 Lubricating ...

Page 106: ... 2 1 0 and replace if air bubbles found Radiator Pressure valve for opening pressure 0 5 kg cm 2 Negative pressure valve for opening pressure 20 mmHg Delivery volume l min Engine speed 2 700rpm Check the water Cooling Water temp 80 C 280 passage For any restrictions system Back pressure 0 8 kg cm 2 Water Clearance between 0 35 Replace if impeller pump impeller housing housing are damaged Perpendic...

Page 107: ... pressure of injection Adjust by shim nozzle kg cm 2 Operating pressure of overflow 1 0 1 5 Replace valve valve kg cm 2 Projection height of nozzle from 2 53 Replace seal ring the cyl head surface mm Running in the engine Refer to supplement running in Inspection Compression pressure of 24 28 24 or Correct at Cylinder cylinder kg cm 2 more at 200rpm or more completion pressure Compression pressure...

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