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DV11

Operation and Maintenance

21

Technical Information

Printed in Mar. 2005 PS-MMA0608-E1A

2.3.4. Common rail system

z

Pressure generation and fuel injection are completely decoupled from each

other in the "Common Rail" fuel injection system. The injection pressure is
generated independent of engine speed and injected fuel quantity stored in the
ECU.

No. 3 injector

No. 2 injector

No. 1 injector

Pressure limiter

valve

No. 6 injector

No. 4 injector

No. 5 injector

Common rail

pressure sensor

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Summary of Contents for DV11

Page 1: ...PS MMG0717 E1B Operation and Maintenance Manual Diesel Engine DV11 65 99897 8098A Downloaded from www Manualslib com manuals search engine...

Page 2: ...y 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 Measur...

Page 3: ...embly 90 3 4 Fuel injection system 115 3 5 Electrical system 129 3 6 Engine brake 142 3 7 Engine diagnostic 153 3 8 Engine control unit ECU 158 4 Commissioning and operation 4 1 Preparations 179 4 2 O...

Page 4: ...consult a doctor immediately 1 1 2 To prevent accidents with injury to persons 1 Engine starting and operation z Before putting the engine into operation for the first time read the operating instruc...

Page 5: ...the risk of scalding and safety accidents z Neither tighten up nor open pipes and hoses lube oil circuit coolant circuit and any additional hydraulic oil circuit during the operation The fluids which...

Page 6: ...in order to prevent more serious of damage 3 Use only genuine DOOSAN spare parts DOOSAN will accept no responsibility for damage resulting from the installation of other parts which are supposedly ju...

Page 7: ...ndling used engine oil Prolonged or repeated contact between the skin and any kind of engine oil decreases the skin Drying irritation or inflammation of the skin may therefore occur Used engine oil al...

Page 8: ...on 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 fun...

Page 9: ...rol type Electric control type ECU Injector type Multi hole 8 x 0 197 Bosch DLLA146 Fuel injection pressure kg cm2 250bar operating pressure 1 600bar Intake valve 0 4 Exhaust valve 0 5 Valve clearance...

Page 10: ...lution ratio 1 1 265 Engine speed Air compressor speed Type Gear driven vane type Capacity l min 16 18 25 Adjusting pressure kg cm2 125 150 Power steering pump Revolution ratio 1 1 265 engine speed pu...

Page 11: ...BD W Jake brake EUJBH W o Jake brake EUJBL 400 1 800 173 1 200 600 2 120 W Retarder EUJBI W Retarder EUJBJ W Jake brake EUJBK 420 1 800 187 1 200 600 2 120 W o Jake brake EUJCA EUJCB 420 1 800 187 1 2...

Page 12: ...Performance Curve 1 4 1 Performance curve 340PS Performance ISO 1585 SAE J1349 Output max 250 kW 340PS 1 800 rpm Torque max 1 423 N m 145 kg m 1 200 rpm Fuel consumption min 203 g kW h 149 g PS h Revo...

Page 13: ...E1A 1 4 2 Performance curve 360PS Performance ISO 1585 SAE J1349 Output max 265 kW 360PS 1 800 rpm Torque max 1 570 N m 160 kg m 1 200 rpm Fuel consumption min 203 g kW h 149 g PS h Revolution rpm Out...

Page 14: ...E1A 1 4 3 Performance curve 380PS Performance ISO 1585 SAE J1349 Output max 280 kW 380PS 1 800 rpm Torque max 1 570 N m 160 kg m 1 200 rpm Fuel consumption min 203 g kW h 149 g PS h Revolution rpm Out...

Page 15: ...E1A 1 4 4 Performance curve 400PS Performance ISO 1585 SAE J1349 Output max 294 kW 400PS 1 800 rpm Torque max 1 697 N m 173 kg m 1 200 rpm Fuel consumption min 203 g kW h 149 g PS h Revolution rpm Out...

Page 16: ...E1A 1 4 5 Performance curve 420PS Performance ISO 1585 SAE J1349 Output max 309 kW 420PS 1 800 rpm Torque max 1 834 N m 187 kg m 1 200 rpm Fuel consumption min 203 g kW h 149 g PS h Revolution rpm Out...

Page 17: ...A 1 5 Engine Assembly 1 5 1 Engine sectional view longitudinal 1 Vibration damper 7 Power steering pump 2 Thermostat 8 Oil seal 3 Exhaust valve 9 Fly wheel 4 Push rod 10 Crank shaft 5 Tappet 11 Oil pu...

Page 18: ...w cross 1 Starting motor 8 Injector 2 Oil cooler 9 Oil spray nozzle 3 Cylinder block 10 Connecting rod 4 Cylinder head 11 Electric control unit E C U 5 Engine brake 12 Oil drain plug 6 Fuel high press...

Page 19: ...Flywheel housing 19 Air heater 4 Idle pulley 12 Mounting bracket front 20 Air pipe 5 Water outlet 13 Oil pan 21 Cylinder head cover 6 Fuel filter 14 Electric control unit ECU 22 Oil filler cap 7 Air...

Page 20: ...ke manifold 4 Turbo charger 12 Exhaust manifold 20 Breather 5 Oil filler cap 13 Water inlet 21 Crank shaft speed sensor 6 Intake manifold 14 Oil filter 22 Exhaust manifold 7 Air heater 15 Primary fuel...

Page 21: ...Engine serial No example 1 DV11 DV11 5 00001 BA z Engine serial No example 2 DV11 DV11 5 00001 CA 2 2 Diagnostic tool SCAN 200 The SCAN 200 is a powerful tool to support the service personal diagnosin...

Page 22: ...jection The injected fuel quantity is defined by the driver and the start of injection and injection pressure are calculated by the ECU on the basis of the stored map The ECU then triggers the solenoi...

Page 23: ...the crankcase penetrations z The connecting rods are die forged diagonally split and can be removed through the top of the cylinders together with the pistons Crankshaft and connecting rods run in ste...

Page 24: ...y decoupled from each other in the Common Rail fuel injection system The injection pressure is generated independent of engine speed and injected fuel quantity stored in the ECU No 3 injector No 2 inj...

Page 25: ...de of flywheel housing 2 3 6 Valves z The overhead valves are actuated via tungsten carbide tappets push rods and rocker arms from the camshaft High pressure pump gear Z 24 Power take off PTO gear Z 4...

Page 26: ...t through the oil cooler and oil filter to the main distributor gallery and from there to the main bearings big end bearings and camshaft bearings as well as to the small end bearings and the rocker a...

Page 27: ...d at the specified intervals Oil filter cartridge should be changed simultaneously First oil change After 5 000km operating First oil change After 5 000km operating 1 day operating distance 500km less...

Page 28: ...ecessary z Change the oil filter cartridge simultaneously at every replacement of engine oil 2 3 10 Fan belt z Use a fan belt of genuine part and replace if damaged frayed or deteriorated z Check the...

Page 29: ...a crack replace it genuine parts use z By the definite interval the elements must be cleaned and replaced 2 3 12 Pre fuel filter z Drain water in cartridge with loosening the drain plug under cartridg...

Page 30: ...el quality is an important factor in obtaining satisfactory engine performance long engine life and acceptable exhaust emission levels DOOSAN engines are designed to operate on most diesel fuels marke...

Page 31: ...lfur content mg kg 0 05 Flash point C 55 Ash content m m 0 01 Water content mg kg 200 Particulate matter content mg kg 24 Copper corrosion 50 C 3h grade 1 Oxidation stability g m3 25 Lubricity wsd 1 4...

Page 32: ...maps The ECU then triggers the solenoid valves so that the injector injection unit at each engine cylinder injects accordingly 2 3 17 Bleeding the fuel system z Loosen the fuel delivery pipe connecte...

Page 33: ...t the oil on the O ring z Assemble after check serial number at replacement z Have to assemble according to assembly order refer to the chapter of the disassembly and reassembly 2 3 19 Inter cooler z...

Page 34: ...pes For leaking air will bring the overheat engine an immediate repair must be done z During the operation that is surrounded by the dust and oil mixed air frequent cleaning must be done on the impell...

Page 35: ...vel of the expansion tank by removing the expansion tank filler cap and add coolant if necessary z When injecting antifreeze solution first drain out the old coolant from the cylinder block and radiat...

Page 36: ...ater not the hard water must be used z The engine cooling water can be used diluting it with anti freezing solution 40 and the additive for rust prevention DCA4 3 5 z The density of above solution and...

Page 37: ...l 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 wi...

Page 38: ...C Cooling water Anti freeze Over 10 10 15 20 25 30 40 85 80 73 67 60 56 50 15 20 27 33 40 44 50 2 3 24 Valve clearance adjust procedure z After letting the 1 cylinder s piston come at the compression...

Page 39: ...Rotating the crankshaft by 1 rotation 360 rotation let 1 cylinder overlap 5 In time that 5 cylinder become the state of top dead center adjust the valve clearance corresponding to of following lists 6...

Page 40: ...ation z Adjusting of valves Type 2 Adjusting of the valve overlapping on each cylinder is done as follow When each cylinder is valve overlap Firing cylinder no order 1 4 2 5 3 6 Valve adjusting cylind...

Page 41: ...ge of electrolytic solution owing to battery crack and replace the battery in case of poor condition z Inspect for amount of electrolytic solution and replenish if insufficient z Measure the gravity o...

Page 42: ...unted on the alternator body interior limits the alternator voltage z The alternator should not be operated except with the regulator and battery connected in circuit to avoid damage to the rectifier...

Page 43: ...N terminal cut off the charging lamp with detect the voltage by regulator A terminal switching the regulator on sensing the output voltage E terminal Regulator earth terminal F terminal supply the amp...

Page 44: ...ing gear should be cleaned with a brush dipped in fuel and then a coat of grease should be applied again Always protect starter motor against moisture IMPORTANT Always disconnect the battery earth cab...

Page 45: ...wing description summarizes the probable cause of and remedy for general failure by item z Inspect the electrical parts problem with SCAN 200 and refer diagnostic manual z Immediate countermeasures sh...

Page 46: ...DV11 Operation and Maintenance 43 Technical Information Printed in Mar 2005 PS MMA0608 E1A Downloaded from www Manualslib com manuals search engine...

Page 47: ...DV11 Operation and Maintenance 44 Technical Information Printed in Mar 2005 PS MMA0608 E1A Downloaded from www Manualslib com manuals search engine...

Page 48: ...DV11 Operation and Maintenance 45 Technical Information Printed in Mar 2005 PS MMA0608 E1A Downloaded from www Manualslib com manuals search engine...

Page 49: ...DV11 Operation and Maintenance 46 Technical Information Printed in Mar 2005 PS MMA0608 E1A Inspect cylinder head gasket Downloaded from www Manualslib com manuals search engine...

Page 50: ...DV11 Operation and Maintenance 47 Technical Information Printed in Mar 2005 PS MMA0608 E1A Downloaded from www Manualslib com manuals search engine...

Page 51: ...DV11 Operation and Maintenance 48 Technical Information Printed in Mar 2005 PS MMA0608 E1A Downloaded from www Manualslib com manuals search engine...

Page 52: ...ction pressure improper or stuck Adjust or replace z Supply pump s function lowered Repair or replace z Fuel pipe system clogged Repair z Air suction amount insufficient Clean or replace air cleaner 1...

Page 53: ...z Oil supply insufficiency as clogging at oil passage progresses Clean oil passage z Piston clearance increase as the wear of piston and piston ring progresses Replace piston piston ring z Wear of pis...

Page 54: ...r Correct position z Piston skirt part damaged or abnormal wear Replace piston z Oil ring s oil return hole clogged Replace piston ring 1 Oil level elevated z Oil ring s contact poor Replace piston ri...

Page 55: ...e the lubricating oil 1st Lubrication system Replace the oil filter cartridge 1st Check the leakage for intercooler hoses clamp Intake Exhaust System Clean and change the air cleaner element Drain the...

Page 56: ...d 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 th...

Page 57: ...ollision each other z In disassembling torn parts should be laid in disassembled order z Before performing service operation disconnect the grounding cable from the battery for reducing the chance of...

Page 58: ...epared vessel 3 1 3 Oil level gauge z Take out the oil level gauge from the guide tube 3 1 4 Engine oil z Remove an oil drain plug from the oil pan and let engine oil discharge into the prepared vesse...

Page 59: ...an and clutch 3 1 7 V belt z Loosen the V belt tension adjusting bolts and remove the V belt 3 1 8 Air pipe air heater z Remove fixing bolts then take off the air pipe and air heater z Be careful abou...

Page 60: ...lts and take off the oil filter head 3 1 10 Alternator z Remove the supporting guide piece for installing the alternator and the bracket bolts z Disassemble the alternator 3 1 11 Turbocharger z Loosen...

Page 61: ...coupling 3 1 13 Air compressor z Remove water and air pipes from air compressor z Unscrew the cylinder head bolts and remove the compressor head z Disassemble the flange on the front side of the flyw...

Page 62: ...le the fuel filter NOTE Seal the fuel filter to prevent from mixing foreign material into inside of the fuel filter after disassembling 3 1 15 Exhaust manifold z Remove the exhaust manifold fixing bol...

Page 63: ...pipe after disassembling 3 1 18 Fuel high pressure pump z Remove the connecting pipe of the fuel high pressure pump z Remove the fuel high pressure pump fixing bolts and take off the fuel high pressur...

Page 64: ...nd take off the oil filter head 3 1 20 Water pump z Loosen the various hose clamps for the connections z Remove the cooling water discharging pipe and disassemble the thermostat z Remove the cooling w...

Page 65: ...z Remove the drain plug from the oil cooler cover and drain out the cooling water z Remove the oil cooler cover fixing bolts and disassemble the oil cooler z Remove the oil cooler fixing bolts and tak...

Page 66: ...n take off the electric control unit and bracket 3 1 26 Cylinder head cover z Remove cylinder head cover fixing bolts and take off the cylinder head cover 3 1 27 Engine brake z Remove the engine brake...

Page 67: ...of the nozzle when take off the injector z Take out the sealing from the nozzle hole of the cylinder head and scrap it CAUTION 1 When disassemble the injector after the fuel high pressure connecter is...

Page 68: ...inate the residue from the cylinder head face and cylinder block face CAUTION Be careful not to damage the cylinder head face where its gasket contacts 3 1 31 Oil pan z Remove the oil pan fixing bolts...

Page 69: ...CAUTION Be careful for the removed pistons not to collide each other or with the other parts At the storage of pistons maintain them in the order of cylinders In order for connecting rod caps not to...

Page 70: ...Flywheel housing z Remove the flywheel housing fixing bolts and take them out z Remove the oil seal from the flywheel housing 3 1 37 Crank shaft z Remove the fixing bolts from bearing caps z Remove th...

Page 71: ...ring caps in turn 3 1 38 Cam shaft tappet z Pull out the tappets from the cylinder block z Remove the camshaft being careful not to damage the camshaft and its bearings 3 1 39 Oil spray nozzle z Remov...

Page 72: ...o check for any leaks water temperature 70 C 5 Inspect the cylinder block s camshaft bush to any damage and the alignment of oil supply holes and if abnormal replace it 3 2 2 Cylinder liner measuremen...

Page 73: ...inspected by a hydraulic test or a magnetic powder test Hydraulic test is same as for cylinder block b Distortion of lower surface z As shown in figure measure the z cylinder head s distortion at 6 d...

Page 74: ...wears is more than max allowable limit value replace the valves Valve stem outer diameter Standard Limit Intake 7 963 7 977 mm 7 94 mm Exhaust 7 950 7 964 mm 7 93 mm z Inspect the scratch and wear of...

Page 75: ...tandard Limit Intake 0 023 0 052 mm 0 10 mm Exhaust 0 036 0 065 mm 0 15 mm z Assemble the valve at cylinder head valve guide and see if it is centered with the valve seat using a special tool c Valve...

Page 76: ...seat z Regarding the valve seat assembling shrink the valve seat by putting it in the dry ices for about 1 hour or so and then press it into the cylinder head by means of a special tool z It is necess...

Page 77: ...icularity of valve spring z In case that the measured value exceeds the limit value replace it Valve spring tension Set length Spring force Limit 44 mm 39 4 kg 2 kg Intake Inner 31 6 mm 65 8 kg 2 5 kg...

Page 78: ...d with a special tool Be careful for the valve stem seals not to be damaged z Install the valve spring washer to valve guide z After putting on the inside outside spring install the valve spring seat...

Page 79: ...cker arm is installed and in case that it exceeds the limit value replace Rocker arm Specification Standard Limit Bush inner diameter 24 991 25 012 mm 25 04 mm Shaft outer diameter 24 739 24 960 mm 24...

Page 80: ...ng the tappet surface that contacts with the camshaft s cam for any crack and scratch etc and if the degree is small correct them with an oil stone or the grinding paper but if severe replace them z P...

Page 81: ...rust washer 2 Inspection and measurement of camshaft z Visual check With inspecting the cam surface for any damage with naked eyes and correct any minor scratch by means of an oil stone grinding and i...

Page 82: ...70 00 70 03 mm 70 06 mm z Clearance between camshaft journal and bush Calculate the clearance by complying measured value of the camshaft bearing inside diameter and journal bearing outside diameter...

Page 83: ...Inspect for any crack by means of magnetic powder and color check and replace the cracked ones a Journal and pin diameter z With outside micrometer measure the outside diameter of crank journal and cr...

Page 84: ...ings for undersize Standard 0 25 Inside diameter 0 25mm less than standard 0 50 Inside diameter 0 50mm less than standard 0 75 Inside diameter 0 75mm less than standard 1 00 Inside diameter 1 00mm les...

Page 85: ...t Run out of crankshaft Standard Limit 0 04 mm 0 2 mm 2 Crankshaft bearing and connecting rod bearing Inspect the crankshaft bearing and connecting rod bearing for any damages such as lopsided wear sc...

Page 86: ...t of bearing inside diameter journal bearing connecting rod bearing with the outside diameter of journal and pin of crankshaft to determine the 0il clearance Standard Limit Journal bearing 0 066 0 132...

Page 87: ...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 Cylinder block and bearing clearance Standard 0...

Page 88: ...dial gauge measure crankshaft end play Crank shaft end play Standard Limit 0 190 0 322 mm 0 452 mm 3 2 7 Piston 1 Piston disassembling z Pull out the snap ring for piston pin and with a pair of snap...

Page 89: ...pin direction Standard 127 739 127 757 mm a Cylinder bore diameter z Measure cylinder liner inside diameter at 3 points cylinder top ring contacting face middle and oil ring contacting face on BDC in...

Page 90: ...eeler gauge measure the gap clearance of piston ring z If the measured value exceeds the limit value replace it Standard Limit Top ring 0 35 0 55 mm 1 5 mm 2nd ring 0 80 0 95 mm 1 5 mm Oil ring 0 40 0...

Page 91: ...rod bush if it is more than the use limit value replace either one that is more severe Limit 0 055 0 071 mm h Connecting rod z Check the connecting rod for distortion As shown in the figure below ins...

Page 92: ...the piston and measure connecting rod small end side clearance z If the measured values are beyond the limit replace the connecting rod 3 2 8 Injector projection z Insert a seal ring on the cylinder...

Page 93: ...cording to the tightening order but the excessive torque must be avoided z Inspect if the movement of engine is smooth after assembling z After completion of assembling whether various bolts are loose...

Page 94: ...p to 150 200 C level push it over the crankshaft by means of a jig z Assemble the main bearing to the cylinder block and coat it with engine oil Then assemble the bearing that has a hole to the cylind...

Page 95: ...ngle method 90 10 and tightening order is as follows Bearing cap bolt s tightening order 1 First step Coat the bolts with engine oil 2 Second step Screw down 1 2 threads 3 Third step Tighten with abou...

Page 96: ...emble the crankshaft gear and the camshaft gear making sure that the gear marks on both gears are aligned together 3 3 7 Flywheel housing z Assemble the following parts in the flywheel housing before...

Page 97: ...o be installed In order to prevent the gasket slip down coat a grease on the cylinder block surface z Temporarily assemble 2ea of guide bolts for installing the flywheel housing to the cylinder block...

Page 98: ...mandrel assemble pilot bearing to the flywheel z By means of mandrel press in the wear ring at the backward face Apply mounting face with 262 loctite z Install two guide bolts for installing the flyw...

Page 99: ...an urethane hammer when in assembling take care not to hurt the oil seal by the crankshaft NOTE Without coating the oil seal with oil or lubricant assemble it in the dry state z Apply lubricating oil...

Page 100: ...pward The surface marked as Y or TOP is upper surface z Push in the piston with hands or wooden bar into cylinder Be careful for piston and rings not be damaged z Pushing the piston down rotate the cr...

Page 101: ...by step Standard length of bolt and use limit From head seat to bolt tip Standard length Use limit 67 5 0 3 mm 69 mm z By moving the connecting rod bearing cap by hands make sure if there is any play...

Page 102: ...the oil suction pipe by tightening the fixing bolts z Assemble the pipe bracket on the cylinder block side with bolts Torque 2 2 kg m 3 3 12 Vibration damper z Install the vibration damper on the cran...

Page 103: ...kes care not to squeeze out the gasket Torque 2 2 kg m 3 3 14 Intake exhaust valve z Identify the marks of I and E impressed on the valve head before assembling the valve with the valve head z With a...

Page 104: ...rder 1 First step Coat bolts with engine oil 2 Second step Tighten temporarily 1 2 threads by hands 3 Third step Tighten to about 8 kg m with a wrench 4 Forth step Tighten to 15kg m with a torque wren...

Page 105: ...in the combustion chamber during disassembling the injectors from the fuel return line and or gap around the injector and high pressure connector please remove the fuel by sucking with hand pump or s...

Page 106: ...ue while aligning an injector and a fuel high pressure connector Through this step the sealing and O ring is placed correctly on the cylinder head and fuel lines are to be fit together Afterwards rele...

Page 107: ...edure and work order Injector fixing bracket bolt Fuel high pressure connector fixing nut Final torque 3 5 kg m 5 5 5 kg m 3 3 17 Rocker arm z Coat the push rod with engine oil and put it into the pus...

Page 108: ...g cover z Coat with the liquid gasket on the surface of the cylinder block for mounting of the fuel high pressure pump housing cover z Assemble the fuel high pressure pump housing cover after check th...

Page 109: ...the loctite z Assemble the fuel high pressure pump fixing bolts with specified torque Torque 4 4 kg m 3 3 21 Intake manifold z Attach a new gasket to the cylinder head side z Assemble the intake mani...

Page 110: ...ue Side of common rail 3 0 kg m Side of fuel high pressure connector 3 0 kg m Fuel high pressure pipe Common rail from fuel high pressure pump 3 0 kg m Torque Common rail fixing bolt 2 2 kg m 3 3 23 C...

Page 111: ...z Assemble both sides in the same method as above Torque 8 0 kg m 3 3 25 Electric control unit z Install the electric control unit fixing bracket on the cylinder block then assemble the electric contr...

Page 112: ...7 Camshaft speed sensor z Measure the clearance of the assembling part of the sensor and timing gear then assemble it with the adjust shim Clearance 1 0 0 1mm Torque 1 0 kg m 3 3 28 Oil cooler z Attac...

Page 113: ...flywheel housing Same method as that of piston reassembly z Fit a gasket to the air compressor fitting surface of the flywheel housing z Assemble the connecting rod of the air compressor liner assembl...

Page 114: ...ousing z Set the power steering pump to the driving coupling carefully to prevent from damage of the O ring z Assemble the steering pump fixing bolt by specified torque Torque 4 4 kg m 3 3 32 Power ta...

Page 115: ...assembly z Install new O rings Packings in the oil filter housing Filter element Cu washer and packing are supplied together as A S parts z Assemble the oil filter housing with the filter head Be car...

Page 116: ...ixing bolts z Attach a gasket on the oil supply pipe and assemble the pipe with the fixing bolts z Attach a gasket on the oil discharge pipe and assemble the pipe by tightening the bolts Turbocharger...

Page 117: ...the fuel filter with the intake manifold z Assemble the fuel filter after fill the fuel into inside of the cartridge when replace the new fuel filter Torque 2 2 kg m 3 3 39 Alternator belt z Install t...

Page 118: ...y between the belt s tangent points with the pulley T 0 015 x S about 1 5mm per 100mm T Deflection S span 3 3 40 Cooling fan z Install the flange to the crankshaft pulley then assemble the cooling fan...

Page 119: ...n and Maintenance 114 Engine Reassembly Printed in Mar 2005 PS MMA0608 E1A 3 3 42 Others z Assemble by connecting the other sensor harness oil and fuel line Downloaded from www Manualslib com manuals...

Page 120: ...e on the condition for operation of the engine then inject the fuel in the cylinder z The fuel is stored under pressure in the common rail ready for injection The injected fuel quantity is defined by...

Page 121: ...by the crankshaft speed sensor and the camshaft speed sensor determines the firing sequence phase length The electrical signal generated across a potentiometer in the accelerator pedal module informs...

Page 122: ...h pressure pump for pressure generation Pressure is generated independently of the injection process The speed of the high pressure pump is coupled directly to the engine speed with a non variable tra...

Page 123: ...system z The common rail fuel injection system comprises a low pressure stage for the low pressure delivery of fuel a high pressure stage for the high pressure delivery and the ECU 3 4 6 Fuel tank z...

Page 124: ...This pressurized fuel then passes through a high pressure line and into the tubular high pressure fuel accumulator common rail z Common rail Even after an injector has taken fuel from the common rail...

Page 125: ...ssible 3 4 11 Construction of the fuel high pressure pump 1 Function The high pressure pump is the interface between the low pressure and the high pressure stages Under all operating conditions it is...

Page 126: ...the high pressure pump s inlet valve into the pumping element chamber whose pump piston is moving downwards suction stroke The inlet valve closes when the pump piston passes through the bottom dead ce...

Page 127: ...passage again With one of its pumping elements switched off when less power is needed the high pressure pump no longer delivers the fuel continuously but rather with brief interruptions in delivery 6...

Page 128: ...g the pressure to an electric signal is mounted on this diaphragm The signal generated by the sensor is inputted to an evaluation circuit which amplifies the measuring signal and sends it to the ECU E...

Page 129: ...holder of the existing engine The fuel is fed from the high pressure connector to the nozzle through the passage and to the control chamber through the feed orifice z The control chamber is connected...

Page 130: ...needle and valve plunger guides These control and leak off fuel quantities are returned to the fuel tank via the fuel return and the collector line to which overflow valve high pressure pump and pres...

Page 131: ...y situated above it and from there via the fuel return to the fuel tank The bleed orifice prevents complete pressure balance and the pressure in the valve control chamber sinks as a result This leads...

Page 132: ...e crankshaft can therefore provide information on the position of all the pistons The rotational speed defines the number of crankshaft rotations per minute This important input variable is calculated...

Page 133: ...d to the intake manifold by the O ring and measures the intake manifold s absolute pressure and temperature z The output signal is inputted to the ECU where with the help of a programmed characteristi...

Page 134: ...rts Truck 1 Boost pressure temperature sensor 2 Fuel temperature sensor 3 Coolant temperature sensor for gauge unit 4 Coolant temperature sensor 5 Oil pressure sensor for gauge unit 6 Engine oil press...

Page 135: ...Electrical parts Bus 1 Fuel temperature sensor 5 Engine oil pressure temperature sensor 2 Boost pressure temperature sensor 6 Camshaft speed sensor 3 Coolant temperature sensor 7 Crankshaft speed sens...

Page 136: ...aintenance 131 Common Rail Fuel injection System Printed in Mar 2005 PS MMA0608 E1A 3 5 3 Harness of electrical control unit a Harness of electrical control unit A Downloaded from www Manualslib com m...

Page 137: ...DV11 Operation and Maintenance 132 Common Rail Fuel injection System Printed in Mar 2005 PS MMA0608 E1A b Harness of electrical control unit B Downloaded from www Manualslib com manuals search engine...

Page 138: ...ance 133 Common Rail Fuel injection System Printed in Mar 2005 PS MMA0608 E1A 3 5 4 Connector of electrical control unit ECU Vehicle side connector Engine side connector Downloaded from www Manualslib...

Page 139: ...CAN2 ECU network 2 shield 1 34 B_D_CANL2 B_D_CANL2 ECU network 2 low 1 35 B_D_CANH2 B_D_CANH2 ECU network 2 high 1 38 I_S_CRCMOD I_S_DIG13 Cruise control mode switch 1 39 I_S_T15 I_S_T15 Key switch Te...

Page 140: ...or 2 07 O_T_MEU O_T_RHS01 Fuel metering unit high side 2 08 O_S_FANCL O_S_RH05 Fan clutch 2 09 V_V_5VOPS V_V_5VSS3B Oil pressure sensor supply 5V 2 10 V_V_5VBPS V_V_5VSS1A Boost pressure sensor supply...

Page 141: ...cylinder injector power return 3 07 nc G_R_GND01 3 08 nc G_R_GND02 3 09 O_P_SVH11 O_P_SVH11 1 cylinder injector power supply 3 10 O_P_SVH22 O_P_SVH22 5 cylinder injector power supply 3 11 O_P_SVH21 O...

Page 142: ...Blue Boost pressure sensor earth 2 29 ECU no 29 Boost pressure sensor 2 White Boost temperature sensor signal 2 10 ECU no 10 Boost pressure sensor 3 White Boost pressure sensor power supply 5V 2 28 B...

Page 143: ...3 Engine brake Injector cylinder 1 2 Injector cylinder 1 6 Injector cylinder 2 5 Injector cylinder 3 4 Engine brake Injector cylinder 3 4 Engine brake Injector cylinder 2 5 Injector cylinder 1 6 Injec...

Page 144: ...jector 3 3 06 P_03 936254 1 AMP 2 White Low side of injector 3 3 11 1 White High side of injector 4 3 16 P_05 936254 1 AMP 2 White Low side of injector 4 3 10 1 White High side of injector 5 3 15 2 Wh...

Page 145: ...side of injector 3 3 White Engine brake 1st P_01 99013 00300 AMP 65 26810 5003 DHIM 4 GP110012 KET 4 White Engine brake 2nd 3 Harness of injector engine brake B inside Side of ECU harness Side of engi...

Page 146: ...1A 4 Harness of injector engine brake Side of engine Side of vehicle Connector no Pin no Connector no Pin no Wire color Circuit name 1 1 White 2 2 White Engine brake 1st 3 3 White P_01 MG 640333 KET 4...

Page 147: ...24V 16 Plug screw 6 Spring inner 17 Housing for right 7 Control valve ass y 18 Master piston 8 Snap ring 19 Plate spring 9 Control valve cover 20 Washer 10 Spring outer 21 Screw 11 Slave piston 1 2 3...

Page 148: ...to the crankshaft during the expansion stroke The energy being lost is slow the vehicle on level roads and help control vehicle speeds on downhill grades z The power required to operate the brake is...

Page 149: ...the underside of the control valve where it is stored for the next cycle Prior to top dead center position the exhaust valve is forced open releasing the compressed cylinder air to the exhaust manifol...

Page 150: ...down engine Clean the gasket surface for the cover 3 6 5 Solenoid valve CAUTION Do not disassemble or tamper with the solenoid valve Engine damage could result The solenoid valve is not field servicea...

Page 151: ...vent Push a wire into the hole in the base of the valve to the distance required to ensure that the ball check is free The ball should lift with light pressure on the wire If the ball is stuck replace...

Page 152: ...ear safety glasses The slave piston is retained by springs that are under heavy compression If the following instructions are not followed and proper tools not used the springs will be discharged with...

Page 153: ...ave piston with the open area toward the center of the housing The open area of the slave piston is for rocker arm clearance 7 Use the clamp fixture to reinstall the piston and springs Be sure the ret...

Page 154: ...If the solenoid valve is defective it must be replaced CAUTION Do not touch the electrical connection when a solenoid is energized Electrical shock could result 4 Resistance check Disconnect the wires...

Page 155: ...es Check solenoid for signs of shorting replace if necessary Replace fuse or circuit breaker if necessary CAUTION Do not touch electrical connection when system is energized Possible cause Incorrect e...

Page 156: ...sure piston travels full range without binding or sticking CAUTION Remove slave piston carefully when disassembly is necessary Use the slave piston removal tool Slave piston springs are under heavy c...

Page 157: ...um required for engine brake operation Possible cause Upper solenoid seal ring damaged Correction Remove solenoid Inspect seal ring and replace all se al rings Possible cause Aeration of lubricating o...

Page 158: ...an be worked speedy and correctly 3 7 2 Method by SCAN 200 SCAN 200 is designed to serve to the maintenance with adding the function of the graphic and oscilloscope to be used for the diagnosis and ma...

Page 159: ...bnormal B Foot brake and accelerator pedal is operated simultaneously on driving Foot brake switch harness is abnormal 2 5 Vehicle speed sensor or vehicle meter is abnormal C Sensor vehicle tachometer...

Page 160: ...solenoid connector harness is abnormal 8 3 Relation to high pressure pump control is abnormal C Fuel metering unit of high pressure pump harness is abnormal 8 6 Engine speed meter of vehicle is abnorm...

Page 161: ...bnormal N Cylinder s deflection of injector solenoid is excessive 11 6 Smooth running control is abnormal N Cylinder s deflection of injector solenoid is excessive Check of the lamp s operation N Case...

Page 162: ...h Vehicle speed Accelerator pedal position sensor and operation switch Cruise OFF switch Cruise RESUME switch Cruise SET INC switch Cruise SET DEC switch Door open sensing switch Engine brake switch D...

Page 163: ...hod of the adjusting is possible by using the cruise control switch z Preparing condition for the adjusting of the idle speed Cruise control switch no trouble Pedal brake no trouble Vehicle speed stop...

Page 164: ...less than specified value 3 8 5 Cruise control z Provide the driver with ability to control in order to travel and maintain a setting speed z Operation switch SET INC SET DEC RESUME CRUISE OFF z Opera...

Page 165: ...hicle speed is not reset When the driver is descending and accelerating steep a grade in cruise driving the engine brake is automatically operated to maintain the set speed of the vehicle z Disablemen...

Page 166: ...s maintained for a long time Regulation for the reduction of the exhaust gas from the vehicle engine idle revolution prohibition law Idle revolution limit time less than 5 minutes If the vehicle is un...

Page 167: ...nformation output lamp The safety driving is leaded to the driver by proposal of information about status of occurred faults 3 8 10 Diagnostic z Diagnostic information output lamp CEL Check engine lam...

Page 168: ...tity according to the division total idle state PTO Fuel consumption rate operating mileage Engine operating time ECU using time z The monitoring is possible by using diagnostic tool 3 8 12 Power take...

Page 169: ...Ensure outmost cleanliness when handling fuels lubricants and coolants be careful about mixing of the foreign matter during the supplement In case that DAEWOO recommended the fuel and lubrication oil...

Page 170: ...min and max marks on dipstick NOTE If you have a problem getting a good oil level reading on the oil level gauge rotate the oil level gauge 180 and re insert for check z Watch the oil pressure warnin...

Page 171: ...the first 5 000km of operation since the oil consumption will be high until the piston rings are properly seated 4 3 Inspections after Starting During operation the oil pressure in the engine lubrica...

Page 172: ...of engine and the sticking of cylinder components And excessively low cooling water temperature increases the fuel consumption accelerates the wears of cylinder liners and shortens the engine life tim...

Page 173: ...lamp turn the key switch to the START position to crank the engine at once Behavior When the key switch is placed in the START position air heater is continuously heated to facilitate starting operati...

Page 174: ...cause drop the cooling efficiency cause being frozen to burst in winter therefore the whole cooling water should be completely discharged after engine running z The freezing of cooling water is the re...

Page 175: ...hrough wear corrosion or deterioration of one or more parts or components z In the normal operation of an engine these changes can take place gradually at a number of points so that it s seldom advisa...

Page 176: ...t ease of starting fuel economy combustion chamber deposits and engine wear At the end of the break in period change the oil sump oil and replace the oil filter cartridge 4 6 3 Oil level gauge z Check...

Page 177: ...t the mixing of dust or contaminator during the supplement of oil Then confirm that oil level gauge indicates the vicinity of its maximum level z For a few minutes operate the engine at idling in orde...

Page 178: ...ilter element after replace the new one The genuine filter element should be used z Insert the O ring to the ho using The filter element and O ring and sealing are supplied simultaneously when the ser...

Page 179: ...tank 4 7 1 Coolant draining z Remove the pressure cap z Open the drain valve at the radiator lower part to drain the coolant as the right figure z Loosen the coolant drain plug of the cylinder block...

Page 180: ...brown mechanically contaminated gray or black sings of a leakage on the water pump casing clean the cooling system prior to removing that water pump as follows a Drain coolant b Remove thermostats so...

Page 181: ...e engine is overhauled and the cylinder heads are disassembled z When severe noise comes from valve train z When the engine is not normally operated even though there is no trouble in the fuel system...

Page 182: ...o 4 Rotating the crankshaft by 1 rotation 360 rotation let 1 cylinder overlap 5 In time that 5 cylinder become the state of top dead center adjust the valve clearance corresponding to of following lis...

Page 183: ...h cylinder is done as follow When each cylinder is valve overlap Explosion cylinder No order 1 4 2 5 3 6 Valve adjusting cylinder No 5 3 6 1 4 2 z Adjusting of engine brake Adjusting of slave piston C...

Page 184: ...er 1 First step Coat the bolts with engine oil 2 Second step Screw down 1 2 threads 3 Third step Tighten with about 8 kg m by wrench 4 Fourth step Tighten with about 15kg m by torque wrench 5 Fifth st...

Page 185: ...then flows through the water jacket of the cylinder block and water passage of the cylinder head to absorb the heat of the combustion chamber z The water absorbing the oil heat and combustion chamber...

Page 186: ...hermostat z General descriptions and main data The thermostat maintains a constant temperature of coolant 90 95 C and improves thermal efficiency of the engine by preventing heat loss Namely when the...

Page 187: ...ax 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 pelle...

Page 188: ...Gases leaking into water jacket due to broken cylinder head gasket z Replace cylinder head gasket 2 Engine overcooling z Thermostat inoperative z Replace thermostat z Ambient temperature too low z In...

Page 189: ...re circulation Oil filter type Full flow Oil pump type Gear type Bypass for cartridge Relief valve opening pressure 10 1 5 kg cm2 Valve opening pressure 1 8 2 4 kg cm2 Oil cooler bypass Bypass for ent...

Page 190: ...the limit Backlash limit 0 50 0 64 mm 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...

Page 191: ...Oil consumption excessive z Valve guide oil seals or valve guides or valve stem worn z Replace z Poor oil z Use suggested oil z Relief valve sticking z Replace z Restrictions in oil pump strainer z C...

Page 192: ...34 1 2 Air pressure at compressor outlet Approx 2 1 kgr cm2 Air suction of turbine revolution Approx 24 m3 min At maximum output Speed of turbine revolution Approx 100 000 rpm Maximum allowable speed...

Page 193: ...ust collar 24 Hex bolt 3 Connector 14 Thrust bearing 25 Turbine housing 4 Compressor housing 15 Journal bearing 26 Actuator bracket 5 Clamp compressor 16 Center housing 27 Hex bolt 6 Hex bolt 17 Beari...

Page 194: ...t gas that is discharged from combustion chamber passes through turbine housing conveying an energy to turbine wings to give the rotating power This is called as the turbine and in order not to influe...

Page 195: ...lubricating system s part are replaced or engine was stalled for long time more than a week and in case of operation under cold weather loosen the oil pipe connecting parts of turbocharger inlet and o...

Page 196: ...ecified up keep thoroughly is needed 1 Air intake system System the intake air system care must be taken to the air cleaner In case of oil passing type air cleaner if the oil level is lower than the s...

Page 197: ...mination 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 If a sound de...

Page 198: ...h tape and so on 4 Precautions for reassembling the turbocharger onto the engine For reassembly of the turbocharger or handling it after reassembly operation be sure to observe the following precautio...

Page 199: ...z Assemble each joint on oil pipes securely to prevent oil leaks 2 Air intake system z Check the inside of the intake system for foreign matters z Assemble each joint on the intake duct and air cleane...

Page 200: ...ogged Check and correct 1 Oil leak into turbine and compressor Disassemble repair or replace 2 Excessive white smoke 2 Worn or damaged seal ring due to excessive wear of bearing Disassemble repair or...

Page 201: ...r and bowl correctly There is a recess in the cover rim and a lug on the collector which should register Where the filter is installed horizontally watch for top mark on cleaner bowl 5 4 2 Changing ai...

Page 202: ...he inside maximum 5 bar until no more dust comes out of the air cleaner pleats z By washing Before washing the element should be precleaned by means of compressed air as described above Then allow the...

Page 203: ...amage e g to the paper pleats and rubber gaskets or for bulges and dents etc in the metal jacket Damaged cartridges should not be reused under any circumstances In cases of doubt discard the cartridge...

Page 204: ...easuring tension Lower indicator arm 1 into the scale z Apply tester to belt at a point midway between two pulleys so that edge of contact surface 2 is flush with the V belt z Slowly depress pad 3 unt...

Page 205: ...the indicator arm 1 intersects with the scale z Before taking readings make ensure that the indicator arm remains in its position z Poly belt tension No of rib PK type Force kgf 3 20 27 4 27 36 5 34 4...

Page 206: ...1 EF 120 232 Fuel high pressure pump gear assembly 2 EF 120 030 Oil seal insert assembly Front 3 EF 120 029 Oil seal insert assembly Rear 4 EF 120 238 Valve spring compression 5 EF 123 365 Cylinder l...

Page 207: ...508 0185 Wearing assembly Crankshaft pulley 9 E1 05508 0025 Wearing assembly Fly wheel 10 E1 76 035 00D Cam shaft assembly 11 EF 120 239 Slave piston disassembly assembly Engine brake 12 60 99901 0027...

Page 208: ...03 Special Tool List Printed in Mar 2005 PS MMA0608 E1A No Part name Figure Tool name Remark 15 T7621010E Piston ring plier 16 EF 123 322 SCAN 200 Diagnostic unit Memory card Downloaded from www Manua...

Page 209: ...m 2 2 kg m 5 kg m 2 2 kg m 8 2 kg m Exhaust manifold Intake manifold M10 x 1 5 M8 10 9T 8 8T 8 0 kg m 2 2 kg m Starting motor Alternator bracket M12 x 1 5 M14 x 1 5 8 8T 8 8T 8 kg m 12 kg m Coolant te...

Page 210: ...31 M16x1 5 6 2 6 5 9 7 8 6 12 5 11 3 17 19 5 20 28 33 M18 7 8 8 3 12 5 11 16 14 5 21 24 2 25 36 43 M18x1 5 9 1 9 5 14 5 12 5 18 5 16 7 24 5 27 5 28 41 49 M20 11 5 12 18 16 22 19 31 5 35 36 51 60 M20x...

Page 211: ...lace cylinder head The flatness of lower surface of cylinder head 0 08 0 1 Thick of cylinder head gasket at assembly status 1 215 1 285 Cylinder block Cylinder head valve Hydraulic test for 1 minute k...

Page 212: ...Top ring 0 105 0 155 0 20 2nd ring 0 050 0 082 0 15 Piston ring side clearance Oil ring 0 030 0 070 0 15 Replace ring or piston Limit for use is if for standard clearance Direction of ring gap Cross...

Page 213: ...gine oil Clean out foreign objects on joining surface Main 0 3 1 2 Crush height of Journal bearing cap Thrust 0 3 1 2 Measure after tightening metal cap and releasing one bolt Out diameter of wear rin...

Page 214: ...3 Correct or replace gear Ring gear assembly part s outer diameter 432 490 432 645 Ring gear inner diameter 432 000 432 155 Overlap 0 335 0645 Heating temperature at ring gear assembly 200 230o C Allo...

Page 215: ...y between valve seat and valve guide 0 05 Replace valve spring Without spring seat Free length 62 5 44mm 37 4 41 4 37 Tension force kg 31 6mm 63 3 68 3 63 Intake valve spring Squareness along free len...

Page 216: ...0 or less Permissible oil temperature in short time C Max 120 Must not exceed this value By pass valve for filter element kg cm 2 1 8 2 4 Operating pressure 1 6 1 9 Closing pressure 1 3 1 6 Engine oil...

Page 217: ...61 Diameter of water pump shaft Impeller side 16 045 16 056 Clearance of bearing 0 050 0 091 Clearance between impeller housing 0 5 0 9 Replace if impeller housing are damaged Water pump Fan belt depr...

Page 218: ...of piston pin 19 994 20 000 Inner diameter of connecting rod small end 20 020 20 033 Inner diameter of connecting rod big end 31 959 31 975 Include connecting rod bush and bearing Diameter of main bea...

Page 219: ...214 1 Engine assembly view DV11 TRUCK Downloaded from www Manualslib com manuals search engine...

Page 220: ...215 2 Engine assembly view DV11 BUS Downloaded from www Manualslib com manuals search engine...

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