Daewoo Doosan DV15, DV15T, DV15TI, DV15TIS Diesel Engine Operation & Maintenance Manual DOWNLOAD by www.heydownloads.com

65.99897-8059

MAINTENANCE MANUAL

Diesel Engine DV15 DV15T DV15TI DV15TIS

PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

FOREWORD This maintenance manual is designed to serve as a reference for DAEWOO Heavy Industries & Machinery Ltd's (here after DAEWOOâ&#x20AC;&#x2122;s) customers and distributors who wish to gain basic product knowledge on DAEWOO's DV series diesel engines (DV15, DV15T, DV15TI and DV15TIS) These economical and high-performance diesel engines (8 cylinders, 4 strokes, V-type, direct injection type) have been so designed and manufactured to be used for overland transport and industrial purpose. That meets all the requirements such as low noise, fuel economy, high engine speed, and durability. (especially, DV15TIS model is an environment friendly one fulfilling the EURO-II emission regulation) To maintain the engine in optimum condition and retain maximum performance for a long time, CORRECT OPERATION and PROPER MAINTENANCE are essential. In this manual, the following symbols are used to indicate the type of service operations to be performed. Removal

Adjustment

Installation

Cleaning

Disassembly

Pay close attention-Important

Reassembly

Tighten to specified torque

Align the marks

Use special tools of manufacturer's

Directional Indication

Lubricate with oil

Inspection

Lubricate with grease

Measurement

During engine maintenance, please observe following instructions to prevent environmental damage; z Take old oil to an old oil disposal point only. z Ensure without fail that oil and diesel fuel will not get into the sea or rivers and canals or the ground. z Treat undiluted anti-corrosion agents, antifreeze agents, filter element and cartridges as special waste. z The regulations of the relevant local authorities are to be observed for the disposal of spent coolants and special waste.

Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

If you have any question or recommendation in connection with this manual, please do not hesitate to contact our head office, dealers or authorized service shops. For the last, the content of this maintenance instruction may be changed without notice for some quality improvement and please feel free to contact to our agents near by your location for any services. Thank you.

DAEWOO Heavy Industries & Machinery LTD. Dec. 2001

Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

CONTENTS 1. GENERAL INFORMATION 1.1. General Repair Instruction 1.2. Engine Characteristics 1.3. Engine Specifications 1.4 Engine General Views

1 2 3 10

2. MAINTENANCE 2.1. Preventive Maintenance 2.2. Diagnosis and Remedy 2.3. Engine Inspection

18 27 37

3. Disassembly and Reassembly of Major Components 3.1. Engine Disassembly 3.2. Measurement and Inspection of Major Parts 3.3. Engine Reassembly 3.4. Starting and Trial Operation

38 49 66 84

4. MAINTENANCE OF MAJOR COMPONENTS 4.1. Cooling System 4.2. Lubricating System 4.3. Specification and Construction

86 90 92

4.4. Fuel Injection Pump

5. SPECIAL TOOL LIST

129

6. APPENDIX 6.1. Tightening torque for major parts 6.2. Standard bolt tightening torque table 6.3. Engine assembly tolerance

130 131 132

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Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

1. GENERAL INFORMATION 1.1. General Repair Instructions 1. Before performing service operation, disconnect the grounding cable from the battery for reducing the chance of cable damage and burning due to short-circuiting. 2. Use covers for preventing the components from damage or pollution. 3. Engine oil and anti-freeze solution must be handled with reasonable care as they cause paint damage. 4. The use of proper tools and special tools where specified is important to efficient and reliable service operation. 5. Use genuine DAEWOO parts necessarily. 6. Used cotter pins, gaskets, O-rings, oil seals, lock washer and self-lock nuts should be discarded and new ones should be prepared for installation as normal function of the parts can not be maintained if these parts are reused. 7. To facilitate proper and smooth reassemble operation, keep disassembled parts neatly in groups. Keeping fixing bolts and nut separate is very important as they vary in hardness and design depending on position of installation. 8. Clean the parts before inspection or reassembly. Also clean oil ports, etc. using compressed air to make certain they are free from restrictions. 9. Lubricate rotating and sliding faces of parts with oil or grease before installation. 10. When necessary, use a sealer on gaskets to prevent leakage. 11. Carefully observe all specifications for bolts and nuts torques. 12. When service operation is completed, make a final check to be sure service has been done property.

GENERAL INFORMATION

Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

1.2. Engine characteristics 1.2.1. 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. Due

the

application

OMEGA

combustion system and optimal utilization of intake and exhaust port configuration within the cylinder head, the DV15TIS diesel engines discharge very low level of hazardous exhaust gases such as smoke, nitrogen oxide, hydrocarbon, or carbon monoxide

and

thus

ensure

high

performance and low fuel consumption.

GENERAL INFORMATION Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

1.3. Engine Specifications 1.3.1. Specification Engine Model Items

DV15

DV15T

Water-cooled,4 cycle Vee type Naturally aspirated

Engine type

Cylinder liner type Timing gear system No. of piston ring No. of cylinder-bore X stroke

(mm)

Total piston displacement

(cc)

Water-cooled,4 cycle Vee type Turbo charged & intercooled

8 – 128 ×142 14,618 16.5 : 1 16.5 : 1

16.9 : 1

Compression ratio Engine dimension (length x width x height)

(mm)

Engine weight

(kg)

1,150x1,060x1,043.5

880

10°

Fuel injection timing (B.T.D.C static) Injection pump type Governor type

Multi-hole(4 x φ0.34)

Injection nozzle type 2

Fuel injection pressure

(kg/cm ) 2

Compression pressure

(kg/cm )

Intake and exhaust valve clearance (at cold) (mm) Open at Close at Open at Close at Lubrication method Oil pump type Oil filter type Lubricating oil capacity (max./min.)

(lit)

Oil cooler type Water pump Cooling Method Cooling water capacity (engine only)

(lit)

Power steering pump Alternator voltage – capacity

Multi-hole(5 x φ0.31)

17.4 : 1

1,377x1,352x1,206.5 1,373x1,352x1,206.5

1,020

5.5°

Multi-hole(4 x φ0.39) Multi-hole(5 x φ0.32)

200+8 200+8 28 (at 200 rpm)

250+8

0.25/ 0.35 12° (B.T.D.C) 15° (B.T.D.C) 48° (A.B.D.C) 35° (A.B.D.C) 61° (B.B.D.C) 71.5° (B.B.D.C) 11° (A.T.D.C) 15.5° (A.T.D.C) Pressurized circulation Gear type Full-flow, paper element type(double) Bus : 24/ 20 , Truck : 21/ 19 Water cooled Belt driven centrifugal type Pressurized circulation 19 Wax pallet type (79 ∼ 94 °C)

Thermostat type Air compressor type & capacity

200+8

1,377x1,352x1,206.5

990 1,020 1-5-7-2-6-3-4-8 Vehicle : 7° 11° Industrial : 9° Bosch in-line P type RQ or RQV type

Fuel injection order

Exhaust valve

DV15TIS

Direct injection type Wet type Gear driven type 2 compression ring, 1 oil ring

Combustion chamber type

Intake valve

DV15TI

Water-cooled,4 cycle Vee type Turbo charged

(cc/rev) (lit/bar) (V - A)

Starting Motor voltage – output

(V - kW)

Air heater capacity

(V – A)

Battery capacity

(V - AH)

Gear driven type : 300 Bus : 16 / 100 , Truck : 18 / 125

Bus : 24-150 , Truck : 24 – 45 , 60 or 80 Bus : 24 – 6.6 , Truck 24 – 7.0 22 – 95 (1.06 kW) 200

GENERAL INFORMATION

Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

1.3.2. Engine power Production tolerance : ±5% Engine Model

Performance Injection

Model

Suffix

timing (BTDC º)

DV15

DV15T

DV15TI

DV15TIS

Power (PS / rpm)

Torque Low idle (kg.m / rpm) (rpm)

High idle (rpm) 2530 ~2600

Remark

ECLBA

305 / 2,300

105 / 1,400

550+50

ECVXA ECVXC

340 / 2,300

132 / 1,300

575 ±25

2530 ~2600

ECVBA ECVBB ECVBC ECVCF

365 / 2,300

138 / 1,300

575 ±25

2530 ~2600

ECVCA ECVCB ECVCC ECVCD ECVCE ECVCH ECVCI ECVCJ

370 / 2,300

145 / 1,300

575 ±25

2530 ~2600

ECVEA ECVEB ECVEC ECVED

300 / 2,000

125 / 1,300

850 ±25

2250±50

TIER-I

ECJCA ECJCB ECJCC

420 / 2,100

170 / 1,200

575±25

2310 ~ 2360

EURO-I

EDJBA EDJXA EDJXC

5.5

390 / 2,100

160 / 1,200

575±25

2320 ~ 2370

575±25

2320 ~ 2370

EDJCA EDJCB EDJCC EDJCF EDJCG

EURO-I

EURO-II 5.5

420 / 2,100

170 / 1,200

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

GENERAL INFORMATION Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

1.3.3. Performance curve 1) DV15

Performance

ISO 1585 (SAE J1349)

Output

(max.)

224 kW (305PS) / 2,300 rpm

Torque

(max)

1,029 N.m (105 kg.m) / 1,400 rpm

Fuel consumption

(min.)

220 g/kW.h (162 g / PS.h)

GENERAL INFORMATION

Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

2) DV15T

Performance Output

(max.)

Torque

(max)

Fuel consumption (min.)

DIN 6270B 238 kW (324PS) / 2,300 rpm

DIN 6270A 229 kW (311PS) / 2,300 rpm

1,255 N.m (128 kg.m) / 1,400 rpm 211 g/kW.h (155 g / PS.h)

GENERAL INFORMATION Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

3) DV15T

Performance

ISO 1585 (SAE J1349)

Output

(max.)

272 kW (370PS) / 2,300 rpm

Torque

(max)

1,422 N.m (145 kg.m) / 1,300 rpm

Fuel consumption

(min.)

211 g/kW.h (155 g / PS.h)

GENERAL INFORMATION

Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

4) DV15TI

Performance Output

(max.)

309 kW (420PS) / 2,100 rpm

Torque

(max)

1,667 N.m (170 kg.m) / 1,200 rpm

Fuel consumption

ISO 1585 (SAE J1349)

(min.)

211 g/kW.h (155 g / PS.h)

GENERAL INFORMATION Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

5) DV15TIS â&#x20AC;&#x201C; 420PS

Performance

ISO 1585 (SAE J1349)

Output

(max.)

309 kW (420PS) / 2,100 rpm

Torque

(max)

1,667 N.m (170 kg.m) / 1,200 rpm

Fuel consumption

(min.)

211 g/kW.h (155 g / PS.h)

GENERAL INFORMATION

Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

1.4. Engine General Views 1.4.1. Engine Sectional View (longitudinal)

4 3

2 1

12 13 14

1 2 3 4 5 6 7 8 9 10

Oil seal(front) Vibration damper Water pump Thermostat Piston pin Piston Exhaust valve Valve cotter Valve guide Power steering pump

11 12 13 14 15 16 17 18 19 20

Air compressor Pilot bearing Oil seal (rear) Fly wheel Crank shaft Drain plug Oil suction pipe Relief valve(Oil pump) Cam shaft Flywheel housing

GENERAL INFORMATION Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

1.4.2. Engine Sectional View (cross)

10 11

12 4 13

1 2 3 4 5 6 7 8 9

Cylinder block Oil cooler Cylinder liner Cylinder head Rocker arm Push rod Breather Priming pump Fuel injection pump

10 11 12 13 14 15 16 17

Fuel injection pipe Intake manifold Fuel injection nozzle Combustion chamber Exhaust manifold Balance weight Oil pump Oil spray nozzle

GENERAL INFORMATION

Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

1.4.3. Engine Assembly Views (1) DV15 (Bus)

3 2

9 14

10 11 12

20 19

1 2 3 4 5 6

Flywheel housing Lift hook Air compressor Breather Fuel filter Exhaust manifold

9 10 11 12 13 14

7 8

Water outlet Mounting bracket

15 16

Oil filler cap Drain plug Oil cooler Oil pan Vibration damper Idle pulley (Water pump) Water pump Idle pulley(Alternator)

17 18 19 20 21 22 23 24

Alternator Oil filter Crank shaft pulley Oil level gauge Starter Air pipe(Air cleaner to intake manifold) Power steering pump Pick-up sensor

GENERAL INFORMATION Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

(2) DV15T (Truck)

3 2 1 12 15 16 7

8 99 10 11 24

20 19 18 17

1 2 3 4 5 6 7

Flywheel housing Exhaust elbow Fuel filter Air pipe (to air tank) Air vent pipe Oil filler cap Oil cooler

10 11 12 13 14 15 16

Mounting bracket Alternator Water pump Water outlet Oil pressure unit Idle pulley(Air con.) Air con. bracket

19 20 21 22 23 24 25

8 9

Oil filler pipe Drain plug

17 18

Fan clutch Cooling fan

26 27

Fan guide Oil filter Air heater relay Mounting bracket Starter Lifting hook Air pipe (Air cleaner to Turbocharger) Power steering pump Pick-up sensor

GENERAL INFORMATION

Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

(3) DV15T (Bus)

6 1

7 12

11 20

18 17

1 2 3 4

Flywheel housing Turbo charger Breather Exhaust manifold

9 10 11 12

5 6 7 8

Water outlet Mounting bracket Oil filler cap Drain plug

13 14 15 16

Oil cooler Oil pan Vibration damper Idle pulley (Water pump) Water pump Idle pulley(Alternator) Alternator Oil filter

17 18 19 20 21 22

Crank shaft pulley Oil level gauge Starter Air pipe (Air cleaner to turbocharger) Power steering pump Pick-up sensor

GENERAL INFORMATION Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

(4) DV15TI (Truck)

4 5

6 7

3 2 1 15 19 20 10 11 12 13 14 30

29 24

23 22 21

25 26

1 2 3 4

Flywheel housing Exhaust elbow Fuel filter Air pipe(to air tank)

12 13 14 15

Drain plug Mounting bracket Alternator Water pump

23 24 25 26

Fan guide Oil filter Mounting bracket Air pipe

5 6 7 8

Air vent pipe Oil filler cap Exhaust manifold Air heater relay

16 17 18 19

Water outlet Control lever Oil pressure unit Idle pulley (Air con.)

27 28 29 30

Air pipe

Air con. bracket

31 Power steering pump

21 22

Fan clutch Cooling fan

32 Pick-up sensor 33

(Turbocharger to intercooler)

Starter PTO (Power take off) Lifting hook Air pipe (Air cleaner

to turbocharger)

(Intercooler to intake manifold)

10 11

Oil cooler Oil filler pipe

GENERAL INFORMATION

Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

(5) DV15TIS (Bus)

15 12

21 17 16

22 23 18

1 2 3

Flywheel housing Turbo charger Air compressor

9 10 11

Drain plug Oil pan Water pump idle pulley

17 18 19

Breather pipe

Water pump

Exhaust manifold

6 7 8

Water outlet Oil filler cap Oil cooler

14 15 16

Air pipe (Intercooler to intake manifold) Alternator Oil filter Mounting bracket

Oil level gauge Starter Air pipe (Air cleaner to turbo charger) Air pipe (Turbocharger to inter cooler) Power steering pump

22 23

Pick-up sensor Fly wheel

GENERAL INFORMATION Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

(6) DV15TIS (Truck)

4 55

6 7

8 9

18 19

3 2 1 16 20 21 11 12 13 14 15 31

30 22

23 24 25

26 27

1 2 3 4 5

Flywheel housing Exhaust elbow Fuel filter Air pipe(to air tank) Air vent pipe

12 13 14 15 16

Oil filler pipe Drain plug Mounting bracket Alternator Water pump

23 24 25 26 27

Fan guide Cooling fan Fan clutch Mounting bracket Air pipe

6 7 8 9

Oil filler cap Exhaust manifold Starter relay Air heater relay

17 18 19 20

Water outlet Control lever Oil pressure unit Idle pulley (Air con.)

28 29 30 31

Starter Power take off (PTO) Lifting hook Air pipe

Air pipe

Air con. bracket

Power steering pump

Oil filter

Pick-up sensor

(Turbo charger to Intercooler)

(Air cleaner to turbocharger) (Intercooler to intake manifold)

Oil cooler

GENERAL INFORMATION

Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

2. MAJOR MAINTENANCE 2.1. Preventive Maintenance The preventive maintenance means that the operator performs the servicing of engine to obtain long life and best performance from DAEWOO diesel engine. 2.1.1. Cooling water z Regarding the cooling water that is to be used for engine, the soft water not the hard water must be used. z The engine cooling water can be used diluting it with antifreezing solution 40% and the additive for rust prevention (DCA4) 3 ～ 5 %. z The density of above solution and additive must be inspected every 500 hours to maintain it properly. NOTE : The proper density control of antifreezing solution and rust preventing additive will be able to prevent the rusting effectively and maintain the stable quality of engine. For the improper control might give the fatal damage to the cooling water pump and cylinder liners, detail care is needed.

z Since DV15, DV15T, DV15TI, DV15TIS (Engine of D28 base engine) cylinder liner is wet type, particularly the cooling water control should be applied thoroughly. z The density of antifreezing solution and additive for rust prevention is able to be confirmed by the cooling water test kit. (Fleetguard CC2602M or DAEWOO 60.99901-0038) z How to use the cooling water test kit (1) When the cooling water temp. of engine is in the range of 10 ～ 55 °C, loosen the plug for cooling water discharge and fill the plastic cup about a half. NOTE: In taking the cooling water sample, if the water in auxiliary tank were taken, it is hard to measure the accurate density. Take the cooling water sample necessarily loosening the cooling water discharge plug.

(2) At the state of a test paper soaked in the sampled water, after taking the paper out through water agitation, shake off the water. (3) Wait for about 45 sec. till the color change of test paper. 18

MAJOR MAINTENANCE Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

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

(4) Make the numerical value by comparing the test paper which hue has changed with the color list of label on storage bottle. (5) By comparing the hue changed into yellowish green or so with the green color indication of test paper storage bottle, confirm the density. (Then, the density indication must be in the hue range of 33% to 50%). (6) The brown at the middle of test paper and the lower pink color indication represent the additive state for rust prevention, and the proper range is that the meeting numerical value of brown (vertical) and pink color (horizontal) locates in the range of 0.3 to 0.8 at the color list of label on the test paper storage bottle. (7) In case of less than 0.3, replenish the additive for rust prevention (DCA4), and in case of more than 0.8, pour out the cooling water about 50% and then readjust the density after refilling with clean fresh water. z Amount of Anti-freeze in winter Ambient Temperature (°C) Over –10 -10 -15 -20 -25 -30 -40

Cooling water (%)

Anti-freeze (%)

85 80 73 67 60 56 50

15 20 27 33 40 44 50

2.1.2. Fan belt z Use

fan

belt

specified

“Y”

dimensions, and replace if damaged,

Press here

frayed, or deteriorated.

Crank shaft pulley

z Check the fan belt for belt tension. If belt tension is lower than the

Water pump pulley

Idle pulley

specified limit, adjust the tension by relocating the alternator and idle pulley. (specified deflection: 10 ∼ 15 mm when pressed down with thumb)

Alternator pulley

Air con. pulley

MAJOR MAINTENANCE

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DV15/T/TI/TIS MAINTENANCE MANUAL

Alternator pulley

Idle pulley

Water pump pulley Crank shaft pulley Idle pulley

2.1.3. Engine oil z Check 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 5 â&#x2C6;ź 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. z Engine oil should be changed at the specified intervals. Oil in the oil filter should be changed simultaneously.

First oil change

After 1,000km (50hr) operation

Short-distance operation vehicle (city bus, dump truck, construction equipments)

DV15/T/TI

every 10,000km (250 hours)

DV15TIS

every 20,000km

DV15/T/TI

every 15,000km

DV15TIS

every 30,000km

Long-distance operation vehicles (express bus, cargo truck)

z The following oils are also recommended Recommend oil Engine model SAE No.

API No.

DV15/T/TI

SAE 15W40

above CD or CE

DV15TIS

SAE15W40 SAE10W40

ACEA-E2 or ACEA-E3 (API CH-4)

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

MAJOR MAINTENANCE Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

z Engine Oil capacity Engine oil capacity Engine Model DV15 DV15T DV15TI DV15TIS

Vehicle Bus Truck Industrial Bus Truck

in Oil pan Max. Min. (lit) (lit) 24 21 21 24 21

20 19 18 20 19

Total (lit) 27 24 24 27 24

2.1.4. Fuel filter z Drain water in cartridge with loosening the cock under filter manually (6) from time to time.

2.1.5. Air cleaner. z In case that elements are deformed, damaged or if the air cleaner has a crack, replace it. z By the definite interval, the elements must be cleaned and replaced.

MAJOR MAINTENANCE

Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

2.1.6. Intercooler (DV15TI, DV15TIS)

The intercooler is air to air type and has a large cooling fan capacity. The intercooler life and performance depends on the intake air condition greatly. Fouled air pollutes and clogs the air fins of intercooler. As a result of this, the engine output is decreased and engine malfunction is occurred. So you always check whether the intake air systems like air filter element are worn or polluted.

2.1.7. Valve clearance adjust procedure z After letting the #1 cylinder's piston come at the compression top dead center by turning the crankshaft, adjust the valve clearances. z 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 respectively and then tighten with the lock nut. z As for the valve clearance, adjust it when in cold, as follows.

Model DV15 DV15T DV15TI DV15TIS 22

Intake Valve

Exhaust Valve

0.25 mm

0.35 mm

MAJOR MAINTENANCE Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

z Adjusting sequence of valve clearance (Type 1) 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. 3) Rotating the crankshaft by one revolution, #6 cylinder become the compression state of top dead center. 4) Thereafter adjust the valve clearances corresponding to “

” of lower

figure. 5) After reinsuring the valve clearances, retighten if necessary. z No. 1 Cylinder is located at the side where cooling water pump was installed. Fly wheel

Cylinder No.

Intake valve

Exhaust valve

1 Cooling fan

: at the #6 cylinder overlap

Exhaust valve

Intake valve

: at the #1 cylinder overlap

z Adjusting sequence of valve clearance (Type 2) Type 1 is the conventional and simple method, but if you have some problem to adjust your engine, please try type 2 sequence. This is a precision method, but it takes more time.

*. 8 Cylinder Engine (DV15/DV15T/TI/TIS) Valve overlapping on cylinder (Intake & Exhaust valve)

Adjusting valves on cylinder (Intake & Exhaust valve)

MAJOR MAINTENANCE

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DV15/T/TI/TIS MAINTENANCE MANUAL

2.1.8. Cylinder compression pressure z Stop the engine after warming up, and take out nozzle holder assembly.

z Install the special tool (compression gauge adapter) at the nozzle holder hole, and connect the compression pressure gauge there. Standard value Limit value Difference between each cylinder

28kg/cm2 over 24kg/cm2 Within ± 10 %

♦ Condition : Water temperature 20°C, Engine rotation 200rpm (10 rotation) 2.1.9. Injection nozzle

z Install a nozzle on the nozzle tester. z If the inspected injection pressure is less than the specified value, adjust using the adjusting shims.

Engine model

DV15

DV15T

DV15TI

DV15TIS

Injection nozzle pressure

200+8 2 kg/cm

200+8 kg/cm2

250+8 kg/cm2

z Check the atomizing state and replace it if abnormal. 24

MAJOR MAINTENANCE Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

2.1.10. Fuel injection pump z Check the housing crack, damage etc. and replace it if abnormal. z Check if the idle operation and speed regulating lever's sealing is removed. z The adjustment and testing of fuel injection pump should necessarily be done at the test bench.

2.1.11. Battery z Inspect for any leakage 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 of electrolytic solution, if less than specified value (1.12 ď˝&#x17E; 1.28), replenish.

2.1.12. Air removal of fuel system The suction room of fuel injection pump has the function of air removal continuously during the operation through a relief valve. In case that the suction room lacks fuel at all, for instance, in case of new installation of injection pump, after loosening the air removing screws of cartridge filter respectively, remove the air by operating the manual pump of fuel supply pump until bubble will disappear. 2.1.13. Fuel supply pump Every time of engine oil replacement, the fuel strainer installed at the fuel supply pump should be removed and cleaned.

MAJOR MAINTENANCE

Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

2.1.14. Turbocharger The turbocharger needs not arty special equipment. Every time of engine replacement, a leakage or clogging of oil pipes should be inspected. Air cleaner should be maintained carefully for nut or foreign material not to get in. Periodic inspection should be applied on the compressed air and exhaust gas pipes, For leaking air will bring the overheat engine, an immediate repair must be done. During the operation that is surrounded by the dust and oil mixed air, frequent cleaning must be done on the impellers. Tear down the impeller casing (attention: be careful not to bend) and must clean with non-acid solvent solution. If necessary, use plastic scraper If impeller is severely polluted, dip the impeller into solution and may be better to clean it with stiff brush. Then one thing to beware is to dip only impeller part and so do not support by impeller but bearing housing. 2.1.15. Starting motor In case of engine maintenance, clean pinion and ring gear thoroughly putting in the fuel, and coat them with grease. Also, In case of washing car and so forth, inspect the wiring state being careful for not to get

MAJOR MAINTENANCE Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

2.2. Diagnosis and Remedy z The following description summarizes the probable cause of and remedy for general failure by item. z Immediate countermeasures should be taken before a failure is inflamed if any symptom is detected.

MAJOR MAINTENANCE

Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

MAJOR MAINTENANCE Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

MAJOR MAINTENANCE

Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

MAJOR MAINTENANCE Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

MAJOR MAINTENANCE

Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

MAJOR MAINTENANCE Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

MAJOR MAINTENANCE

Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

Condition 1) Starting difficult (1) Starting motor trouble (2) Fuel system trouble (3) Compression pressure lack

Causes z z z z z z

2) Idle operation abnormal

z z

Remedies

Refer to diagnostics Refer to diagnostics Valve's poor shut, stem distortion Valve spring damage Cylinder head gasket's leak Wear of piston, piston ring or liner Injection timing incorrect Air mixing at injection pump

Repair or replace Replace valve spring Replace gasket Adjust Adjust Remove air

3) Engine output insufficient (1) Continuous output insufficient

z z z z z z z z z z

(2) Output insufficient when in acceleration

z z z z z z z z

4) Overheating

z z z z z z z

Valve clearance incorrect Valve tightness poor Cylinder head gasket's leak Wear, stick, damage of piston ring Injection timing incorrect Fuel injection amount insufficient Nozzle injection pressure improper or stuck Supply pump's function lowered Fuel pipe system clogged Air suction amount insufficient Turbocharger poor Compression pressure insufficient Injection timing incorrect Fuel injection amount insufficient Injection pump timer's function insufficient Nozzle infection pressure, infection angle improper Supply pump's function lowered Air intake amount insufficient Engine oil insufficient or poor Cooling water insufficient Fan belt loosened, worn, damaged Cooling water pump's function lowered Water temp. regulator's operation poor Valve clearance incorrect Exhaust system's resistance increased

Adjust Repair Replace gasket Replace piston ring Adjust Adjust injection pump Adjust or replace Repair or replace Repair Clean or replace air cleaner Repair or replace Disassemble engine Adjust Adjust injection pump Repair or replace Repair, replace Repair or replace Clean or replace air cleaner Replenish or replace Replenish or replace Adjust or replace Repair or replace Replace Adjust Clean or replace

MAJOR MAINTENANCE Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

Condition 5) Engine noisy

(1) Crankshaft

(2) Con.-rod and Con.-rod bearing

Causes For noises arise compositely such as rotating parts, lapping parts etc., there is necessity to search the cause of noises accurately. z As the wear of bearing or crankshaft progress, the oil clearances increase. z Lopsided wear of crankshaft z Oil supply insufficient due to oil passage clogging z Stuck bearing z z z z z

(3) Piston, piston pin & Piston ring

(4) Others

z z z z z z z z z z z z

6) Fuel Consumption Excessive

Remedies

z z

Replace bearing & grind crankshaft Grind or replace Clean oil passage

Replace bearing & Grind Lopsided wear of con rod Replace bearing bearing Lopsided wear of crank pin Grind crankshaft Connecting rod distortion Repair or replace Stuck bearing Replace & grind crankshaft Oil supply insufficiency as Clean oil passage clogging at oil passage progresses Piston clearance increase Replace piston & as the wear of piston and piston ring piston ring progresses Wear of piston or piston pin Replace Piston stuck Replace piston Piston insertion poor Replace piston Piston ring damaged Replace piston Wear of crankshaft, thrust Replace thrust bearing bearing Camshaft end play Replace thrust plate increased Idle gear end play increased Replace thrust washer Timing gear backlash Repair or replace excessive Valve clearance excessive Adjust valve clearance Abnormal wear of tappet, Replace tappet, cam cam Turbocharger inner part Repair or replace damaged Injection timing incorrect Adjust Fuel injection amount Adjust injection pump excessive

MAJOR MAINTENANCE

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DV15/T/TI/TIS MAINTENANCE MANUAL

Condition 7) Oil Consumption Excessive (1) Oil level elevated

Causes z z z z z z

(2) Oil level lowered

z z

(3) Oil leak

z z z z z

Remedies

Clearance between cylinder liner & piston Wear of piston ring, ring groove Piston ring's damage, stick, wear Piston ring opening's disposition improper Piston skirt part damaged or abnormal wear Oil ring's oil return hole clogged Oil ring's contact poor Looseness of valve stem & guide Wear of valve stem seal Cylinder head gasketâ&#x20AC;&#x2122;s leak Looseness of connection parts Various parts' packing poor Oil seal poor

Replace Replace piston, piston ring Replace piston ring Correct position Replace piston Replace piston ring Replace piston ring Replace in set Replace seal Replace gasket Replace gasket, repair Replace packing Replace oil seal

MAJOR MAINTENANCE Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

2.3. Engine Inspection 2.3.1. Stopping engine After checking the engine for any unusual condition at the idling speed, then turn the key switch to stop the engine. 2.3.2. General engine inspection cycle О : Check & adjust

● : Replace

Inspection time(km)

Inspection

Daily

Remark

1,000

Cooling System

Check for leakage(hoses, clamp) Check the water level Check the V-belt tension

10,000

15,000

20,000

О О О ●

Change the coolant water Check for leakage Check the oil level gauge

О О ● 1st ● 1st

Lubrication Change the lubricating oil System Replace the oil filter cartridge Check the leakage for intercooler

Intake & (hoses, clamp) Exhaust Clean and change System the air cleaner element

Fuel System

Drain the water in separator Clean the fuel strainer of fuel feed pump Check the fuel line leakage

(●) (●)

О О О О О When necessary

Check fuel Injection timing ●

Replace the fuel filter cartridge

When necessary

Check the injection nozzles

Engine Adjust

40,000

Check the exhaust gas state

Check the battery charging

Check the compression pressure Adjust Intake/Exhaust valve clearance

When necessary When necessary

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

2.3.3. Use of original parts for repair and replacement For engine is being mechanically harmonized with many parts, only when the original parts that the manufacture recommends to use is used, the engine trouble would be preventively maintained and capable to keep up the maximum performances. For the analogous parts not the original parts are poor in qualities and gives ill performances, it may rather bring early engine failure. MAJOR MAINTENANCE

Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

3. Disassembly and Reassembly of Major Components 3.1. Engine Disassembly 3.1.1. General precautions z Maintenance operation should be carried out in a bright and clean place. z Before disassembly, provide parts racks for storage of various tools and disassembled parts. z Arrange the disassembled parts in the disassembly sequence and use care to prevent any damage to them. 3.1.2. Cooling water z Remove the radiator cap. Open the Radiator cap

drain valve at the radiator lower part to drain the coolant as the right figure.

CAUTION: When removing radiator filler cap while the engine is still hot, cover the cap with a rag, then turn it slowly to release the internal steam pressure This will prevent a person from

Drain valve

scalding with hot steam spouted out from the filler port.

Remove the cooling water drain plug from the cylinder block and oil cooler, various pipes, etc. and let the cooling water

discharge

into

the

prepared

vessel.

ENGINE DISASSEMBLY Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

3.1.3. Oil level gauge z Take out the oil level gauge. 3.1.4. Engine oil z Remove an oil drain plug from the oil pan, and let engine oil discharge into the prepared vessel

3.1.5. Cooling fan z Remove fan fixing bolts, then take off the cooling fan.

3.1.6. V-belt. z Loosen the V-belt tension adjusting bolts, and remove the V-belt.

3.1.7. Alternator z Remove the supporting guide piece for installing the alternator and the bracket bolts. z Disassemble the alternator.

ENGINE DISASSEMBLY

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DV15/T/TI/TIS MAINTENANCE MANUAL

3.1.8. Vibration damper z Remove the fixing bolts for crankshaft pulley in reverse order of assembling and disassemble the crankshaft pulley and vibration damper.

3.1.9. Oil filter z Loosen the filter housing fixing bolts then the spring will force the filter housing to move upward a little.

z Allow an interval of 2 ~ 3 minutes until the engine oil by-passes to the oil pan, then take off the filter. z Do not use again the cartridge removed after use.

z Unscrew the oil filter head fixing bolts and take off the oil filter head

ENGINE DISASSEMBLY Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

3.1.10. Cooling 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 water pump fixing bolts and disassemble the cooling water pump. 3.1.11. Starting motor z Remove the starting motor fixing nuts and disassemble the starting motor.

2.1.12. Fuel filter z

Disassemble the fuel hose for the fuel supply and suction.

Remove the fuel filter fixing bolts and disassemble the filter.

3.1.13. Fuel filter z

Disassemble the fuel hose for the fuel supply and suction.

Remove the fuel filter fixing bolts and disassemble the fuel filter.

3.1.14. Fuel injection pipe z Disassemble various fuel pipe and hose. z Disassemble the fuel injection pipe from

the

nozzle

holder

and

fuel

injection pump.

ENGINE DISASSEMBLY

Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

3.1.15. Oil cooler 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.

Clamp the oil cooler assembly to the vise, remove the oil cooler insert fixing bolts, then disassemble the cooler insert.

3.1.16. Turbocharger z Loosen the hose clamp for connecting the intake stake and tear down the air intake stake. z Loosen the fixing bolts for connecting the air intake manifold. z Remove the hollow screws of pipes for turbocharger lubrication and its discharge, and tear the pipes down. z Remove the turbocharger fixing nuts. z Remove the turbocharger using care so that the connecting pipes of the intake flange and O-ring may not be damaged.

ENGINE DISASSEMBLY Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

3.1.17. Intercooler (DV15TI, DV15TIS) z Tear down the various hoses and air pipes from the inter cooler. z Remove the intercooler fixing bolts and tear it down.

3.1.18. Exhaust manifold z Remove the exhaust manifold fixing bolts and tear down the manifold from the cylinder head.

3.1.19. Intake manifold z Remove the manifold fixing bolts and tear down the manifold from the cylinder head.

3.1.20. Air compressor z Remove the oil, water, air pipes and hoses between cylinder block and air compressor. z Remove the power steering oil pump. z Unscrew the cylinder head bolts and remove the compressor head.

ENGINE DISASSEMBLY

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DV15/T/TI/TIS MAINTENANCE MANUAL

z Remove the side cover. z Remove the flywheel housing side cover. z Unscrew the liner fixing bolts and take off the air compressor liner over the piston. z Unscrew the connecting rod bearing cap fixing bolts and take them off together with the cylinder liner. z Unscrew

the

fixing

nuts

the

compressor driving gear using a special spanner and disassemble the driving gear. z Disassemble the flange on the front side of the flywheel housing. z Disassemble the crank shaft. z Disassemble the bearing flange on rear side. 3.1.21. Fuel Injection pump z Remove the oil pipes for lubrication and the fuel hoses. z Remove the fixing bolts of fuel injection pump and take out the fuel Injection pump.

3.1.22. Cylinder head cover z Remove cylinder head cover fixing bolts and take off the cylinder head cover.

3.1.23. Nozzle holder z Unscrew nozzle holder fixing nut by using a special tool and remove the nozzle holder.

ENGINE DISASSEMBLY Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

3.1.24. Rocker arm z Remove the rocker arm bracket fixing bolts and take out the rocker arm. z Pull out the push rod.

3.1.25. Cylinder head z Loosen the cylinder head fixing bolts in the reverse order of assembling, and remove them all and then take the cylinder head out. z Remove the cylinder head gasket and scrap it. z Eliminate 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. 3.1.26. Oil pan z Remove the oil pan fixing bolts and separate the oil pan. z Remove the oil pan gasket and scrap it.

3.1.27. Oil pump z Remove the oil suction pipe fixing bolts and tear them down. z Remove the oil relief valve fixing bolts and take them out. z Remove the oil pump fixing bolts and separate it.

ENGINE DISASSEMBLY

Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

3.1.28. Piston z Remove the connecting rod cap bolts in the reverse order of assembling and follow the similar method as in the cylinder head bolt removal. z Tapping the upper and lower connecting rod caps lightly with an urethane hammer, separate them and take the bearings out. z By pushing the piston assembly with a wooden bar toward the cylinder head's direction remove the piston. NOTES: 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 mix one another, temporarily assemble them to the corresponding connecting rods.)

3.1.29. Front oil seal holder z Remove the oil seal holder fixing bolts and tear down. z Remove the oil seal and gasket from the oil seal holder and scrap them.

3.1.30. Flywheel z Remove the flywheel fixing bolts in the order of disassembling and remove the flywheel.

ENGINE DISASSEMBLY Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

z Remove the flywheel ring gear. -

Heat the ring gear evenly with a gas burner (up to 200 Â°C) to invite volumetric expansion.

Tapping around the edges of the ring gear with a hammer and brass bar to remove it. CAUTION: Do not damage the flywheel.

3.1.31. Flywheel housing z Remove the flywheel housing fixing bolts and take them out. z Remove the oil seal from the flywheel housing. 3.1.32. Crankshaft z Remove the bolts from bearing caps. z Remove the main bearing cap fixing bolts in the order of assembling. (Remove them in the same way of the cylinder head bolts.) z Maintain the removed bearing caps in the order of cylinders. z Temporarily install the bolts at the both side of crankshaft, and lift the shaft with a rope. NOTES : Do not mingle with the metal bearings and bearing caps randomly. To prevent mixing, temporarily assemble the metal bearings to the corresponding bearing caps in turn.

ENGINE DISASSEMBLY

Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

3.1.33. Camshaft and tappet z Pull out the tappets from the cylinder block. z Remove the camshaft being careful not to damage the camshaft and its bearings.

3.1.34. Oil spray nozzle z Remove the oil injection nozzle fixing bolts and tear down the oil injection nozzles.

3.1.35. Cylinder liner z By means of a special tool (Extractor), pull out the liner from the cylinder block.

ENGINE DISASSEMBLY Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

3.2. Measurement and Inspection of Major Parts 3.2.1. Cleaning and inspection of cylinder block z Clean the cylinder block and inspect it for any crack or a damage. z Inspect the oil passage and water passage for any clog and erosion. z By performing the hydraulic test, inspect for any leaks. With plugging the water and oil passages of cylinder block, put in the air of 5 kg/cm2 pressure in the Inlet port of cylinder block and then soak the cylinder block in the water for about 1 minute to check for any leaks. (water temperature: 70 °C) z 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 measurement z Assemble the cylinder liner at the cylinder

block

and

measure

inner

diameters at upper, middle, lower 3 levels by 45° interval and calculate the average values after eliminating the max. and min. values. z If the measured values are very close to the limit value or beyond, replace it. Standard Liner inner diameter φ127.990 ∼ φ128.010 mm

Limit 0.15 mm

3.2.3. Cylinder head (1) Cylinder head disassembly z Be careful for the cylinder head gasket

contacting surface of cylinder head not to be damaged. z Remove the cotter pin pressing the valve spring by means of a special tool.

MEASUREMENT & INSPECTION

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DV15/T/TI/TIS MAINTENANCE MANUAL

z Take out the valve stem seal. z Pull out the intake and exhaust valves. z Remove the valve guides from the combustion room side of cylinder head by means of a special tool.

2) Inspection and measurement of cylinder head a) Damage check z Inspect the cylinder head for any crack or damage. z Eliminate the carbon residue and gasket piece from the cylinder head lower face thoroughly. Then be careful for the valve seat not to be damaged. z The cracks or damages that are difficult to search may be inspected by a hydraulic test or a magnetic powder test. (Hydraulic test is same as for cylinder block.) b) Distortion z Measure the flatness degree (any distortion) of cylinder head. Even beyond the limit value of maintenance, it may be corrected by grinding. (if more than limit value of use, replace it.)

Warpage

Standard

Limit

0.05 mm or less

0.2 mm

MEASUREMENT & INSPECTION Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

3) Inspection and measurement of valve and valve guide a) Valve z After cleaning the valves with clean diesel oil, measure the valve stem's outside diameter at upper, middle, and lower to determine the wears and when the wear limit is more than 0.15mm, replace the valves. Valve

Standard

Limit

Intake φ11.969 ∼ φ11.980 mm

φ12.130 mm

Exhaust φ11.945 ∼ φ11.955 mm

φ12.105 mm

z Inspect the scratch and wear of valve stem seal contacting face, and if necessary correct with the grinding paper but if severe replace it. z If valve head thickness (H) becomes less than 1.6mm for intake and 1.3mm for exhaust, replace the valve. Valve

Standard

Limit

Intake

2.6 ∼ 3.0 mm

1.6 mm

Exhaust

1.9 ∼ 2.3 mm

1.3 mm

b) Valve guide z Insert the valve into valve guide and measure the clearance between valve and valve guide by the shaking degree of valve. If the clearance is bigger, measure the valve and then replace the more worn valve guide.

MEASUREMENT & INSPECTION

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DV15/T/TI/TIS MAINTENANCE MANUAL

If the valve guide has already been replaced, measure the center with valve seat if it deviates or not and if abnormal it must be corrected. (Simultaneously be processed when in guide reamer process.) Valve

Standard

Limit

Intake

0.020 ∼ 0.049 mm

0.20 mm

Exhaust

0.045 ∼ 0.074 mm

0.25 mm

c) Valve seat thickness and angle z

Inspect the damage and wear of valve seat and if necessary replace it.

Assemble the valves at the cylinder head and using the measuring instrument from the lower face, measure the projection amount of valve. If the measured value is more than the use limit, replace the valve seat. <Valve seat thickness> Standard

Limit

0.65 ∼ 0.95 mm

2.5 mm

<Valve seat angle> Intake valve

30°

Exhaust valve

45°

z The disassembly of valve seat can be pulled out by means of a special tool with the arc welding done at two points of valve seat rotating tool or valve seat.

MEASUREMENT & INSPECTION Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

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 After coating the grinding powder paste on valve head contacting face of valve seat, and after executing a sufficient lapping operation with the rotating and grinding motion of valve, wipe off the z grinding agent thoroughly. d) Valve spring z

Inspect the outlook of valve spring and if necessary replace it.

By means of spring tester, measure the tension and free length.

z Measure the perpendicularity of valve spring. z

In case that the measured value exceeds the limit value, replace it. <Perpendicularity regular> Free length Inside spring

When compressed with load of 15 ∼ 17 kg When compressed with load of 44.5 ∼ 49.5 kg Free length

Outside spring

When compressed with load of 37 ∼ 41 kg When compressed with load of 26.5 ∼ 30 kg

DV15/T/TI DV15TIS

72.43 mm 68.3 mm

DV15/T/TI 46.3 mm DV15TIS DV15/T/TI DV15TIS

68.17 mm 61.9 mm

DV15/T/TI 46.8 mm DV15TIS

e) Cylinder head assembling z Clean the cylinder head thoroughly. z Coat the valve stems and valve guides with engine oil and assemble the valves. z Replace the valve stem seals with new ones and insert the stem seals to the valve guides of cylinder head 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 on them.

MEASUREMENT & INSPECTION

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DV15/T/TI/TIS MAINTENANCE MANUAL

z Install the valve spring seat with â&#x20AC;&#x153;TOPâ&#x20AC;? (painted in red) side up.

Painted portion

z Pressing the spring down with a special tool, assemble by inserting the valve cotter. z After the valve is assembled, inspect the valve tapping it lightly with an urethane

hammer

accurate

assembling was done. 3.2.4. Rocker arm 1) Rocker arm disassembling z Remove the snap rings in both ends of rocker arm with a pair of pliers. z Tear down washer, rocker arm. z Disassemble the rocker arm bush by means of a press.

2) Inspection and measurement a) Rocker arm bracket (Single unit type with a shaft)

z Measure the outer diameter of rocker arm bracket with outside micrometer at the position that the rocker arm is installed, and in case that it exceeds the limit value, replace.

MEASUREMENT & INSPECTION Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

Standard

Limit

Bush inner Diameter

φ25.005 ∼ φ25.035 mm

φ25.055 mm

Shaft outer Diameter

φ24.967 ∼ φ24.990 mm

φ24.837 mm

0.015 ∼ 0.068 mm

0.25 mm

Clearance

b) Rocker arm z Inspect the rocker arm surface that contacts with the valve stem for any scratch, step wear and correct the minor degree of wear with an oil stone or the fine grinding paper and replace if they are severe. c) Tappet and push rod z By

means

outside

micrometer,

measure the outer diameter of tappet and replace the severe ones. Standard

Limit

Tappet clearance 0.035 ∼ 0.077 mm 0.25 mm

z By inspecting 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 Place the push rod on the surface plate and rolling it, Inspect the curving degree with a clearance gauge and if abnormal, replace it. <Run-out> Limit

0.3 mm or less

d) Rocker arm reassembling

MEASUREMENT & INSPECTION

Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

z Inspect the oil passages of rocker arm and rocker arm bracket for any clogs and reassemble them in the reverse order of disassembling after thorough cleaning. 3.2.5. Camshaft 1) Axial end play z Push the camshaft toward the pulley side. z Place a dial gauge onto the camshaft gear.

z Measure the camshaft's axial end play, moving the camshaft gear by means of a driver. Limit

0.2ď˝&#x17E;0.9mm

z If excessive end play, assemble it by means of other thrust washer. 2) Inspection and measurement z With inspecting the cam surface for any damage with naked eyes and correct any minor scratch by means of an oil stone grinding and if severe, replace it. a) Cam lobe height z Use a micrometer to measure the cam lobe height and journal diameter. If the measured number is less than the specified

limit,

the

camshaft

must

replaced.

MEASUREMENT & INSPECTION Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

Standard

Limit

47.7 mm 46.5 mm

Cam lobe height (C)

Cam journal diameter (A,B) φ56.0 mm φ55.6 mm

b) Cam journal diameter z By

means

outside

micrometer,

measure the camshaft journal. φ69.91 ～ φ69.94 mm

Standard

c) Cam bearing diameter z Measure

the

camshaft

bush

inside

diameter with a cylinder gauge and by comparing

the

inside

and

outside

diameters, replace if abnormal. Standard

φ70.077 ∼ φ70.061 mm

d) Clearance between camshaft journal and body Standard

Limit

0.060 ∼ 0.120 mm

0.18 mm

e) Camshaft bearing replacement z Remover, installer

MEASUREMENT & INSPECTION

Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

f) Camshaft run-out z With placing the camshaft on the 2ea of V-blocks, and inspect the run-out of the camshaft, adjust or replace the severe one. Standard

0.1 mm

2.2.6. Crankshaft 1) Inspection and measurement z Inspect for any scratch or damage with naked eyes, and grind to the undersize according to the damaged degree and use the undersized bearing. z 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 crank pin at the direction and position of the figure shown and take the wear. <Crankshaft journal outside diameter> Standard φ103.98 ∼ φ104.00 mm <Crankshaft pin outside diameter> Standard

φ89.98 ∼ φ90.00 mm

z In case that the lopsided wear is more than the limit value, grind to the undersize, and use the undersized bearing. 58

MEASUREMENT & INSPECTION Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

<Kinds of bearings for undersize> (a) Standard (b) 0.25 (Inside diameter 0.25mm less than standard) (c) 0.50 (Inside diameter 0.50mm less than standard) (d) 0.75 (Inside diameter 0.75mm less than standard) (e) 1.00 (Inside diameter 1.00mm less than standard) z There are 4 kinds as above, and the crankshaft also can be used by regrinding as above.

<"R” part standard value> (a) Crank pin "R” part :

4.0− 0.05

(b) Crank journal "R” part :

4.0− 0.05

NOTE: In case of crankshaft regrinding, the "R” part at the end of bearing must accurately be ground without fail and should avoid any processed jaw or coarse surface. b) Run out of crankshaft z Place the crankshaft on the V-block. z Place the dial gauge on the surface plate and measure the run out of crankshaft rotating the crankshaft. Standard

Limit

0.06 mm

0.4 mm

MEASUREMENT & INSPECTION

Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

2) Inspection on crankshaft bearing and connecting rod bearing z Inspect the crankshaft bearing and connecting damages

rod

bearing

such

for

lopsided

any wear,

scratch etc. and if abnormal, replace it. z Inspect the oil clearance between the crankshaft and bearing. a) How to utilize the cylinder gauge z Assemble the main bearing at the cylinder block and after tightening the bearing cap at the specified torque, measure the inside diameter. Journal bearing nominal diameter

φ104 mm

Bearing cap Bolt torque

Initial 30 kg.m + angle 90°

z Assemble the bearing at the bigger end

tightening

connecting the

rod,

bearing

and

cap

after the

specified torque, measure the inside diameter Connecting rod bearing journal diameter Connecting rod Bolt torque

φ90 mm

Initial 10 kg.m + angle 90°

z Crankshaft pin and bearing clearance In case that this clearance value exceeds the limit value, grind the crankshaft journal and pin and then use the undersized bearing.

Standard

Limit

0.066 ∼ 0.132 mm

0.166 mm

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DV15/T/TI/TIS MAINTENANCE MANUAL

b) How to utilize plastic gauge z Install the crankshaft in the cylinder block and place the plastic gauge on the crankshaft journal and pin at axial direction and then after tightening the bearing cap at the specified torque and again after tearing apart the bearing cap, measure the flatten plastic gauge thickness by pick it up. This is the oil clearance. z With the same points, the oil clearance of

connecting

rod

also

can

measured. c) End play z Assemble the crankshaft in the cylinder block. z Install the dial gauge, and measure the end play of crankshaft by pushing the crankshaft to axial direction. Standard

Limit

0.190 â&#x2C6;ź 0.322 mm

0.452 mm

2.2.7. Piston 1) Piston disassembling z Pull out the snap ring for piston pin and with a pair of snap ring pliers. z With a round bar, remove the piston pin.

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z With a pair of pliers, remove the piston rings. z Clean the piston thoroughly.

2) Piston z With naked eyes, inspect the piston for any

wear,

crack

and

scratch

and

particularly inspect carefully at the ring grooves for any wear. z With the outside micrometer, measure the

piston's

outside

diameter

the

measuring position is 71.5mm from the piston lower end, and the direction of measurement must be perpendicular to the piston pin direction. Standard

φ127.739 ∼ φ127.757 mm

z By comparing the measured value of the piston outside diameter with the cylinder

liner

inside

diameter,

the

bigger clearance is replaced. 3) Piston ring and ring groove a) Inspection z In case of piston ring's wear, damage or engine overhaul, replace piston rings. b) Gap clearance z Measure the piston ring cut part. z Insert the piston ring at the cylinder liner's upper part perpendicularly. z With a feeler gauge, measure the gap clearance of piston ring. z If the measured value exceeds the limit value, replace it. 62

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c) Piston ring gap Division Top ring 2nd ring Oil ring

Standard 0.35 ∼ 0.55 mm 0.40 ∼ 0.60 mm 0.35 ∼ 0.55 mm

Limit 1.5 mm 1.5 mm 1.5 mm

c) Piston side clearance. z Assemble the piston ring at the piston. z Measure the each ring's side clearance and if the measured value exceeds the limit value, replace rings or piston. d) Piston side clearance Division Top ring 2nd ring Oil ring

Specified value Limit value 1.5 mm 0.35 ∼ 0.55 mm 0.050 ∼ 0.082 mm 1.5 mm 0.030 ∼ 0.062 mm 1.5 mm

4) Piston pin a) Outside diameter z With the outside micrometer, measure the piston pin's outside diameter and if the value is same as the use limit value or less, replace it.

Standard

Limit

φ45.994 ∼ 46.000 mm φ45.983 mm or less

b) Piston pin and connecting rod bush clearance z Inspect the clearance between the piston pin and the connecting rod bush, if it is more than the use limit value, replace either one that is more severe.

Limit

0.003 ∼ 0.015 mm

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5) Connecting rod z Inspect and measure the bigger end bearing hole and the smaller end bearing

hole

with

respect

the

parallelness and if abnormal, replace the rod. Standard

Limit

0.02 mm

0.2 mm

6) Piston reassembling z After heating the piston at the piston heater for about 5 min (120 ∼ 150 °C), by aligning the piston pin hole with the pin hole of connecting rod's smaller end, insert the oil coated piston pin.

NOTE : Confirm the direction of connecting rod and assemble. z With the snap ring plier, insert the piston pin snap ring. z With confirming the upper side indication of piston ring, after assembling the ring in the piston ring groove, inspect if the movement of ring is smooth. z Keep in order of the assembled piston as the cylinder No. turn. 7) Water temperature inspection z Inspect the wax case and spring for any damage. z With putting the water temperature gauge into water and heating the water at the indirect method, when the water temp reaches to 83 °C, the valve begin to open and fully open when it reaches to 95 ° C. z Measure

the

valve

opening

temperature and the valve full opening 64

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temperature and inspect if the valve lift is more than 8mm and if abnormal, replace it. 8) Injection nozzle z Set the nozzle assembly between the vise holder and disassemble it. z Remove

the

nozzle

nuts

and

disassemble the inner parts.

z Inspect the disassembled parts if there is any damage, replace it. z Assembling can be done in the reverse order of disassembling. z After assembling the nozzle, set it in the injection pressure measuring tester. z By manipulating the tester handle, inspect the injection pressure and atomizing state. <Operating pressure> Engine model

DV15

DV15T

DV15TI

Injection nozzle pressure

200+8 kg/cm2

200+8 kg/cm

DV15TIS 2

250+8 kg/cm2

z In case of low or high injection pressure, adjust by adding or reducing the spring tension adjusting shims. z In case that atomizing state is not good, it should be replaced.

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3.3. Engine Reassembly 3.3.1. Preparation and precaution before and after engine reassembly z

Clean all the parts thoroughly and also clean thoroughly by blowing into each passage of oil and cooling water.

Disposition the various special and general tools for assembling in order.

In order to coat the lapping parts with engine oil, prepare the clean engine oil.

Prepare the sub-material such as an adhesive etc.

Use three bond as an adhesive in the engine oil system and use silicone in the cooling system.

Scrap the used gasket and seal ring, consumable parts etc. and replace with new ones.

z Tighten the various bolts in the specified tightening torque, and also according 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 or not should necessarily be insured. z Make sure that there is any missing parts or insufficient parts after full completion of assembling. z Work only with clean hands. 3.3.2. Cylinder liner z Replace O-ring with new one without fail and at the upper side, insert to the cylinder liner, but at the lower side, to the cylinder block. z Coat the joint parts where O-ring contacts with oil.

z After slipping the cylinder liner smoothly into the cylinder block, press it in being careful for O-ring not to damage. z After

completion

assembling

the

cylinder liner, confirm no leaks with 4 kg/cm2 hydraulic test.

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3.3.3. Oil spray nozzle z Tighten the oil injection nozzle flange with hollow screws. z Assemble the oil injection nozzle with the fixing bolts. Torque

1.2 kg.m

3.3.4. Tappet z Coat the tappet wholly clean oil and push in the tappet hole of the cylinder block.

3.3.5. Crankshaft z Put the wear ring into the heater to heat it up to 150 â&#x2C6;ź 200 Â°C level, push it over the crankshaft by means of a jig.

z Assemble

the

main

bearing

the

cylinder block and coat it with engine oil. Then assemble the bearing that has a hole to the cylinder block side and one that has no hole to the bearing cap and be careful not to change. z Assemble temporarily one bolt each at

Tightening order

both bolt holes and by connecting the wire to the bolts, lift it with crane or chain block and put down on the cylinder block carefully. Bearing cap

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z Coat the crankshaft journal and pin parts with engine oil, and after fitting the main bearing

into

the

bearing

cap

and

assemble it to the cylinder block making sure of the number in order not to change the bearing cap. z Coat the bearing cap bolt and its bolt seat part with engine oil necessarily and according to the tightening order, tighten them with 30 kg.m and with rotating angle 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 about 15 kg.m by wrench. (4) Fourth step: Tighten with about 25kg.m by torque wrench. (5) Fifth step: Tighten with 30kg.m by torque wrench. (6) Sixth step: Tighten with final rotating angle method 90° +10°. However, according to above tightening order, tighten step by step. z

Inspect if the crankshaft's rotation is smooth.

Assemble the crankshaft gear on the crankshaft and coat a white paint mark on "1" part in order to find easily.

3.3.6. Camshaft z

Coat the cam bush of cylinder block and camshaft with engine oil.

Crankshaft gear

Assemble the cam bush and camshaft for them not to be damaged.

Assemble the crankshaft gear and the camshaft gear making sure that the gear marks

both

gears

are

aligned

together.

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3.3.7. Flywheel housing z Assemble

the

following

parts

the

flywheel housing before installing the flywheel housing onto the cylinder block. z Assemble the air compressor crankshaft with the drive gear. Torque z Apply

loctite

36 kg.m to

the

fixing

bolt

and

assemble the thrust washer. Torque

4 kg.m

z Coat the oil seal (P.T.F.E.) with lubricating oil and assemble the oil seal carefully for it not to deviate or be damaged by means of special tool. (Mandrel for assembling).

Thrust washer

z Attach the gasket on the surface of cylinder block where the flywheel housing is to be installed. (In order to prevent the gasket slip down, coat a grease on the

Oil seal

cylinder block surface.) z Temporarily assemble 2ea of guide bolts

Crank shaft

Flywheel housing Oil seal(Rear)

for installing the flywheel housing to the cylinder block. z After fitting the flywheel housing holes to

Flywheel

the guide pins and engage temporarily 2 â&#x2C6;ź 3 threads of fixing bolts, and according to the tightening order (zigzag method) tighten them in the specified torque. Torque

7.5 kg.m

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DV15/T/TI/TIS MAINTENANCE MANUAL

3.3.8. Tacho sensor z Move the lock nut to hexagonal side of sensor completely. z Rotate (CW) the tacho sensor on flywheel housing, until the end of it reach on flywheel ring gear. z Rotate (CCW) the tacho sensor for 270° (gap 1.0 mm) and fix lock nut. z Tolerance limit is 27°. (gap ± 0.1 mm)

3.3.9. Flywheel z Installation of flywheel ring gear with a gas burner, heat the ring gear evenly until heat expansion takes place, then install it using a hammer. z Do not allow the temperature of the ring gear to exceed 200 °C (390 °F). z By means of mandrel, assemble pilot bearing to the flywheel. z By means of mandrel, press in the wear ring at the backward face.

z Install two guide bolts for installing the flywheel to the crankshaft. z After letting the guide pin insert through the flywheel holes and engaging the fixing bolts by 2～3 threads temporarily, tighten them to the specified torque 70

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according to lightening order. (Zigzag order) Torque

26 kg.m

3.3.10. Oil cooler z Attach a gasket on the surface in the oil cooler housing where the oil cooler is installed. z Tighten the oil cooler with fixing bolts. z Install

the

oil

cooler

assembly

tightening the fixing bolts in the zigzag order. 3.3.11. Air compressor z Assemble the piston assembly into air compressor cylinder liner before installing it to the 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 assembly with the air compressor crankshaft and tighten it to the specified torque. Torque

3.5 kg.m

z Tighten the liner fixing bolts to the specified torque. Torque

4 kg.m

z Tighten the air compressor head fixing bolts to the specified torque. Torque

4 kg.m

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3.3.12. Starting motor z Install stud bolts at the bolt holes on the flywheel housing for installing the starter. z Insert the starter into the flywheel housing and tighten the fixing nuts. Torque

8 kg.m

3.3.13. Piston z Line up the piston assembly in the order of cylinders and fit the bearings to the connecting

rods

and

bearing

caps.

However, take care not to swap between the connecting rods and bearing caps. z Coat the pistons and connecting rod bearings sufficiently with clean engine oil. z By means of a special tool, insert the piston rings and adjust the angles between the ring gaps at 120°. 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 crankshaft about 180° and fit the bearing cap to the connecting rod. z Coat the tap parts of connecting rod bolts and their seats with engine oil, and after engaging 2～3 threads of bolts primarily rind then tighten them to the specified torque. (10 kg.m + 90°+10°) <Connecting rod bolt Tightening Order> (1) First step: Coat the bolts with engine oil. (2) Second step: Engage 2～3 threads by hands. (3) Third step: Tighten to about 7kg.m with wrench. (4) Fourth step: By means of torque wrench tighten to 10 kg.m. 72

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(5) Fifth step: Finally assemble by means of rotation angle method 90°+10°. However, according to above tightening order, tighten them step by step. * Standard length of bolt and use limit: from head seat to bolt tip Standard length 67.5

-0.3

Use limit

69 mm

z By moving the connecting rod bearing cap by hands, make sure if there is any play in left and right. z With

the

same

method

above,

assemble in each cylinder rotating the crankshaft. 3.3.14. Fuel injection pump z Coat the O-ring with grease and insert it at the lower part of fuel injection pump. (Be careful for O-ring not to be removed) z Prior to installing the fuel pump drive gear, fit the rubber gasket. z Tighten temporarily the fuel injection pump drive gear with aligning the pointer on drive gear with injection pump pointer. z Rotate the flywheel so as to let No. 6 cylinder for come to top dead center (TDC), that is, the above cylinder's valves may be overlapped. z Rotate the flywheel to the opposite direction about 30° (in order to remove a backlash) and then rotate in normal direction to set the injection angle. z After

completing

the

preparation

for

injection pump assembling, install the fuel injection pump and tighten the bolts in the zigzag method. z After assembling the fuel injection pump,

ENGINE REASSEMBLY

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DV15/T/TI/TIS MAINTENANCE MANUAL

find out if the fuel pump pointer and drive gearâ&#x20AC;&#x2122;s pointer are aligned, and if aligned, tighten

the

fixing

bolts

that

were

temporarily tightened. However, if not aligned, loosen the fixing bolts and turn the fuel pump camshaft so as to align the pointers and tighten the fixing bolts. Torque

3.1 kg.m

3.3.15. Flywheel housing cover z Attach a gasket to the flywheel housing cover. z Install the flywheel housing cover and tighten the fixing bolts by the zigzag method.

3.3.16. Front oil seal holder z After placing the oil seal in the oil seal holder hole properly, press it in with a special tool. (Be careful for oil seal not be damaged.) z Attach a gasket at the oil seal holder. z Align the dowel pin with the oil seal holder dowel hole and assemble them by tapping lightly the dowel pin part with an urethane hammer When in assembling, take care not to hurt the oil seal by the crankshaft.

Crankshaft

pulley

Oil seal holder Oil seal (front)

NOTE: Without coating the oil seal with oil or lubricant, assemble it in the dry state.

Cylinder block Crankshaft

z Tighten the fixing bolts in the zigzag method.

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3.3.17. Oil pump z Put the oil pump at the place to be installed on the cylinder block. z Attach a gasket at the surface of oil pump where the pressure regulating valve is to installed and place the regulating valve on a gasket. z Assemble the oil pump by tightening the fixing bolts. z Attach a gasket at the surface of the oil pump where the oil suction pipe is to be installed, and install the oil suction pipe by tightening the fixing bolts. z Assemble

the

pipe

bracket

the

cylinder block side with bolts. 3.3.18. Oil pan z Clean thoroughly the gasket that is projecting at the junction parts of front oil seal holder and flywheel housing of cylinder block's lower face with a scraper. z In the process of gasket removal, be careful for the gasket pieces not to get into the engine inside. z Apply silicon to each joint and attach a gasket to the cylinder block. z Install the oil pan and tighten the fixing bolts. Then takes care not to squeeze out the gasket. Torque

3.1 kg.m

z Install the guide tube and insert the oil level gauge.

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3.3.19. Cylinder head z Blow the cylinder head bolt holes with compressed air to remove the foreign material cleanly. z Wipe off cleanly the junction part of cylinder block's head gasket. z After confirming whether there is foreign material or not necessarily, if there is, remove it. z Assemble a gasket fitting with the fixing Intake side/ injector

pin of cylinder block. z Position the cylinder head assembly on the cylinder block aligning with its dowel pin. (Take care not to damage the head gasket.) z Coat the cylinder head bolts with engine oil and tighten them to the specified torque according to step by step. However, prior to tightening the bolts, with a long steel rule, the parallelness between the cylinder

Exhaust side

heads must be adjusted. <Cylinder head bolts tightening order> 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 wrench. 5) Fifth step: Rotate 90° by rotation angle method. 6) Sixth step: Finally tighten additionally rotating 90°. * Standard length of bolt and use limit:

Bolt No. 3,6 2,4,5 1 76

Standard length “L” on new bolts (mm) 168 144 109

Permissible maximum repair length (mm) 171 147 112

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z Take care for the foreign material not to get into the cylinder head suction passages. 3.3.20. Fuel injection nozzle z

Put a new seal ring in the nozzle hole of cylinder head and after inserting the nozzle

assembly

into

it,

tighten

assemble However, coat the nozzle outer part with the stuck preventing agents and assemble it. Torque

7 kg.m

3.3.21. Rocker arm z Coat the push rod with engine oil and put it into the push rod hole. z Position the rocker arm assembly on the cylinder head and tighten the fixing bolts to the specified tightening torque. Torque

6.5 kg.m

1) Valve clearance adjust procedure z After letting the #1 cylinder's piston come at the compression top dead center by turning the crankshaft, adjust the valve clearances. z 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 respectively and then tighten with the lock nut. z As for the valve clearance, adjust it when in cold, as follows. Model DV15 DV15T DV15TI DV15TIS

Intake valve

Exhaust valve

0.25 mm

0.35 mm

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DV15/T/TI/TIS MAINTENANCE MANUAL

2) Adjusting sequence of valve clearance (Type 1) 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.

” of lower

figure. 5) After reinsuring the valve clearances, retighten if necessary. z No. 1 Cylinder is located at the side where cooling water pump was installed. Fly wheel

Cylinder No.

Intake valve

Exhaust valve

1 Cooling fan

: at the #6 cylinder overlap

Exhaust valve

Intake valve

: at the #1 cylinder overlap

3) Adjusting sequence of valve clearance (Type 2) Type 1 is the conventional and simple method, but if you have some problem to adjust your engine, please try type 2 sequence. This is a precision method, but it takes more time.

*. 8 Cylinder engine (DV15/DV15T/TI/TIS)

Valve overlapping on cylinder (Intake & Exhaust valve)

Adjusting valves on cylinder (Intake & Exhaust valve)

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3.3.22. Cylinder head cover z Attach a new gasket on the surface of cylinder head where the cover is to be installed. z Assemble the cylinder head cover by tightening the fixing bolts. z Insert the oil filler cap. z After

inserting

the

oil

bleeder

pipe,

assemble by tightening clamp.

3.3.23. Vibration damper z Assemble

the

vibration

damper

tightening firstly by the crankshaft pulley and the fixing bolts. z Insert the crankshaft pulley assembly to the crankshaft and tighten the fixing bolts in the method of zigzag to the specified torque. Torque

21 kg.m

3.3.24. Oil filter z Insert greased O-rings into the oil port of the oil filter head.(Prevent the O-ring from slipping out.) z

Install the filter head on the cylinder block and tighten bolts in a diagonal sequence.

Install the oil filter element in the oil filter assembly.

Install new O-rings(packings) in the oil filter housing. (Filter element, Cu-washer, and packing are supplied together as A/S parts.)

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Assemble the oil filter housing with the filter head (Be careful not to damage the O-ring.)

Place Cu-washer over filter housing fixing bolt and tighten the bolt.

3.3.25. Cooling water pump z Attach a gasket at the cooling water pump. (at cylinder block side) z Assemble the cooling water pump by tightening

the

fixing

bolts.

(zigzag

method) z Insert the thermostat of cooling water pump. z Insert the O-ring to the thermostat and assemble the cooling water pipes by tightening the fixing bolts.

3.3.26. Intake manifold z Attach a new gasket to the cylinder head side. z Assemble

the

intake

manifold

tightening the fixing bolts. z Attach a gasket to the inlet flange and assemble by tightening the fixing bolts. z Assemble both sides by the above method. z Attach a gasket to the equalizing pipe that connects the intake manifolds of both sides and assemble both manifolds by tightening the fixing bolts.

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3.3.27. Exhaust manifold z Connect the exhaust manifold that is consists of two sets after inserting the exhaust gas ring between them. z Attach a new gasket to the exhaust manifold. z Attach a gasket to the exhaust elbow that Is connected to the exhaust manifold, and assemble the elbow by tighten the nuts for connection. z Assemble both sides in the same method as above. 3.3.28. Turbocharger z Attach a gasket to the exhaust elbow and assemble the turbocharger with fixing bolts. z Install the connecting pipes and an O-ring between the inlet flange and turbocharger Then, it is assembled with the O-ring that was coated with engine oil. z Attach a gasket on the oil supply pipe and assemble the pipe with the fixing bolts. z Attack a gasket on the oil discharge pipe and assemble the pipe by tightening the bolts. z At the same method as above, both sides are assembled. 3.3.29. Intake stake and air hearter z Assemble the air hearter according to the direction of an arrow impressed on the air heater

and

assemble

tightening the bolts.

the

pipe

From air cleaner

Intake stake Wire harness Air heater

Intake manifold

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3.3.30. Fuel injection pipe z Connect the fuel injection pipes between the fuel injection pump and the nozzle holder and tighten clamping nuts. z Fix the fuel return pipe by tightening hollow screw.

3.3.31. Fuel filter z Assemble the fuel filter to the intake stake by tightening bolts.

Fuel inlet

z Assemble the fuel feed hose according to the direction of an arrow impressed on the fuel filter head so that fuel can

Fuel outlet

Fuel filter head

be fed in the sequence of FUEL FEED Fuel filter cartridge

PUMP â&#x2020;&#x2019; FUEL FILTER â&#x2020;&#x2019; FUEL INJECTION PUMP. 3.3.32. Power steering oil pump z Connect the power steering oil pump to the air compressor and push them

Power steering pump (16 or 18lit) Flywheel housing

inward. z Be careful not to damage power steering pump O-ring. Ensure that the driving dog is cross-assembled with the air compressor coupling. z Tighten fixing bolts.

Coupling Power steering pump (25lit)

Driving dog

3.3.33. Hoses and pipes z Connect fuel strainer to fuel feed pump and assemble the fuel hoses therewith. z Connect fuel delivery and return hoses z Connect lubrication oil delivery pipes and hoses to air compressor.

ENGINE REASSEMBLY Printed in Aug. 2001 PS-MMA0700-E1A

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3.3.34. Alternator z Assemble

the

alternator

mounting

bracket with fixing bolt to the lower side of cylinder block. z Assemble the alternator support(V-belt tension adjusting bolt) with fixing bolt to oil pan. z Assemble the alternator with bracket and support. z Install V-belt over water pump pulley, crankshaft and alternator pulley. z Adjust the V-belt tension by adjusting bolt) (The belt deflection should be within the range 10~15mm) 3.3.35. Cooing fan z Assemble cooling fan to fan coupling with fixing bolts. z Install the cooling fan assembly to the crankshaft pulley fitting surface with fixing bolts and tighten to the specified torque.

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3.4. Starting and Trial Operation 3.4.1. Operation of a new engine (Breaking-In) Because the sliding surfaces of a new engine are not lapped enough, the oil film can be destroyed easily by overload or overspeed and the engine life-time may be shortened. Therefore the following things must be obeyed by all means. Up to the first 1,000km(50 hours) ▲ Engine should be run at fast idling until the temperature of the engine becomes normal operating condition. ▲ Overload or continuous high speed operation should be avoided. ▲ High speed operation with no load should be prevented. ▲ Abrupt start and stop of the engine should be avoided. ▲ Engine speed must be under 70% of its maximum speed. ▲ Maintenance and inspection must be accomplished thoroughly.

3.4.2. 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 oil level gauge.

NOTE : If you have a problem getting a good oil level reading on oil level gauge 180° and re-insert for check.

b) Watch the oil pressure warning lamp. If the lamp blinks, it may be the oil pick-up screen is not covered with oil. Check oil level gauge oil to the oil pan, if required. Do not overfill. If level is correct and the status still exists, see your DEALER for possible switch or oil pump and line malfunction.

NOTE : Oil pressure will rise as RPM increases, and fall as RPM decreases. In addition, cold oil will generally show higher oil pressure for any specific RPM than hot 84

ENGINE REASSEMBLY Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

oil. Both of these conditions reflect normal engine operation. 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 cartridge. Fill oil pan with recommended engine oil. Refer to following table.

z Engine Oil capacity Engine oil capacity Engine Model DV15 DV15T DV15TI DV15TIS

Vehicle

in Oil pan Max. Min. (lit) (lit)

Total (lit)

Bus

Truck Industrial Bus Truck

21 18 24 21

19 21 20 19

24 24 27 24

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

ENGINE REASSEMBLY

Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

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. Looking into the cooling system, the water pumped up by the water pump circulates around the oil cooler through the water pipe to absorb the oil heat, and 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. 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 opening temperature. At the radiator, the heat absorbed in the coolant is radiated to cool down and the coolant recirculates to the water pump.

z Specification Item 1. Water pump Type Delivery Pumping speed Pumping back pressure 2. Thermostat Operating temperature 3. Cooling fan and belt Fan diameter – Number of blades Fan belt tension 86

Specification Centrifugal type About 350 liter/min 2,100 rpm 760 mmHg 83 ∼ 95°C 700mm – 9 15mm / deflection by thumb

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DV15/T/TI/TIS MAINTENANCE MANUAL

4.1.2. Thermostat z General descriptions and main data The thermostat maintains a constant temperature of coolant (90 ∼ 95 °C) and improves

thermal

efficiency

the

engine by preventing heat loss. Namely,

when

the

temperature

coolant is low, the thermostat valve is closed to make the coolant bypass to directly enter the water pump; when the coolant temperature rises to open wide the thermostat valve, the bypass circuit is closed and the water passage to the radiator is opened so that the coolant is forced to flow into the radiator.

Item Type Open at Open wide at Valve lift

Specifications In moderate climates In tropical climates Bus Truck Wax-pallet type Wax-pallet type 79 °C 83 °C 71 °C 94 °C 95 °C 85 °C 8 mm or more 8 mm or more

NOTE: There are 2 kinds of thermostats according to surrounding and operating conditions. One is named by 71 °C type and the other is 83 °C. z Inspecting (1) Check the wax pallet and spring for damage. (2) Put the thermostat in a container of water, then heat the water slowly and

Thermometer Ruler

check temperature with a thermometer. If the valve lift is 0.1 mm (starting to open) at temperature of 83 °C and 8 mm

(opening

wide)

Wood plate

temperature of 95 °C, the thermostat is normal. MAINTENANCE OF MAJOR COMPONENTS

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DV15/T/TI/TIS MAINTENANCE MANUAL

z 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. 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 overspeed it immediately after engine starting. (2) When draining out or replenishing coolant, do it slowly so that air is bled sufficiently from the entire cooling system. (3) Replacing thermostat If the thermostat is detected defective, retrace with a new one.

MAINTENANCE OF MAJOR COMPONENTS Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

4.1.3. Diagnostics and troubleshooting Complaints 1. Engine overheating

Possible causes z z z z z z z z z z

2. Engine overcooling

z z

3. Lack of coolant

z z z z z z z

4. Cooling system noisy

z z z z

Lack of coolant Radiator cap pressure valve spring weakened Fan belt loosened or broken Fan belt fouled with oil Thermostat inoperative Water pump defective Restrictions in water passages due to deposit of scales Injection timing incorrect Restriction in radiator core Gases leaking into water jacket due to broken cylinder head gasket Thermostat inoperative Ambient temperature too low Radiator leaky Radiator hoses loosely connected or damaged Radiator cap valve spring weakened Water pump leaky Heater hoses loosely connected or broken Cylinder head gasket leaky Cylinder head or cylinder block cracked Water pump bearing defective Fan loosely fitted or bent Fan out of balance Fan belt defective

Corrections z z

Replenish coolant Replace cap

Adjust or replace fan belt

z z z z

Replace fan belt Replace thermostat Repair or replace Clean radiator and water passages

Adjust injection timing correctly Clean exterior of radiator

z z

Replace gasket

z z

Replace thermostat Install radiator curtain

z z z

Correct or replace Retighten clamps or replace hoses Replace cap

z z

Repair or replace Tighten or replace hoses

z z

Replace cylinder head gasket Replace cylinder head block

Replace bearing

Retighten or replace fan

z z

Replace fan Replace fan belt

cylinder

head

MAINTENANCE OF MAJOR COMPONENTS

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DV15/T/TI/TIS MAINTENANCE MANUAL

4.2. Lubricating System 4.2.1. General descriptions and main data z 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. z Specifications Item

Specifications Forced pressure circulation

Item

Specifications

Lubricating system Oil filter type Oil pump type Gear type Bypass for filter element Relief valve opening pressure 8.5~10 kg/cm2 Valve opening pressure Adjusting valve for spray nozzle Bypass for entire oil filter Opening pressure Valve opening pressure 1.6 ∼ 1.9 kg/cm2

Full flow 2.1±0.3 kg/cm2 4.5±0.2 kg/cm2

z Diagram of lubricating system

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DV15/T/TI/TIS MAINTENANCE MANUAL

4.2.2. Oil filter The oil filter mounted in this engine is of element type, so it is necessary to replace it with a new one at the specified intervals.

Oil filter head

Oil filter element

4.2.3. Diagnostics and troubleshooting Complaints Possible causes 1. Oil consumption excessive

Poor oil

Use suggested oil

Oil seal or packing leaky Pistons or piston rings worn Cylinder liner worn Piston rings sticking

Replace

z z z z

Use suggested oil Replace Clean strainer

z z

Replace Replace

z z

Correct or replace Correct or replace

z z

Valve guide oil seals or valve guides, or valve stem worn Poor oil Relief valve sticking Restrictions in oil pump strainer Oil pump gear worn Oil pump feed pipe cracked Oil pump defective Oil pressure gauge defective Various bearings worn Restriction in oil filter

Replace pistons and/or piston rings Replace cylinder liner Replace pistons and/or piston rings Replace

z z

Replace Replace filter element

Gases leaking

Replace piston rings and cylinder liner

z z z z

2. Oil pressure too low

z z z z z z z

3. Oil deteriorates quickly

Corrections

z z

MAINTENANCE OF MAJOR COMPONENTS

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DV15/T/TI/TIS MAINTENANCE MANUAL

4.3. Specification and Construction 4.3.1. Main data and specification Model

DV15T

Air pressure at Allied Signal T04E compressor outlet At Air suction of maximum Approx.20 m3/min turbine output revolution Speed of turbine Approx. 90,000 rpm revolution 112,000 rpm Maximum allowable speed Maximum allowable temperature of exhaust gas 750°C at turbine inlet External oil supply Lubricating system 14 kg Weight

DV15TI

DV15TIS

Allied Signal T04E

Approx.29 m3/min

Approx.33 m3/min

Approx. 108,000 rpm Approx. 115,000 rpm 120,458 rpm

120,458 rpm

750°C

External oil supply 14 kg

4.3.2. Operating principle

1. Impeller casing 2. Turbine casing 3. Bearing casing 4. Impeller 5. Turbine A. Air inlet B. Gas outlet C. Gas inlet D. Oil supply E. Oil return

MAINTENANCE OF MAJOR COMPONENTS Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

4.3.3. Construction Make sure that servicing should be performed at the professional maintenance shop as authorized by Allied signal Company.

1 2 3 4 5 6 7 8 9 10 11 13 14

Turbine shaft Thrust bush Oil shut off Fixing nut Seal ring Seal ring Seal ring Compressor wing wheel Turbine housing Bolt Clamp Bearing housing Retainer ring

15 16 17 18 19 21 22 23 24 27 30 31

Seal plate Thrust bearing Journal bearing Screw Screw Heat dissipator Compressor housing Clamp Bolt Liquid gasket Loctite Liquid anti-burn agents

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4.3.4. General information The engine output depends upon the supplied fuel quantity and the engine efficiency. In order to transform into the effective work of engine by burning the supplied fuel fully, the sufficient air to burn the fuel should be supplied to the cylinder. Therefore, the engine output is essentially determined by the size of the cylinder, and for if the air is supplied to the given volume of cylinder with the air being compressed, the air quantity in the cylinder will Increase as much to result in that it may burn more fuel. the output will also be able to increase, Supplying the air by compressing like this into the engine cylinder is called as super charging, and super charging by means of exhaust gas energy that discharges to the atmosphere is called as the turbo charging.

4.3.5. Function 1) Turbine The exhaust 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 influence a bad effect at bearing part, there are the seal ring and heat dissipator. 2) Compressor It is connected to the same shaft with the turbine to make a revolving assembly, and receive the revolving force of turbine, and sends air to the suction manifold by suctioning and compressing it. This is called as the compressor. 3) Bearing z Thrust bearing force is applied to the turbine wheel and an arrangement is made for the shaft not to shift. z Journal bearing (floating bearing) is adopted and it forms the double oil films at the inner and outer surfaces in comparison to the general stationary type so that the bearing may be able to rotate independently and consequently the double layers of films act as the damper to make the slipping speed on the bearing surface less than the rotating speed of shaft so that the dynamic stability may be obtained. 4) Sealing at compressor shaft In order for the compressed intake air and lubricating oil not to leak, a seal plate and a seal ring are made to the double structures. 94

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4.3.6. How to handle the engine 1) Precautions for operation of the engine Operation following items must be observed at the starting, operation and stop of engine. Operation At starting

Caution Reason 1) Inspect oil quantity 2) After confirming that oil 2) If engine is started quickly, of course beginning with every pressure rises by starting parts of engine, for it revolves engine with starter (until the without oil that is to reach to pointer of oil pressure gauge the turbocharger, the bearing's moves or pressure indicating abnormal wear or stuck may lamp operates), the starting be caused. must be done. 3) In case that oil, oil filter and 3) In case that engine stalled for long time and of cold weather, lubricating system's part are the fluidity of oil may be get replaced or engine was stalled worse. 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 operate the starting motor until oil comes out the connecting parts. Care must be paid that after the confirming above, retighten the pipe connecting parts without fail, and proceed with the normal starting. Immediately 1) Perform idling operation for 1) Sudden load at time soon after After starting about 5 min. immediately after engine starting and at the engine starting. state when turbocharger did not yet reach to smooth revolution, if abrupt load is applied to engine, some parts where oil did still not reach may cause a burn to be stuck. 2) Various inspections must 2) If there are the leakage of oil, insure that there are no gas, air, particularly oil, for the leakage of oil, gas and air. oil pressure lowers, it causes a burn of bearing to be stuck.

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Operation During operation

Caution

Reason

Following items must be confirmed.

1 ) Oil pressure at idling: 90～300 kPa (0.9～3.0 bar) at full load 300～650 kPa (3.0～6.5 bar)

2) When abnormal noises and vibration are generated, slow down the revolution and must stop it to investigate the causes. At stop

At stopping the engine, perform the idling operation for 5min. and then stop it.

1) If the pressure is too low, abnormal wear or stuck may be caused. Or if too high, the oil leak may be generated. 2) If the engine operation were continued with abnormal noises and vibration, it causes the engine trouble that can not be repaired or some other troubles. 1) After heavy load operation, if the engine were stopped suddenly, the heat would be conducted to bearing parts from red hot turbine wings that would result in burning the oil to cause the stuck bearing metal and revolving shaft.

4.3.7. Routine inspection and maintenance Since the state of turbocharger depends largely on the state of engine maintenance, to perform the specified up keep thoroughly is needed. 1) Air intake system System in 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 specified value, the cleaning efficiency get worse, if higher, the sucked oil pollutes a case. Particularly, for if the rotor were polluted, the balance adjusted precisely would be deviated to cause a vibration that may cause the stuck or abnormal wear by loading large force to the bearing, the perfect air cleaner must always be used. In case of dry type filter, according to the indication of a dust indicator, cleaning must be done to make the intake air resistance as small as possible 2) Exhaust system In exhaust system, a care must be taken to the gas leak and the stuck prevention If exhaust gas leaks from the exhaust pipe and turbocharger etc., for the super charging effect will be lowered, the installed states of various parts must be paid with careful attention. Since the parts that reach to high temperature during operation such as the turbine room use the anti- heat nuts, a care must be paid not to mix with the general 96

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nuts and at the same time, bolt stuck preventing paint should be coated on the nut for the designated places. 3) Fuel system If the full load stopper that restricts the maximum fuel injection quantity of fuel injection pump and the maximum speed stopper that restricts the maximum speed are adjusted without the pump tester, the turbocharger may overrun to be damaged. Also, if the atomizing state of fuel injection nozzle becomes worse or the injection timing gets wrong, for the raised temperature of exhaust gas will influence badly to the turbocharger, the nozzle testing must be done. 4) Lubricating system In the lubricating system, a care must be paid to the oil quality and oil element replacement cycle. For the oil deterioration of turbocharger equipped engine, needless to speak of engine assembly itself, influences badly to the turbocharger too, the specified engine oil (15W40, CE class) should used.

4.3. 8. Periodical servicing The turbocharger assembly must be inspected periodically. 1) Rotating condition of the rotor and checking tips Inspection on the revolving state of rotor is performed according to abnormal noises. In case of using an acoustic bar, touch the turbocharger housing with a tip of bar and raise the engine revolution slowly, Then, in case that high sound is heard by every 2 ď˝&#x17E; 3 sec. continuously, for there should be the possibility to be abnormal metal and rotor, replace or repair the turbocharger. 2) Measuring rotor clearance Disassemble the turbocharger from the engine and should inspect the end plays in axial and circumference direction. In case of disassembling the turbocharger, the oil inlet and outlet should necessarily be sealed with a tape.

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DV15/T/TI/TIS MAINTENANCE MANUAL

a) Rotor axial direction end play z Wear limit : 0.20mm

b) Rotor's circumference direction end play. z Wear limit : 0.65mm

c) In case that the end plays to axial and circumference directions, replace or repair the turbocharger. 3) Overhaul and cleaning points Be sure to dismantle the turbocharger from the engine before cleaning. Also, make sure to seal the oil inlet and outlet with tape or similar. 4) Precautions for turbocharger reassembly When in assembling the turbocharger or the handling after assembling should work observing the following precautions necessarily. Particularly, precise care should be taken for foreign material not to get into the turbocharger. a) Lubricating system z Prior to assembling it into the engine, fill new oil into oil Inlet and turning turbine shaft with hand, lubricate journal and thrust bearing. z Clean the pipe and oil outlet pipe between engine and oil inlet, and confirm if there is any pipe damage or foreign material. 98

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z In order for oil not to leak from various connections, assemble securely. b) Air intake system z Confirm if there is any foreign material inside the air intake system. z Assemble securely the air intake duct and air cleaner so that the connections from them may not leak an air. c) Exhaust system z Confirm if there is any foreign material in the exhaust system. z Bolts and nuts must be made of anti-heat steel and in assembling, care should be taken not use the general nuts and coat the bolts and nuts with the anti-stuck agents at the same time. z Assemble securely for gas not to leak from various connecting parts of exhaust pipes

4.3.9. Trouble cause diagnosis and remedy Condition 1. Exhaust gas excessive

2. White smoke excessive

3. Output lowered

4. Abnormal noises or vibrations

Causes

Remedies

1) Air cleaner elements clogged 2) Air Inlet port clogged 3) Air leaks from air intake system 4) Turbocharger impossible to rotate due to stuck 5) Turbine wing's contact 6) Piping deformation or clogging of exhaust system 1) Oil leaks into turbine and compressor. 2) Seal ring's abnormal wear or damage 1) Gas leak from various parts of exhaust system 2) Air cleaner's elements clogged 3) Turbocharger's pollution or damage 4) Air leaks from discharge part of compressor side 1) Revolving parts' contact 2) Revolving imbalance of rotor 3) Stuck 4) Various connections loose

Replace or clean Inspect or repair Inspect or repair Overhaul and repair or replace Overhaul and repair or replace Inspect and repair Overhaul and repair or replace Overhaul and repair or replace Inspect and repair Replace or clean Overhaul and repair or replace Inspect and repair Overhaul and repair or replace Overhaul and repair or replace Overhaul and repair or replace Inspect and repair

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DV15/T/TI/TIS MAINTENANCE MANUAL

4.4. Fuel Injection Pump 4.4.1. 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.

9 10

“X”

2 1

FUEL RETURN

VIEW “X” 1. 2. 3. 4. 5.

Fuel tank Fuel strainer Hand priming pump Fuel injection pump Fuel supply line

6. 7. 8. 9. 10.

Air bleeding plug Fuel filter Fuel injection nozzle Over flow valve Fuel return pipe

4.4.2. 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. 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. 100

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DV15/T/TI/TIS MAINTENANCE MANUAL

1) DV15(RQ) engine (1) Injection pump

: 65.11102-7360 (0 401 848 829 BOSCH)

Model

: PE8P110A320LS3865 (0 411 818 728)

Governor

: RQ 250/1150PA1250 (0 421 801 796)

Plunger & barrel

: 65.11125-0016 (2 418 455 071)

Delivery valve

: 65.11119-6016 (2 418 552 075)

Overflow valve

: 65.12505-5004 (1 417 413 047)

Feed pump

: 65.12101-7025 (0 440 008 101)

Prestroke

: 4.0 ±0.05mm at 10.5 ±1.5mm

Rotating direction

: Counter clockwise (viewed from driving gear)

(2) Nozzle holder assembly : 65.10101-7074 (0 432 231 666) (3) Nozzle

: 65.10102-0118 (0 433 271 487)

(4) Injection pipe

: 65.10302-6110A , 65.10301-6111A

(5) Injection order:

:1–5–7–2–6–3–4–8

(6) Injection timing

: BTDC 10°

1 688 901 105

Opening pressure : 208.5 ±1.5 bar

φ3.0 x φ8.0– 600 mm

ISO4113

Temperature :40 ±5°C

Nozzle & holder Ass’y

65.10101-7074

200+8 kg/cm2

Nozzle

65.10102-0118

Multi hole (4 x φ0.34)

65.10302-6110A 65.10302-6111A

φ2 x φ6 - 650mm

Nozzle & Holder Ass’y (A) Test condition for injection pump

Injection pipe(IDxOD-L) Test oil

(B) Engine standard parts

Injection pipe(IDxOD-L) Rack diagram and setting valve at each point

Rack Pump Check position speed point (mm) (rpm)

Injection Q’ty on RIG Pressure (mm3 / 1,000 st) (A) Test condition (B) Engine (mbar) for inj. pump standard parts

11.8

1,150

126 ±1

11.8

650

127 ±3

500

8.1

250

25±3

0.5

1,350

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2) DV15T(RQ : 365PS ECVBA/B/C) engine (1) Injection pump

: 65.11101-7322 (0 402 648 974 BOSCH) (use 2nd stage LDA spring at 65.11102-7358)

Model

: PE8P120A320LS7915 (0 412 628 929)

Governor

: RQ 300/1150PA1374 (0 421 801 833)

Plunger & barrel

: 65.11125-0015 (2 418 455 501)

Delivery valve

: 65.11108-6015 (2 418 552 149)

Overflow valve

: 65.12505-5004 (1 417 413 047)

Feed pump

: 65.12101-7016 (0 440 008 099)

Coupling

: 2 416 434 074

Rotating direction

: Counter clockwise (viewed from driving gear)

(2) Nozzle holder assembly : 65.10101-7084A (9135 – 278 LUCAS) (3) Nozzle

: 65.10102-0008 (9135 – 261 LUCAS)

(4) Injection pipe

: 65.10301-6060A , 65.10301-6061A

(5) Injection order:

:1–5–7–2–6–3–4–8

(6) Injection timing

: BTDC 7°

(A) Test condition for injection pump

(B) Engine standard parts

Nozzle & Holder Ass’y Injection pipe(IDxOD-L) Test oil Nozzle & holder Ass’y Nozzle Injection pipe(IDxOD-L)

1 688 901 105 Opening pressure : 208.5 ±1.5 bar 1 680 750 089 φ3.0 x φ8.0– 600 mm ISO4113 Temperature :40 ±5°C 65.10101-7084A 200+8 kg/cm2 65.10102-0008 Multi hole (5 x φ0.313) 65.10301-6060A φ2 x φ6.35 - 650mm 65.10301-6061A

Rack diagram and setting valve at each point Rack Pump Check Position speed point (mm) (rpm)

V1 V2 VS LQ A3

14.25 14.25 8.3 5.8 0.5

1,150 650 500 300 1,350

Injection Q’ty on RIG Pressure (mm3 / 1,000 st) (A) Test condition (B) Engine (mbar) for inj. pump standard parts

220.5 ±1 239 ±3 121 ±1 18±3 -

1500 1500 0 0 0

(C) LDA adjust data : (1st stage LDA spring : 2 424 618 046, k=15 N/mm, L=27.7mm) (2nd stage LDA spring : 2 424 618 062, k=10 N/mm, L=19.1mm) Adjusting point Rack position (rpm) Pump speed (rpm) Pressure (mbar) P0 500 600 11.65 ±0.1 P1 500 1,500 14.25 ±0.05 P2 500 0 8.3 ±0.2 P3 500 250 9.0 ±0.05 P4 500 450 11.05 ±0.2 P5 500 725 12.05 ±0.05 P6 500 900 13.15 ±0.2 102

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7) Performance curve of governor

14.25

8.3

14.25

13.15

12.05

11.65 11.05

9.0 8.3

P3 P2 250

450 600 725

900

1500

LDA Pressure (mbar)

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3) DV15T(RQ : 370PS ECVCA/B) engine (1) Injection pump

: 65.11101-7323 (0 402 648 974 BOSCH) (use 2nd stage LDA spring at 65.11102-7358)

Model

: PE8P120A320LS7915 (0 412 628 929)

Governor

: RQ 300/1150PA1374 (0 421 801 833)

Plunger & barrel

: 65.11125-0015 (2 418 455 501)

Delivery valve

: 65.11108-6015 (2 418 552 149)

Overflow valve

: 65.12505-5004 (1 417 413 047)

Feed pump

: 65.12101-7016 (0 440 008 099)

Coupling

: 2 416 434 074

Rotating direction

: Counter clockwise (viewed from driving gear)

(2) Nozzle holder assembly : 65.10101-7084A (9135 – 278 LUCAS) (3) Nozzle

: 65.10102-0008 (9135 – 261 LUCAS)

(4) Injection pipe

: 65.10301-6060A , 65.10301-6061A

(5) Injection order:

:1–5–7–2–6–3–4–8

(6) Injection timing

: BTDC 7°

(A) Test condition for injection pump

(B) Engine standard parts

Nozzle & Holder Ass’y Injection pipe(IDxOD-L) Test oil Nozzle & holder Ass’y Nozzle Injection pipe(IDxOD-L)

Rack diagram and setting valve at each point Rack Pump Check position speed point (mm) (rpm)

V1 V2 VS LQ A3

14.35 14.35 8.15 5.8 0.5

1,150 650 500 300 1,400

Injection Q’ty on RIG Pressure (mm3 / 1,000 st) (A) Test condition (B) Engine (mbar) for inj. pump standard parts

220.5 ±1 240 ±3 109 ±1 18±3 -

1,500 1,500 0 0 0

(C) LDA adjust data : (1st stage LDA spring : 2 424 618 046, k=15 N/mm, L=27.7mm) (2nd stage LDA spring : 2 424 618 062, k=10 N/mm, L=19.1mm) Adjusting point Rack position (rpm) Pump speed (rpm) Pressure (mbar) P0 500 600 12.6 ±0.1 P1 500 1,500 14.35 ±0.05 P2 500 0 8.15 ±0.2 P3 500 250 9.10 ±0.05 P4 500 500 11.8 ±0.2 P5 500 725 12.9 ±0.05 P6 500 900 13.9 ±0.2 104

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7) Performance curve of governor

14.35

8.15

14.35

13.9

12.9 12.6 11.8

P5 P4

9.1 8.15

P3 P2 250 500 600

725

900

1500

LDA Pressure (mbar)

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4) DV15T(RQ : 370PS ECVCC/F/G/H) engine (1) Injection pump

: 65.11101-7358 (0 402 648 974 BOSCH)

Model

: PE8P120A320LS7915 (0 412 628 929)

Governor

: RQ 300/1150PA1374 (0 421 801 833)

Plunger & barrel

: 65.11125-0015 (2 418 455 501)

Delivery valve

: 65.11108-6015 (2 418 552 149)

Overflow valve

: 65.12505-5004 (1 417 413 047)

Feed pump

: 65.12101-7016 (0 440 008 099)

Coupling

: 2 416 434 074

Rotating direction

: Counter clockwise (viewed from driving gear)

(2) Nozzle holder assembly : 65.10101-7068 (0 432 231 669 BOSCH) (3) Nozzle

: 0 433 271 627

(4) Injection pipe

: 65.10301-6060A , 65.10301-6061A

(5) Injection order:

:1–5–7–2–6–3–4–8

(6) Injection timing

: BTDC 7°

(A) Test condition for injection pump

(B) Engine standard parts

Nozzle & Holder Ass’y Injection pipe(IDxOD-L) Test oil Nozzle & holder Ass’y Nozzle Injection pipe(IDxOD-L)

1 688 901 105 Opening pressure : 208.5 ±1.5 bar 1 680 750 089 φ3.0 x φ8.0– 600 mm ISO4113 Temperature :40 ±5°C 65.10101-7068 200+8 kg/cm2 0 433 271 627 Multi hole (5 x φ0.313) 65.10301-6060A φ2 x φ6.35 - 650mm 65.10301-6061A

Rack diagram and setting valve at each point Rack Pump Check position speed point (mm) (rpm)

V1 V2 VS LQ A3

14.35 14.35 9.0 6.0 0.5

1,150 650 500 300 1,350

Injection Q’ty on RIG Pressure (mm3 / 1,000 st) (A) Test condition (B) Engine (mbar) for inj. pump standard parts

220.5 ±1 238 ±3 137 ±1 18±3 -

1,500 1,500 0 0 0

106

Adjusting point

Rack position (rpm)

Pump speed (rpm)

Pressure (mbar)

P1 P2 P3 P4

14.35 ±0.05 9.0 ±0.2 10.0 ±0.05 12.3 ±0.2

500 500 500 500

1,500 0 250 650

MAINTENANCE OF MAJOR COMPONENTS Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

7) Performance curve of governor

14.35

9.0

6.0

300

14.35 12.3

10.0 9.0 250

650

MAINTENANCE OF MAJOR COMPONENTS 107 Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

4) DV15T(RQV-300PS) industrial engine (1) Injection pump

: 65.11102-7366 (0 401 848 830 BOSCH)

Model

: PE8P120A320LS3865 (0 411 818 728)

Governor

: RQV 250/1000PA1286 (0 421 814 175)

Plunger & barrel

: 65.11125-0016 (2 418 455 071)

Delivery valve

: 65.11108-6016 (2 418 552 075)

Overflow valve

: 65.12505-5004 (1 417 413 047)

Feed pump

: 65.12101-7025 (0 440 008 101)

Coupling

: 2 416 434 068

Rotating direction

: Counter clockwise (viewed from driving gear)

(2) Nozzle holder assembly : 65.10101-7084A (9135 – 278 LUCAS) (3) Nozzle

: 65.10102-0008 (9135 – 261 LUCAS)

(4) Injection pipe

: 65.10302-6110A , 65.10302-6111A

(5) Injection order:

:1–5–7–2–6–3–4–8

(6) Injection timing

: BTDC 9°

Nozzle & Holder Ass’y (A) Test condition for injection pump

1 688 901 105

Opening pressure : 208.5 ±1.5 bar

φ3.0 x φ8.0– 600 mm

ISO4113

Temperature :40 ±5°C

65.10101-7084A

200+8 kg/cm2

65.10102-0008

Multi hole (5 x φ0.313)

65.10301-6110A 65.10301-6111A

φ2 x φ6 - 650mm

Injection pipe(IDxOD-L) Test oil Nozzle & holder Ass’y

(B) Engine standard parts

Nozzle Injection pipe(IDxOD-L)

Rack diagram and setting valve at each point Rack Pump Check position speed point (mm) (rpm)

Injection Q’ty on RIG Pressure (mm3 / 1,000 st) (A) Test condition (B) Engine (mbar) for inj. pump standard parts

1,000

142 ±1

650

145 ±3

8.2

250

20±3

108

MAINTENANCE OF MAJOR COMPONENTS Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

4) DV15T(RQV ECVXA) engine (1) Injection pump

: 65.11102-7364 (0 402 648 796 BOSCH)

Model

: PE8P120A320LS7875 (0 412 628 881)

Governor

: RQV 250/1150PA1240 (0 421 814 160)

Plunger & barrel

: 65.11125-0015 (2 418 455 501)

Delivery valve

: 65.11108-6015 (2 418 552 149)

Overflow valve

: 65.12505-5004 (1 417 413 047)

Feed pump

: 65.12101-7016 (0 440 008 099)

Coupling

: 2 416 434 074

Rotating direction

: Counter clockwise (viewed from driving gear)

(2) Nozzle holder assembly : 65.10101-7084A (9135 – 278 LUCAS) (3) Nozzle

: 65.10102-0008 (9135 – 261 LUCAS)

(4) Injection pipe

: 65.10301-6060A , 65.10301-6061A

(5) Injection order:

:1–5–7–2–6–3–4–8

(6) Injection timing

: BTDC 7°

Nozzle & Holder Ass’y (A) Test condition for injection pump

Opening pressure : 208.5 ±1.5 bar

φ3.0 x φ8.0– 600 mm

ISO4113

Temperature :40 ±5°C

65.10101-7084A

200+8 kg/cm2

65.10102-0008

Multi hole (5 x φ0.313)

65.10301-6060A 65.10301-6061A

φ2 x φ6.35 - 650mm

Injection pipe(IDxOD-L) Test oil Nozzle & holder Ass’y

(B) Engine standard parts

1 688 901 105

Nozzle Injection pipe(IDxOD-L)

Rack diagram and setting valve at each point Rack Pump Check position speed point (mm) (rpm)

V1 V2 VS LQ A3

12.7 12.7 8.4 5.5 0.5

1,150 650 500 250 1,350

Injection Q’ty on RIG Pressure (mm3 / 1,000 st) (A) Test condition (B) Engine (mbar) for inj. pump standard parts

200 ±1 218 ±3 135 ±1 20±3 -

1,500 1,500 0 0 0

Rack position (rpm) 12.7 ±0.05 8.4 ±0.2 11.7 ±0.05 9.5 ±0.2

Pump speed (rpm) 500 500 500 500

Pressure (mbar) 1,500 0 725 315

MAINTENANCE OF MAJOR COMPONENTS 109 Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

7) Performance curve of governor

315

110

725

MAINTENANCE OF MAJOR COMPONENTS Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

4) DV15T(RQV ECVCD/E/ECVXC) engine (1) Injection pump

: 65.11102-7290 (0 401 648 702 BOSCH)

Model

: PE8P120A320LS7915 (0 412 628 929)

Governor

: RQV 250/1150PA1346 (0 421 814 193)

Plunger & barrel

: 65.11125-0015 (2 418 455 501)

Delivery valve

: 65.11108-6015 (2 418 552 149)

Overflow valve

: 65.12505-5004 (1 417 413 047)

Feed pump

: 65.12101-7016 (0 440 008 099)

Coupling

: 2 416 434 074

Rotating direction

: Counter clockwise (viewed from driving gear)

(2) Nozzle holder assembly : 65.10101-7068 (0 432 231 669) (3) Nozzle

: 0 433 271 627

(4) Injection pipe

: 65.10301-6060A , 65.10301-6061A

(5) Injection order:

:1–5–7–2–6–3–4–8

(6) Injection timing

: BTDC 7°

(A) Test condition for injection pump

Nozzle & Holder Ass’y

1 688 901 105

Opening pressure : 208.5 ±1.5 bar

Injection pipe(IDxOD-L)

1 680 750 089

φ3.0 x φ8.0– 600 mm

ISO4113

Temperature :40 ±5°C

Nozzle & holder Ass’y

65.10101-7068

200+8 kg/cm2

Nozzle

0 433 271 627

Multi hole (5 x φ0.313)

65.10301-6060A 65.10301-6061A

φ2 x φ6.35 - 650mm

Test oil

(B) Engine standard parts

Injection pipe(IDxOD-L) Rack diagram and setting valve at each point

Rack Pump Check position speed point (mm) (rpm)

V1 V2 VS LQ A3

13.8 13.8 8.1 5.6 0.5

1,150 650 500 250 1,400

Injection Q’ty on RIG Pressure (mm3 / 1,000 st) (A) Test condition (B) Engine (mbar) for inj. pump standard parts

222 ±1 241 ±3 123 ±1 20±3 -

1,500 1,500 0 0 0

Rack position (rpm) 13.8 ±0.05 8.1 ±0.2 12.1 ±0.05 10.0 ±0.2

Pump speed (rpm) 500 500 500 500

Pressure (mbar) 1,500 0 735 350

MAINTENANCE OF MAJOR COMPONENTS 111 Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

7) Performance curve of governor

13.8

8.1

5.6

1400

13.8 12.1

10.0

8.1

112

MAINTENANCE OF MAJOR COMPONENTS Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

5) DV15TI(RQ) engine (1) Injection pump

: 65.11102-7368 (0 401 848 832 BOSCH)

Model

: PE8P120A320LS3868 (0 411 828 730)

Governor

: RQ 300/1050PA1345 (0 421 801 823)

Plunger & barrel

: Ø12mm (2 418 455 082)

Delivery valve

: 65.11108-6015 (2 418 552 149)

Overflow valve

: 1 417 413 047

Feed pump

: FP/KG24P215 (0 440 008 101)

Prestroke

: 3.5 ±0.05mm at 20.5 ±0.5mm

Rotating direction

: Counter clockwise (viewed from driving gear)

(2) Nozzle holder assembly : 65.10101-7266 (0 432 231 657) (3) Nozzle

: 0 433 271 486

(4) Injection pipe

: 65.10301-6060A , 65.10301-6061A

(5) Injection order:

:1–5–7–2–6–3–4–8

(6) Injection timing

: BTDC 11°

(A) Test condition for injection pump

Nozzle & Holder Ass’y

1 688 901 105

Opening pressure : 208.5 ±1.5 bar

Injection pipe(IDxOD-L)

1 680 750 089

φ3.0 x φ8.0– 600 mm

ISO4113

Temperature :40 ±5°C

Nozzle & holder Ass’y

65.10101-7266

200+8 kg/cm2

Nozzle

0 433 271 486

Multi hole (4 x φ0.39)

Injection pipe(IDxOD-L )

65.10302-6042 65.10301-6043

φ2 x φ6 - 650mm

Test oil

(B) Engine standard parts

Rack diagram and setting valve at each point Rack Pump Check position speed point (mm) (rpm)

V1 V2 VS LQ A3

11.3 11.3 8.3 6.3 0.5

1,050 650 500 300 1,300

Injection Q’ty on RIG Pressure (mm3 / 1,000 st) (A) Test condition (B) Engine (mbar) for inj. pump standard parts

191 ±1 204 ±3 21±3 -

172 ±1 182 ±3 108 ±2 -

1,000 1,000 0 0 0

Rack position (rpm) 11.3 ±0.05 8.03 ±0.2 9.05 ±0.05 10.55 ±0.2

Pump speed (rpm) 500 500 500 500

Pressure (mbar) 1,000 0 280 580

MAINTENANCE OF MAJOR COMPONENTS 113 Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

7) Performance curve of governor

6.3

8.03

114

MAINTENANCE OF MAJOR COMPONENTS Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

6) DV15TIS(RQ-390PS) engine (1) Injection pump

: 65.11101-7662 (0 402 648 708 BOSCH)

Model

: PE8P120A320LS7927 (0 412 628 934)

Governor

: RQ 300/1050PA1389 (0 421 801 836)

Plunger & barrel

: Ø12mm (2 418 455 155)

Delivery valve

: Ø8mm (2 418 552 157)

Overflow valve

: 65.12505-5004 (1 417 413 047)

Feed pump

: 65.12101-7016 (0 440 008 099)

Coupling

: 2 416 434 105

Rotating direction

: Counter clockwise (viewed from driving gear)

(2) Nozzle holder assembly : 65.10101-7299 (0 432 131 682) (3) Nozzle

: 65.10102-0190 (0 433 171 569)

(4) Injection pipe

: 65.10301-7011A , 65.10301-7012A

(5) Injection order:

:1–5–7–2–6–3–4–8

(6) Injection timing

: BTDC 5.5°

(A) Test condition for injection pump

(B) Engine standard parts

Nozzle & Holder Ass’y Injection pipe(IDxOD-L) Test oil Nozzle & holder Ass’y Nozzle Injection pipe(IDxOD-L)

1 688 901 105 Opening pressure : 208.5 ±1.5 bar 1 680 750 089 φ3.0 x φ8.0– 1000 mm ISO4113 Temperature :40 ±5°C 65.10101-7299 250+8 kg/cm2 65.10102-0190 Multi hole (5 x φ0.32) 65.10301-7011A φ1.8 x φ6.35 - 650mm 65.10301-7012A

Rack diagram and setting valve at each point Rack Pump Check position speed Point (mm) (rpm)

V1 V2 VS LQ A3

12.52 12.52 8.6 7.62 0

1,050 600 500 300 1,250

Injection Q’ty on RIG Pressure (mm3 / 1,000 st) (A) Test condition (B) Engine (mbar) for inj. pump standard parts

227.3 ±1 217 ±4 127.5 ±1 62.3 ±3 0

2,000 2,000 0 0 2,000

Rack position (rpm) 12.0 ±0.05 12.52 ±1.35 8.6 ±0.2 9.5 ±0.05 11.45 ±0.2 12.0 ±0.05 12.52 ±0.1

Pump speed (rpm) 500 500 500 500 500 500 500

Pressure (mbar) 800 1,600 0 333 600 1,200 1,347

MAINTENANCE OF MAJOR COMPONENTS 115 Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

7) Performance curve of governor

12.52

8.6

LQ 7.62

A3 300

500

600

1050

1250

Pump Speed (rpm)

1347

1600

12.52 P0

P5 P4

11.45

9.5 8.6

P3 P2 333

600 800

1200

Pump Speed (rpm) 116

MAINTENANCE OF MAJOR COMPONENTS Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

7) DV15TIS(RQ-420PS) engine (1) Injection pump

: 65.11101-7662 (0 402 648 708 BOSCH)

Model

: PE8P120A320LS7927 (0 412 628 934)

Governor

: RQ 300/1050PA1389 (0 421 801 836)

Plunger & barrel

: Ø12mm (2 418 455 155)

Delivery valve

: Ø8mm (2 418 552 157)

Overflow valve

: 65.12505-5004 (1 417 413 047)

Feed pump

: 65.12101-7016 (0 440 008 099)

Coupling

: 2 416 434 105

Rotating direction

: Counter clockwise (viewed from driving gear)

(2) Nozzle holder assembly : 65.10101-7299 (0 432 131 682) (3) Nozzle

: 65.10102-0190 (0 433 171 569)

(4) Injection pipe

: 65.10301-7011A , 65.10301-7012A

(5) Injection order:

:1–5–7–2–6–3–4–8

(6) Injection timing

: BTDC 5.5°

(A) Test condition for injection pump

Nozzle & Holder Ass’y

1 688 901 105

Opening pressure : 208.5 ±1.5 bar

Injection pipe(IDxOD-L)

1 680 750 089

φ3.0 x φ8.0– 600 mm

ISO4113

Temperature :40 ±5°C

Nozzle & holder Ass’y

65.10101-7299

250+8 kg/cm2

Nozzle

65.10102-0190

Multi hole (5 x φ0.32)

65.10301-7011A 65.10301-7012A

φ1.8 x φ6.35 - 650mm

Test oil

(B) Engine standard parts

Injection pipe(IDxOD-L) Rack diagram and setting valve at each point

Rack Pump Check position speed point (mm) (rpm)

V1 V2 VS LQ A3

13.7 13.7 8.5 6.0 0.5

1,050 600 500 300 1,300

Injection Q’ty on RIG Pressure (mm3 / 1,000 st) (A) Test condition (B) Engine (mbar) for inj. pump standard parts

249 ±1 263 ±4 128 ±1 18 ±3 -

1800 1800 0 0 0

Rack position (rpm) 12.65 ±0.05 13.7 ±0.2 8.5 ±0.05 9.6 ±0.2 11.7 ±0.05 13.0 ±0.05 13.6 ±0.05

Pump speed (rpm) 500 500 500 500 500 500 500

Pressure (mbar) 800 1800 0 300 600 1200 1400

MAINTENANCE OF MAJOR COMPONENTS 117 Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

7) Performance curve of governor

13.7

8.5

LQ 6.0

0.5 300

500

600

1050

1250

Pump Speed (rpm)

RACK POSITION(mm)

13.7 13.6

P6 P0

12.65

P5 P4

11.7

9.6 8.5

P2 300

600 800

1200 1400

1800

LDA PRESSURE (mbar) 118

MAINTENANCE OF MAJOR COMPONENTS Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

8) DV15TIS(RQV-390PS) engine (1) Injection pump

: 65.11101-7359 (0 402 648 718 BOSCH)

Model

: PE8P120A320LS7927 (0 412 628 934)

Governor

: RQV 300…1050PA1456 (0 421 814 234)

Plunger & barrel

: Ø12mm (2 418 455 155)

Delivery valve

: Ø8mm (2 418 552 157)

Overflow valve

: 65.12505-5004 (1 417 413 047)

Feed pump

: 65.12101-7016 (0 440 008 099)

Coupling

: 2 416 434 105

Rotating direction

: Counter clockwise (viewed from driving gear)

(2) Nozzle holder assembly : 65.10101-7299 (0 432 131 682) (3) Nozzle

: 65.10102-0190 (0 433 171 569)

(4) Injection pipe

: 65.10301-7011A , 65.10301-7012A

(5) Injection order:

:1–5–7–2–6–3–4–8

(6) Injection timing

: BTDC 5.5°

(A) Test condition for injection pump

Nozzle & Holder Ass’y

1 688 901 105

Opening pressure : 208.5 ±1.5 bar

Injection pipe(IDxOD-L)

1 680 750 089

φ3.0 x φ8.0– 600 mm

ISO4113

Temperature :40 ±5°C

Nozzle & holder Ass’y

65.10101-7299

250+8 kg/cm2

Nozzle

65.10102-0190

Multi hole (5 x φ0.32)

65.10301-7011A 65.10301-7012A

φ1.8 x φ6.35 - 650mm

Test oil

(B) Engine standard parts

Injection pipe(IDxOD-L) Rack diagram and setting valve at each point

Rack Pump Check position speed Point (mm) (rpm)

V1 V2 VS LQ A3

12.52 12.52 8.6 7.62 0

1,050 600 500 300 1,250

Injection Q’ty on RIG Pressure (mm3 / 1,000 st) (A) Test condition (B) Engine (mbar) for inj. pump standard parts

227.3 ±1 217 ±4 127.5 ±1 62.3 ±3 0

2,000 2,000 0 0 2,000

Rack position (rpm) 12.0 ±0.05 12.52 ±1.35 8.6 ±0.2 9.5 ±0.05 11.45 ±0.2 12.0 ±0.05 12.52 ±0.1

Pump speed (rpm) 500 500 500 500 500 500 500

Pressure (mbar) 800 1,600 0 333 600 1,200 1,347

MAINTENANCE OF MAJOR COMPONENTS 119 Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

7) Performance curve of governor

12.52

8.6

LQ 7.62

A3 300

500

600

1050

1250

Pump Speed (rpm)

1347

1600

12.52 P0

RACK POSITION(mm)

P5 P4

11.45

9.5 8.6

P3 P2 333

600 800

1200

Pump Speed (rpm) LDA PRESSURE (mbar) 120

MAINTENANCE OF MAJOR COMPONENTS Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

9) DV15TIS(RQV-420PS) engine : 65.11101-7359 (0 402 648 718 BOSCH)

(1) Injection pump -

Model

: PE8P120A320LS7927 (0 412 628 934)

Governor

: RQV 300/1050PA1456 (0 421 814 234)

Plunger & barrel

: Ø12mm (2 418 455 155)

Delivery valve

: Ø8mm (2 418 552 157)

Overflow valve

: 65.12505-5004 (1 417 413 047)

Feed pump

: 65.12101-7016 (0 440 008 099)

Coupling

: 2 416 434 105

Rotating direction

: Counter clockwise (viewed from driving gear)

(2) Nozzle holder assembly : 65.10101-7299 (0 432 131 682) (3) Nozzle

: 65.10102-0190 (0 433 171 569)

(4) Injection pipe

: 65.10301-7011A , 65.10301-7012A

(5) Injection order:

:1–5–7–2–6–3–4–8

(6) Injection timing

: BTDC 5.5°

(A) Test condition for injection pump

Nozzle & Holder Ass’y

1 688 901 105

Opening pressure : 208.5 ±1.5 bar

Injection pipe(IDxOD-L)

1 680 750 089

φ3.0 x φ8.0– 600 mm

ISO4113

Temperature :40 ±5°C

Nozzle & holder Ass’y

65.10101-7299

250+8 kg/cm2

Nozzle

65.10102-0190

Multi hole (5 x φ0.32)

65.10301-7011A 65.10301-7012A

φ1.8 x φ6.35 - 650mm

Test oil

(B) Engine standard parts

Injection pipe(IDxOD-L) Rack diagram and setting valve at each point

Rack Pump Check position speed point (mm) (rpm)

V1 V2 VS LQ A3

13.7 13.7 8.5 6.0 0.5

1,050 600 500 300 1,300

Injection Q’ty on RIG Pressure (mm3 / 1,000 st) (A) Test condition (B) Engine (mbar) for inj. pump standard parts

249 ±1 263 ±4 128 ±1 18 ±3 -

1800 1800 0 0 0

Rack position (rpm) 12.65 ±0.05 13.7 ±0.2 8.5 ±0.05 9.6 ±0.2 11.7 ±0.05 13.0 ±0.05 13.6 ±0.05

Pump speed (rpm) 500 500 500 500 500 500 500

Pressure (mbar) 800 1800 0 300 600 1200 1400

MAINTENANCE OF MAJOR COMPONENTS 121 Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

7) Performance c

13.7

8.5

LQ 6.0

0.5 300

500

600

1050

1250

Pump Speed (rpm)

RACK POSITION(mm)

13.7 13.6

P6 P0

12.65

P5 P4

11.7

9.6 8.5

P2 300

600 800

1200 1400

1800

LDA PRESSURE (mbar) 122

MAINTENANCE OF MAJOR COMPONENTS Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

4.4.3. 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). The piston in the fuel feed pump is driven by the push rod and tappet via the camshaft of injection pump and performs reciprocating 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 pressure increases abnormally, the spring is compressed, resulting in interrupting further delivery of fuel as shown in (C).

MAINTENANCE OF MAJOR COMPONENTS 123 Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

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. When using the priming pump, fix it securely to prevent 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.

2) disassembly

124

MAINTENANCE OF MAJOR COMPONENTS Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

z Clamp the feed pump with a vise and disassemble the hollow screw (30, 32), strainer (31) and seal ring (35, 36). z Take off the priming pump (25), plug (16), both seal rings (18), spring (15), and check valve (14). z Take off the plug (7), seal ring (8), spring (6), and piston (5) on the piston side. z Pull out the snap ring (20) holding the tappet (10). z Disassemble the snap ring, then take off the tappet (10) and push rod (1). 3) Inspection z If the check valve is damaged or scored on its seat face, replace it with a new one. z Inspect the piston and tappet for damage. z Replace the push rod if excessively worn, and replace together with the pump housing if required. The inspection for wear should be performed in the same procedure as for suction pressure test described below. 4) Reassembly Reassembly operation is performed in reverse order of disassembly. All the gaskets must be replaced with new ones at reassembly.

5) Testing a) Suction capacity test z

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.

Operate the tappet at the rate of 100 rpm and check to see if fuel is drawn in and delivered for 40 seconds or so.

MAINTENANCE OF MAJOR COMPONENTS 125 Printed in Aug. 2001 PS-MMA0700-E1A

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b) Delivery test z

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 z

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 container of diesel fuel and check for air leak.

4.4.4. 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.

126

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2) Construction 1. Nozzle holder 2. Union nut 3. Shim 4. Spring 5. Guide bush 6. Intermediate washer 7. Cap nut 7. Nozzle ass`y

3) Disassembly z

Clamp the nozzle assembly and remove the nozzle holder.

Remove the nozzle nut and components inside.

4) Inspection z

Visually inspect the disassembled components for damage.

5) Reassembly z

After removing carbon deposit, submerge the nozzle in diesel oil and clean it.

z Replace all the seal rings with new ones. z Assemble the parts and tighten them to specified torque. 6) Adjustment z After reassembly, install the nozzle on a tester. z With the adjusting screw loosened, operate the nozzle 2 â&#x2C6;ź 3 times to bleed it. z Operate the nozzle tester lever at the specified rate. z Adjust the injection pressure to the standard

pressure

spring

tension shims. MAINTENANCE OF MAJOR COMPONENTS 127 Printed in Aug. 2001 PS-MMA0700-E1A

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z After adjusting the injection pressure, tighten the cap nut to specified torque. z Re-check the injection pressure and see if the spray pattern is normal. Spray pattern should be uniform and free of spattering. 7) Testing z With the nozzle assembled to a nozzle tester and specified pressure applied, check the nozzle for fuel leakage.

Engine model

DV15

DV15T

DV15TI

Injection nozzle pressure

200+8 kg/cm2

200+8 kg/cm

DV15TIS 2

250+8 kg/cm2

4.4.5. Installing fuel system z

Oil purifier should be installed between fuel tank and engine. For tank is always surrounded with humidity, water part often infiltrates into fuel and then engine to result in the nozzle stuck and engine efficiency drop etc.

z Example of Fuel System Installation

z The position of fuel tank should be high than the engine fuel pump but when it is compelled to install at lower position, its lift should be within 1 m, and the fuel pipe be straight in order to prevent air bubble generation. 128

MAINTENANCE OF MAJOR COMPONENTS Printed in Aug. 2001 PS-MMA0700-E1A

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4.4.6. Diagnostics and troubleshooting Complaints 1. Engine won't start 1) Fuel not being pumped out from feed pump

2) Fuel not being injected from injection pump

3) Fuel injection timing Incorrect

4) Injection nozzles inoperative

2. Engine starts but stalls immediately

3. Engine lacks power

4. Engine knocking

5. Engine knocks seriously producing excessive exhaust smoke

Possible causes ① Fuel pipes clogged or air into pipe fine ② Feed pump valve defective ③ Feed pump piston or Push rod sticking ① Fuel filter element restricted ② Air in fuel filter or injection pump ③ Plunger and/or delivery valve sticking or defective ① Injection pump not properly installed on pump bracket ② Injection pump tappet incorrectly adjusted ③ Cams on cam shaft worn excessively ① Needle valves sticking ② Fuel leaking past clearance between nozzle and needle valve ③ injection pressure incorrect ① Pipe from feed pump to injection pump clogged or filter clogged ② Air in fuel ③ Feed pump delivery insufficient ④ Fuel delivery insufficient due to clogging of fuel tank air breather ① Plunger worn excessively ② Injection timing incorrect ③ Delivery valves defective ④ Nozzle leaks excessively ⑤ Nozzle not working normally ① Injection timing too fast ② Nozzle injection pressure too high ③ Nozzles not working normally ① Injection timing incorrect ② Nozzle injection pressure too low ③ Nozzle spring broken ④ Nozzles not working normally ⑤ Plungers worn excessively ⑥ Delivery valves seat defective ⑦ Supply of fuel excessively

Corrections Correct Replace Disassemble, correct Clean Bleed Disassemble, correct Check, correct Check, correct Replace Correct or replace Correct or replace

Adjust Clean

Bleed Disassemble, correct Replace breather

Replace Adjust Replace Correct or replace Disassemble, correct Adjust Adjust Disassemble, correct Adjust Adjust Replace Replace Adjust Replace Check feed pump

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Complaints 6. Engine output unstable

Possible causes ① ② ③ ④ ⑤ ⑥ ⑦

7. Engine does not reach maximum speed 8. Engine idling Unstable

⑧ ① ② ① ② ③

130

supply of fuel insufficient Air in fuel Water in fuel Operation of plungers unsmooth Movement of control rack sluggish Nozzles defective Injection starting pressure of each barrel incorrect Automatic timer defective Nozzles not working normally Governor defective Movement of control rod sluggish Operation of plungers unsmooth Control pinions not engaged with control rod correctly

Corrections Check feed pump Bleed Replace fuel Disassemble, correct Disassemble, correct Disassemble, correct Adjust Disassemble, correct Disassemble, correct Disassemble, correct Disassemble, correct Disassemble, correct Disassemble, correct

MAINTENANCE OF MAJOR COMPONENTS Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

5. SPECIAL TOOL LIST No.

Part No.

Figure

Tool Name

Remark

EF.120-030

Front oil seal insert assembly

EF.120-029

Rear oil seal insert assembly

EF.123-065

Valve cotter extractor

EF.120-183

Valve stern oil seal installer

EI.00308-0084

Nozzle holder extractor

EU.2-0532

Compression gauge adapter

60.99901-0036

Nozzle plug socket

EF.120-189

Injection pump alignment

DV15/T/TI DV15TIS

EF.120-031 Piston sleeve

9 EF.120-208

All engine

SPECIAL TOOL LIST

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No.

130

Part No.

Figure

Tool Name

Remark

EU.2-0131

Valve clearance adjust ass`y

60.99901-0027

Feeler gauge

T7610001E

Snap ring plier

T7621010E

Piston ring plier

SPECIAL TOOL LIST Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

6. APPENDIX 6.1. Tightening torque for major parts Major parts Cylinder block bearing cap - main bolt - side bolt Oil spray nozzle Flywheel housing - tightening bolt - cover bolt Balance weight Crank pulley Vibration damper Flywheel Fan clutch Connecting rod cap Cylinder head Cylinder head cover Fuel injection nozzle holder Fuel injection pipe Cam shaft timer Rocker arm bracket Lock nut (adjusting screw) Oil pump cover Oil pump Oil cooler Oil pan Oil pan drain plug Exhaust manifold Intake manifold Fuel injection pump(cylinder block)

Fuel filter Starting motor Alternator bracket Oil pressure unit Thermo sensor P.T.O gear shaft - flange - coupling Air compressor drive gear - connecting rod cap - cylinder liner

Screw

Strength

(Diameter x pitch)

(Grade)

M18 x 2 M12 x 1.5 M14 x 1.5 M12 x 1.5 M10 M8 M16 x 1.5 M16 x 1.5 M10 M16 x 1.5 M8 M16 x 1.5 M15 x 2 M8 M28 M14 x 1.5 M10 M10 M12 x 1 M8 M8 M12 M8 M26 x 1.5 M10 M8 M10 M12 x 1.5 M12 x 1.5 M14 M10 x 1.5 M14 x 1.5 M33 x 1.5 M24 x 1.5 M12 x 1.5 M18 x 1.5 M8 M8

12.9T 10.9T 10.9T 12.9T 8.8T 10.9T 10.9T. 10.9T 12.9T 8.8T 10.9T 12.9T 8.8T CK60 10.9T 10.9T 8.8T 8.8T 8.8T 10.9T 8.8T 10.9T 8.8T 10.9T 8.8T 8T 8.8T 10.9T 10.9T 10.9T

Tightening torque Initial 30 kg-m + angle torque 90° 8 kg-m 7 kg-m 10 kg-m 7.5 kg-m 2.2 kg-m Initial 10 kg-m + angle torque 90° 21 kg-m 6 kg-m 26 kg-m 2.2 kg-m Initial 10 kg-m + angle torque 90° 8 kg.m + 15 kg.m +angle torque 90°+ 90°

2.2 kg-m 7 ±0.5 kg-m 2.5 kg-m 9 kg-m 6.5 kg-m 5 kg-m 2.2 kg-m 2.2 kg-m 5 kg-m 2.2 kg-m 8 kg-m 5.0 kg-m 2.2 kg-m 6.5 kg-m 8 kg-m 8 kg-m 12 kg-m 2 kg-m 2 kg-m 30 kg-m 30 kg-m 5 kg-m 5 kg-m 3.5 kg-m kg-m

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6.2. Standard bolt tightening torque table Refer to the following table for bolts other then described above Degree of strength Diameter x pitch (mm)

3.6

4.6

4.8

5.6

5.8

6.6

6.8

(4A)

(4D)

(4S)

(5D)

(5S)

(6D)

(6S)

6.9

8.8

10.9

12.9

(6G) (8G)

(10K)

(12K)

108

0.5 0.9 1.4 2.2 2.4 4.4 5 7.5 8 12 13 18 20 25 28 36 41 49 56 63 74

0.75 1.25 1.95 3.1 3.35 6.2 7 10.5 11.2 17 18.5 26 28 36 41 51 58 67 75 82 93

0.9 0.5 2.35 3.8 4.1 7.4 8.4 12.5 13.4 20 22 31 33 43 49 60 68 75 85 92 103

Limit value for elasticity (kg/mm ) 20

Tightening torque (kg.m) M5 M6 M7 M8 M8x1 M10 M10x1 M12 M12x1.5 M14 M14x1.5 M16 M16x1.5 M18 M18x1.5 M20 M20x1.5 M22 M22x1.5 M24 M24x1.5

0.15 0.28 0.43 0.7 0.73 1.35 1.5 2.4 2.55 3.7 4.1 5.6 6.2 7.8 9.1 11.5 12.8 15.5 17 20.5 23

0.16 0.30 0.46 0.75 0.8 1.4 1.6 2.5 2.7 3.9 4.3 6 6.5 8.3 9.5 12 13.5 16 18.5 21.5 25

0.25 0.45 0.7 1.1 1.2 2.2 2.5 3.7 4 6 6.6 9 9.7 12.5 14.5 18 20.5 24.5 28 33 37

0.22 0.4 0.63 1 1.1 1.9 2.1 3.3 3.5 5.2 5.7 8 8.6 11 12.5 16 18 21 24 27 31

0.31 0.55 0.83 1.4 1.5 2.7 3.1 4.7 5 7.5 8.3 11.5 12.5 16 18.5 22 25 30 34 40 45

0.28 0.47 0.78 1.25 1.34 2.35 2.8 4.2 4.6 7 7.5 10.5 11.3 14.5 16.7 19 22.5 26 29 34 38

0.43 0.77 1.2 1.9 2.1 3.7 4.3 6.3 6.8 10 11.1 17.9 17 21 24.5 31.5 35 42 47 55 61

0.48 0.85 1.3 2.1 2.3 4.2 4.9 7.2 7.7 11.5 12.5 18.5 19.5 24.2 27.5 35 39.5 46 52 58 67

Others : 1. The above torque rating have been determined to 70% or so of the limit value for bolt elasticity. 2. Tension is calculated by multiplying tensile strength by cross section of thread. 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. z

Tightening torque for hollow screw(4-hole) Material

SM25C â&#x2DC;&#x2026; SUM22L STS304

M8 0.8 0.8

M10 1.6 1.8 1.8

M12 2.5 3.0 3.0

M14 3.5 4.0 4.0

M16 4.5 5.5 5.5

M18 5.5 6.5 6.5

M22 9.0 11.0 11.0

M26 13.0 16.0 16.0

M30 18.0 20.0 20.0

M38 30.0 35.0 35.0

â&#x2DC;&#x2026; : Adopted in DAEWOO engine 132

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6.2. Engine assembly tolerance (Unit : mm) DV series

Remarks

Cylinder

Inside dia. of liner forced in joint part (upper part)

Items

φ145.800~φ145.840

φ145.8 H7

block

Inside dia. of liner forced in joint part (lower part)

φ144.500~φ144.540

φ144.5 H7

Inside dia. of liner color forced in part

φ153.900~154.150

φ153.9 H11

Liner colored surface depth Cylinder liner

9.97~9.99

Outside dia.of liner forced in joint part(upper)

φ145.741~φ145.786

φ145.8 g6

Outside dia. of liner forced in joint part(lower)

φ144.432~φ144.457

φ144.5 f6

φ153.65~φ153.75

φ153.8

Outside dia. of liner color part Liner collar height

10.03~10.05

Liner forced in joint part (upper)

0.014~0.079

Liner forced in joint part (lower)

0.043~0.108

Liner collar part clearance

0.150~0.500

Inside dia. of liner Liner’s roundness & columness (upper)

φ127.990~φ128.010

φ128 ±0.01

0.01

from top up to 168mm

Liner’s roundness & columness (lower)

0.015

from bottom up to 85mm

Liner’s projection Piston

Outside diameter of piston Inside diameter of piston pin

φ127.739~φ127.757 φ46.003~46.009

Max. allowable weight per engine

50g

1st ring groove width

3.5

2nd ring groove width

3.040 ~ 3.060

Oil ring home width

4.020 ~ 4.040

Piston

1st ring height (thickness)

3.5

ring

2nd ring height (thickness)

2.978~2.990

Oil ring height (thickness)

3.97~3.99

Piston pin

1st ring axial direction clearance

2nd ring axial direction clearance

0.050~0.082

Oil ring axial direction clearance

0.030~0.070

1st ring end part clearance

0.35~0.55

2nd ring end part clearance

0.40~0.60

Oil ring end part clearance

0.40~0.70

Piston pin’s outside diameter Clearance between piston pin & pin hole

measure at 4 place

0.04 ~ 0.08

measure 71.5mm part from bottom(long length)

φ45.994 ~ φ46.000 0.003~0.015

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Items

DV series

Remarks

Connecting

Con rod small end part width

38.070~39.000

rod

Con rod large end part width

35.341~35.380

35.5 C8

Con rod cap

32.800~33.100

32.8+0.3

Con rod axial direction clearance Con rod small end part axial direction clearance

Con rod bush oil clearance

0.240~0.392 0.064~0.126

0.055~0.071

Con rod small end inside diameter (w/h bush)

φ46.055~φ46.065

Con rod small end inside diameter (w/o bush)

φ50.600~φ50.630

Con rod bush’s diameter

φ50.670~φ50.700

Tighteness Con rod large end part’s inside diameter Con rod bearing spread (MIBA) Con rod max. weight tolerance per engine Perpendicularity of large end inside diameter Large end part’s inside roundness & columness

Large end part’s inside straightness Parallelness of small end inside with large end

Crank

Bearing housing diameter

shaft

Maximum shaking

φ50.6 H7

0.04~0.10 φ95.000~φ95.022

φ95H6

0.5~1.4 50g 0.035

reference to

0.01

con rod side face

0.005 0.02 φ111.000~φ111.022

φ111 H7

0.05

Main bearing journal diameter Standard

φ103.98~φ104.00

Undersize 0.10

φ103.88~φ103.90

Undersize 0.25

φ103.73~φ103.75

Undersize 0.50

φ103.48~φ103.50

Undersize 0.75

φ103.23~φ103.25

Undersize 1.00

φ102.98~φ103.00

Thrust bearing journal width Standard

38.000~38.062

Undersize 1 , 2

38.500~38.562

Undersize 3 , 4

39.000~39.062

38 H9

Con rod bearing journal diameter

134

Standard

φ89.98~φ90.00

Undersize 0.10

φ89.88~φ89.00

Undersize 0.25

φ89.73~φ89.75

Undersize 0.50

φ89.48~φ89.50

Undersize 0.75

φ89.23~φ89.25

Undersize 1.00

φ89.98~φ89.00

APPENDIX Printed in Aug. 2001 PS-MMA0700-E1A

DV15/T/TI/TIS MAINTENANCE MANUAL

(Unit : mm) Items

DV series

Remarks

Crank

Main bearing journal’s roundness

0.01

shaft

Main bearing journal’s parallelness

0.005

Medium main bearing journal’s shake

0.06

no 1, no 5 support

Wear ring press in part’s journal diameter

φ99.985~φ100.020

φ100 j7

Wear ring’s inside diameter

φ99.9907~φ99.942

φ100 S7

Overlap

0.043~0.113

Thrust bearing width Standard

37.74~37.81

Oversize

38.24~38.31

Oversize

38.74~38.81

Crankshaft’s axial direction’s clearance

0.190~0.322

Main bearing thickness

Flywheel

Standard

3.460~3.472

Oversize 0.10

3.510~3.522

Oversize 0.25

3.585~3.597

Oversize 0.50

3.710~3.722

Oversize 0.75

3.835~3.847

Oversize 1.00

3.960~3.972

Main bearing oil gap

0.066~0.132

Main bearing spread

0.3 ~ 1.2

Thrust bearing’s spread

0.3 ~ 1.2

Ring Gear assembly part’s Outside diameter

φ432.490~φ432.645

Ring gear inside diameter

φ432.000~φ432.155

Overlap

0.335~0.645

Heat fitting temp. (°C) Allowable shaking amount after assembly Outside diameter after reassembly used ring

200~230 0.5 φ114.980~φ115.015

Cylinder

Head gasket thickness (after tightening bolts)

1.205 ~ 1.295

head

Cylinder head height

113.9 ~ 114.0

& valve

Cylinder head seal surface roughness Valve projecting amount

max. 16µ - 0.65 ~ - 0.95

Exhaust valve Stem diameter Radius direction clearance Seat angle

φ11.945 ~φ11.955 0.045 ~ 0.073 45°

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(Unit : mm) Items Head diameter “H” thickness of valve head

Cylinder

DV series

Remarks

φ50.9~φ51.1

1.9~2.3

Valve seat part diameter of head

φ53.00~φ53.03

Outside diameter of valve seat

φ53.10~φ53.11

Intake valve

head

Stem diameter

& valve

Radius direction clearance Seat angle Head diameter “H” thickness of valve head

φ11.969~φ11.980

0.020~0.049 30° φ57.85~φ58.15 2.6~3.0

Valve seat part diameter of head

φ61.00~φ61.03

Outside dia. of valve seat

φ61.10~φ61.11

Depth of head’s valve seat assembly part

φ61 H7

12.5~12.6

Valve guide inside diameter

φ12.000~φ12.018

φ12 H7

Valve guide’s inside diameter of head

φ18.000~φ18.018

φ18 H7

Valve guide’s outside diameter

φ18.028~φ18.046

φ18.25 S7

Valve guide assembly locking piece Valve seat’s shaking

0.010~0.046 0.04

reference to valve guide

Valve

Valve lift

spring

Projecting amount of valve guide Free length of inside spring

14.1 17.1~17.5

Above valve spring

DV15/T/TI : 72.43 DV15TIS : 68.3

Spring load of inside spring

DV15/T/TI :15~17kg

at 46.3mm

DV15TIS:44.5~49.5

Free length of outside spring

DV15/T/TI :68.17 DV15TIS:61.9

Spring load of outside spring

DV15/T/TI:37~41kg

at 46.8mm

DV15TIS:26.5~30

136

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Items Timing

DV series

Remarks

Rocker arm bush’s inside diameter

φ25.005~φ25.035

when assembled

Rocker arm bearing journal’s diameter

φ24.967~φ24.990

Bearing’s clearance

0.015~0.068

Push rod’s shaking

0.3

Valve tappet ass’y part’s inside dia. of block Push rod’s outside diameter Tappet clearance

φ20.000~φ20.021

φ19.944~φ19.965 0.035~0.077

Bush assembly’s inside diameter of block

φ70.077~φ70.061

Camshaft diameter

φ69.910~φ69.940

Camshaft bearing oil gap Camshaft axial direction play

φ20 H7

φ70 e7

0.060~0.120 0.20~0.90

Backlash (crank gear-camshaft gear)

0.118~0.242

Backlash (driving gear – injection pump gear)

0.102~0.338

Intake valve clearance

0.25

Exhaust valve clearance

0.35

Engine

Oil pressure at idling

0.9~3.0 bar

lubricating

Oil pressure at rated speed operation

3.0~6.5 bar

system

Oil temperature

less than 110°C

Instantaneous allowable temperature

max. 100°C

Bypass valve opening pressure

1.8~2.4 bar

Pressure regulating valve of oil pump

8.5~10 bar

Spray nozzle Operating pressure

1.6~1.9 bar

Crossing pressure

1.3~1.6 bar

Tip diameter Backlash (crankshaft gear-oil pump drive gear)

Oil pump housing’s depth/gear width

Oil pump housing axial play Engine

Cooling water pump shaft diameter

cooling

Bearing gap

system

Impeller clearance (impeller – body) Thermostat Operating temperature (°C)

φ2 0.10~0.45 43.000~43.039

43 H8

42.910~42.950

43 e8

0.050~0.128 φ21.930~φ21.950 0.050~0.091 1.0~1.5 71°C, 79°C or 79°C above 28 kg/cm2

Inspection

Good

Possible to use

25~28 kg/cm2

compressed

Need up keep

bellow 24 kg/cm2

pressure

Allowable max pressure difference between cylinders

4 kg/cm2

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Items Fuel system

DV series

Overflow valve’s operating pressure of injection pump

Maker of fuel injection pump Governor type

Remarks

1.3 ~ 1.8 kg/cm2 Bosch RQ or RQV

Injection nozzle’s manufacture Injection nozzle tip diameter

Bosch DV15 : Ø0.34x4holes DV15T : Ø0.32x5holes DV15TI: Ø0.39x4holes DV15TIS : Ø0.32x5holes

Nozzle tip projection on cylinder head Air

0.9~1.8

Cylinder bore. B grade

Ø90.000~Ø90.010

C grade

Ø90.010~Ø90.020

D grade

Ø90.020~Ø90.030

compressor

Piston outer diameter B grade

Ø89.910~Ø89.920

C grade

Ø89.920~Ø89.930

D grade

Ø89.930~Ø89.940

Piston ring groove -

1st and 2nd ring

2.51~2.53

3rd and 4th ring

4.02~4.04

Piston pin bore

Ø20.003~Ø20.008

Piston pin diameter

Ø19.994~Ø20.000

Connecting rod bush bore at small end

Ø20.020~Ø20.033

Connecting rod bearing shell width

138

2.004~2.010

When assembled Ø20f6

Connecting rod bearing journal diameter

Ø31.957~Ø31.975

Main bearing journal diameter

Ø29.959~Ø29.980

Main bearing inner diameter

Ø32.020~~Ø30.041

Ø30f7

Piston protrusion

-0.75~0.2

when assembled

Piston clearance

0.080~0.100

Connecting rod bearing oil clearance

0.027~0.073

Back lash(air comp. drive gear-cam shaft gear)

0.097~0.353

APPENDIX Printed in Aug. 2001 PS-MMA0700-E1A

z WORLDWIDE NETWORK