Doosan D1146 Installation Operation & Maintenance
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Doosan D1146 Installation Operation & Maintenance

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Summary of Contents for Doosan D1146

  • Page 2 This manual is designed to serve as an instruction for the Operation & Maintenance of the generating- set engines of Doosan POLUS series and the power unit engines: P086TI /P086TI-1/ D1146T/ D1146/ PU086T/ PU086. The POLUS means ‘Power Plus’ that is represented more powerful Doosan generating-set engines and it is marked on engine name as an initial P.

  • Page 3: Table Of Contents

    CONTENTS <Operation> 1. Safety Regulations ........................1 1.1. General Notes 1.4. Regulations Designed to Prevent Pollution 1.2. Regulations Designed to Prevent Accidents 1.5. Notes on Safety in Handling Used Engine Oil 1.3. Regulations Designed to Prevent Damage to Engine and Premature Wear 2.
  • Page 4 9.4. Breaking-in 10. Maintenance of Major Components .................. 121 10.1. Cooling System 10.3. Fuel Injection Pump 10.2. Lubricating System 10.4. Turbocharger 11. Special Tool List ........................167 • Appendix • Part & After service center • Applications for Doosan Engine...

  • Page 5: Safety Regulations

    1. Safety Regulations 1.1. General Notes Handling diesel engines and the necessary resources is no problem when the personnel com- missioned with operation and maintenance are trained accordingly and use their common sense. This summary is a compilation of the most important regulations. These are broken down into main sections which contain the information necessary for preventing injury to persons, damage to property and pollution.
  • Page 6 1.2.2. During maintenance and care • Always carry out maintenance work when the engine is switched off. If the engine has to be maintained while it is running, e.g. changing the elements of change-over filters, remember that there is a risk of scalding. Do not get too close to rotating parts. •...

  • Page 7: Regulations Designed To Prevent Pollution

    1.3. Regulations Designed to Prevent Damage to Engine and Premature Wear 1) Never demand more of the engine than it was designed to yield for its intended purpose. Detailed information on this can be found in the sales literature. The injection pump must not be adjusted without prior written permission of DAEWOO.
  • Page 8 1.5. Notes on Safety in Handling Used Engine Oil Prolonged or repeated contact between the skin and any kind of engine oil decreases the skin. Drying, irritation or inflammation of the skin may therefore occur. Used engine oil also contains dangerous substances which have caused skin cancer in animal experiments.

  • Page 9: General Information

    2. General Information 2.1. Engine Assembly 2.1.1. Engine sectional view (longitudinal) 16 17 EA9O1001 Cooling fan Vavle seat Intake valve Valve spring Exhaust valve Oil filter cap Cylinder head Combustion chamber Pistion Cylinder liner Push rod Tappet Camshaft Connecting rod Crankshaft pulley Vibration damper Oil Pump...
  • Page 10 2.1.2. Engine sectional view (cross) EA9O1002 Fuel filter Rocker arm Intake manifold Exhaust manifold Injection nozzle assembly Cylinder block Valve cotter Oil filter Valve stem seal Oil cooler Valve guide - 6 -...
  • Page 11 2.1.3. Engine assembly views 1) D1146/PU086 2 3 4 13 14 15 8 9 10 11 20 21 22 23 EA9O1003 Cooling fan Oil pan Intake manifold Alternator Oil drain valve Fuel filter Thermostat Flywheel Injection pump Oil filter Flywheel housing...
  • Page 12 2) D1146T/PU086T 2 3 4 5 15 16 17 18 13 14 EA9O1004 Cooling fan Cooling water pipe Air pipe Alternator (from radiator) (Turbocharger to Thermostat Oil cooler Intake manifold) Oil filter cap OIl drain valve Intake manifold Cylinder head cover Flywheel housing Fuel filter Exhaust manifold...
  • Page 13 3) P086TI 14 15 9 10 18 19 20 21 EA9O1005 Cooling fan Vibration damper Intake manifold Thermostat Oil cooler Injection pump Oil filter cap Oil fan Oil filter Air pipe OIl drain valve Oil level gauge (Turbocharger to Starter Air pipe Intake manifold) Flywheel housing...

  • Page 14: Engine Specification

    2.2. Engine Specification 2.2.1. Specification Engine Model D1146/PU086 D1146T/PU086T P086TI Items 4 cycle in - line, 4 cycle in - line, 4 cycle in - line, Water - cooled Water - cooled Water - cooled Engine type type Naturally type Turbo...
  • Page 15 Condition Generating-Set Engines Continuous Prime Stand by 50 HZ 105 PS 116 PS (1,500 rpm) (77 kW) (85 kW) D1146 Standard 60 HZ 130 PS 143 PS (1,800 rpm) (96 kW) (105 kW) 50 HZ 145PS 160 PS (1,500 rpm)

  • Page 16: Technical Information

    They are also referred to as engine model and serial number because of their location. EA9O2001 • Engine serial No. (example 1 : D1146) EACOA300001 Serial No. MODEL BORE Production Year(2003)

  • Page 17: Engine Type

    Engine Model Suffix 3.2. Engine Type The Engines D1146/ D1146T/ P086TI/PU086/PU086T are in-line vertical water-cooled 6-cylin- der four-stroke diesel engines with direct injection. D1146/PU086 are natural aspiration engine, D1146T/PU086T are turbo-charged type, and P086TI is turbo-charged and inter-cooled engine. 3.2.1. Cylinder block The cylinder block is a single piece of alloy cast iron.

  • Page 18: Engine Timing

    3.3. Engine Timing Camshaft, oil pump and injection pump are driven by a gear train arranged at the front end. Camshaft gear Injection pump gear (Z = 54) (Z = 54) Idle gear (Z = 42) Crankshaft gear (Z = 27) Oil pump idle gear (Z = 23) Oil pump drive gear...

  • Page 19: Lubrication System

    The cylinder walls and timing gears are splash-lubricated. Each cylinder has an oil jet provided for cooling the underside of the pistons. The lube oil is cleaned in a full-flow oil filter. • D1146/D1146T/ P086TI/PU086/PU086T D1146T/P086TI/PU086T CYLINDER BLOCK MAIN GALLERY OVER FLOW VALVE...
  • Page 20 3.5.2. Oil filter Check for oil pressure and oil leaks, and repair or replace the oil filter if necessary. Oil filter head Change the oil filter cartridge simultaneously at every replacement of engine oil. Oil filter (Cartridge) EA9O2005 3.6. Air Cleaner In case that elements are deformed, dam- aged or if the air cleaner has a crack, replace it.
  • Page 21 3.7. Fuel System The fuel is delivered by the fuel feed pump via the fuel filter to the injection pump and from there to the injection nozzles. The fuel is sprayed into the cylinders through nozzles fitted in screw-fit injection nozzle holders in the cylinder heads.
  • Page 22 Fuel Oil Selection Chart General Fuel ASTM No. 1 No. 2 DIN 51601 Classification Test ASTM 1-D ASTM 2-D API #) ˚ Gravity, D 287 40 ~ 44 33 ~ 37 0.815 ~ 0.855 Flash Point D 93 100 (38) 125 (52) 131 (55) ˚F (˚C...
  • Page 23 3.8. Cooling System The engine has a liquid-cooling system. The fresh water pump is a maintenance-free by V-belt from the crankshaft pulley. Depending on the agreed extent of delivery and the design of the engine, the coolant circuit can be equipped with temperature monitors which, in the event of loss of coolant, shut the engine down.
  • Page 24 • Since D1146/PU086, D1146T/PU086T and P086TI cylinder liner is dry type, particularly the cooling water control should be applied thoroughly. •...
  • Page 25 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 loosen- ing 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.
  • Page 26 3.9. V-belt Tension Check and Adjust By the finger-pressure the belt is pressed Press here by 10mm ~ 15mm between the fan pulley 10~15mm and the alternator pulley in normal condi- tion. For the adjustment of the tension, loosen the adjusting bolts which support Water pump pulley the alternator, adjust the tension and tight-...
  • Page 27 3.10. Turbocharger (for D1146T, P086TI, PU086T) The exhaust gases of the engine are passed through the turbine rotor of the turbocharger. Air compressor impeller mounted on the same shaft draws in fresh air and delivers it at a higher pressure to the cylinders. The turbocharger is naturally air-cooled.

  • Page 28: Electrical Equipment

    3.11. Electrical Equipment 3.11.1. Wiring circuit KEY SWITCH LOW OIL PRESS. OVER HEAT CHARGE (60.25501-7003) W/R LAMP W/R LAMP LAMP * OPTION HEAT START BR R1 0.85 SQ * STANDARD OIL PRESS. W/R SW 5.0 SQ STARTER (65.27441-7006) (65.26201-7063) 5.0 SQ 60 SQ * STANDARD OVER HEAT W/R SW...
  • Page 29 The alternator is maintenance-free, nevertheless, it must be protected against dust and, above all, against moisture and water. Wiring Diagram To Battery + Regulator RL = 150~250 OHM EA8O3007 Operate the alternator according to the instructions given in the chapter. 3.11.3.
  • Page 30 • P086TI (24V X 6.0kW) 24V x 6.0kW TERMINAL S/W TERMINAL "B" 24V x 6.0kW M5 x P0.8 M10 x P1.5 EA8O3008 Wiring Diagram Motor 2.5A(20 C 24V) EA8O3009 - 26 -...
  • Page 31 • D1146 / D1146T / PU086 / PU086T (24V X 4.5kW) 24V X 4.5kW EA902009 Wiring Diagram STARTER S/W MAGNET SWITCH STARTER MOTOR EA9O2010 Always protect starter motor against moisture. WARNING : Always disconnect the battery earth cable before starting work on the electrical system.

  • Page 32: Commissioning And Operation

    4. Commissioning and Operation 4.1. Preparation At the time of initial commissioning of a new or overhauled engine make sure to have observed the “Technical Information for the installation DAEWOO generator engines”. • Oil filler neck on cylinder head cover Before daily starting of the engine, check the fuel, coolant and oil level, replenish if necessary.
  • Page 33 At the end of the break-in period, remove break-in oil and replace the oil filter. Fill oil pan with recommended engine oil. Refer to following table. <Recommended engine oil and capacity> Model Oil pan (only) Engine oil D1146/PU086 15.5 liter SAE 15W40 D1146T/PU086T 15.5 liter API CD or CE...

  • Page 34: Operation In Winter Time

    4.3.1. Pressure of lubricating oil The normal pressure comes up to 1 kg/cm (1.0 bar) at idling and 3 ~ 5 kg/cm (3.0 ~ 4.9 bar) at maximum speed. If the pressure fluctuates at idling or does not reach up to the expected level at high speed, shut down the engine immediately and check the oil level and the oil line leakage.

  • Page 35: Tuning The Engine

    4.5. Tuning the Engine The purpose of an engine tune-up is to restore power and performance that’s been lost through wear, corrosion or deterioration of one or more parts or components. In the normal operation of an engine, these changes can take place gradually at a number of points, so that it’s seldom advisable to attempt an improvement in performance by correction of one or two items only.

  • Page 36: Maintenance And Care

    5. Maintenance and Care 5.1. Periodical Inspection and Maintenance In order to insure maximum, trouble-free engine performance at all times, regular inspection, adjustment and maintenance are vital. • Daily inspections in below figure should be checked every day. • The maintenance should be executed thoroughly at regular intervals. (Refer to "7.1.
  • Page 37 5.2.3. Oil exchange procedure While the oil is still hot, exchange oil as follows: • Take out the oil dip dipstick. • Remove the drain valve from oil pan, then drain out the engine oil into a con- tainer. • Reassemble the drain valve with the oil pan and the drain plug with oil filter head after draining out the engine oil.
  • Page 38 Engine oil viscosity - ambient temperature SAE 20, 20W SAE 40, 50 Single SAE 10W SAE 30 grade Ambient -30 C -15 C -0 C 15 C 25 C 30 C temp (-20 F) (-0 F) (-32 F) (60 F) (80 F) (90 F) Multi...
  • Page 39 5.3. Cooling System The coolant must be changed at intervals of 1,200 hours operation or six months whichever comes first. If the coolant is being fouled greatly, it will lead an engine overheat or coolant blow off from the expansion tank. 5.3.1.
  • Page 40 5.3.2. Cleaning of the cooling system inside circuit (by authorized specialist personnel) When the cooling system circuit are fouled with water scales or sludge particles, the cooling efficiency will be lowered. Investigations have shown that in many cases the poor condition of the coolant and /or the cooling system accounts for damage to the water pump mechanical seal, The poor condition of the cooling system is normally due to use of unsuitable or no anti-freezing agents and cor- rosion inhibitor or defect, not early enough replaced covers for filler neck and working valves.
  • Page 41 5.3.3. Intercooler (for P086TI) 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.

  • Page 42: Air Intake System

    5.4. Air Intake System 1. Connection port, fouling indicator 2. Cleaner housing 3. Clamp 4. Element 5. Hexagon nut 6. Cover 7. Dust bowl EA6O5012 5.4.1. Maintenance (only when engine is switched off) Empty the dust bowl (7) regularly. The bowl should never be filled more than halfway with dust. On slipping off the two clamps (3), the dust bowl can be removed.
  • Page 43 5.4.3. Cleaning filter elements • By compressed air (wear goggles) For the purpose, the air gun should be fit- ted with a nozzle extension which is bent 90? at the discharge end and which is long enough to reach down inside to the bottom of the element.
  • Page 44 5.5. Fuel System 5.5.1. Fuel filter • After every 200 hour of operation, drain the water and sediment from the fuel- water separator. • Shut off the engine. Use your hand to open the drain valve • Turn the valve counter clockwise approx- imately 2 ~ 3 turns until draining occurs.
  • Page 45 5.5.3. Fuel system checks Fill the tank with the recommended fuel. Keeping tanks full reduces water condensation and helps keep fuel cool, which is important to engine performance. Make sure fuel supply valves (if used) are open. To insure prompt starting and even running, the fuel system must be primed with the fuel feed pump manually before starting the engine the first time, or after a fuel filter change.
  • Page 46 5.5.5. Priming pump strainer cleaning Clean the priming pump strainer filter every 200 operation hours. The strainer filter is incorporated in the priming pump inlet side. Strainer EA9O4004 5.5.6. Bleeding the fuel system Whenever fuel filter is changed or the engine is stopped by cause of the fuel lack, the air of fuel line must be removed as follows.
  • Page 47 • Install a nozzle to a nozzle tester. • Check injection pressure, and adjust the nozzle using the adjusting shim if the pressure does not meet the specified limit. Engine Model D1146/PU086 D1146T/PU086T P086TI Opening pressure 214 kg/cm 214 kg/cm 214 kg/cm •...
  • Page 48 5.7. Turbocharger (for D1146T/PU086T, P086TI) 5.7.1. Maintenance (by authorized specialist personnel) The turbochargers do not call for any specific maintenance. The only points to be observed are the oil pipes which should be checked at every oilchange for leakage and restrictions. The air cleaners should be carefully serviced.
  • Page 49 Dial gauge Magnetic vise Move the turbine shaft Radial play in both directions Limit of wear : 0.57mm simultaneously Oil inlet EA4M2018 - 45 -...

  • Page 50: Checking And Setting

    6. Checking and Setting 6.1. Adjustment of Valve Clearance 6.1.1. General information The valve clearances are to be adjusted at the times of the following situations. • After initial 50 hour’s operation. • When the engine is overhauled and the cylinder heads are disassembled. •...
  • Page 51 Loosen the lock nuts of the rocker arm adjusting screws and push the specified feeler gauge and adjust the valve clearance with adjusting screw respectively. Model Intake Valve Exhaust Valve D1146/PU086 D1146T/PU086T 0.3 mm 0.3 mm P086TI 6.1.3. Method of adjusting the valve clearance 1) Loosen the lock-nuts aausing a ring span- ner.
  • Page 52 Timing check hole ing the notch mark of the right figure cor- responding to the injection timing is aligned with the pointer ( ) on the fly- wheel housing. D1146/PU086 P086TI D1146T /PU086T Fuel injection timing Flywheel ˚ ˚...

  • Page 53: Cylinder Compression Pressure

    • Tighten the coupling fixing bolts and nuts to specified torque. Torque 6.0 ~ 6.5 kg.m EAMD021I 6.3. Cylinder Compression Pressure 1) Stop the engine after warming it up, then remove the nozzle assemblies. EA9O5003 2) Install a special tool (gauge adapter) in nozzle holder hole and connect the com- pression pressure gauge to the adapter.

  • Page 54: V-Belts

    6.4. V-belts The tension of the V-belts should be checked after every 2,000 hours of operation. 1) Change the V-belts if necessary If in the case of a multiple belt drive, wear or differing tensions are found, always replace the complete set of belts.
  • Page 55 75 kg 70 kg 60 kg 20.2 mm 75 kg 70 kg 60 kg : Adopted in D1146/PU086, D1146T/PU086T and P086TI 5) Tensioning and changing V-belt • Loosen fixing bolts and nuts. • Adjust the alternator until V-belts have correct tensions.

  • Page 56: Operation Tip

    7. Operation Tip 7.1. Periodic Inspection Cycle : Check & adjust : Replace Every Every Every Every Every Inspection Daily Remark 50hrs 200hrs 400hrs 800hrs 1200hrs Check for leakage(hoses, clamp) Check the water level Cooling Change the coolant water System Every Adjust the V-belt tension 2,000hrs...
  • Page 57 7.2. Trouble Shooting - 53 -...
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  • Page 64: Causes And Remedies

    7.3. Causes and Remedies Condition Causes Remedies • 1) Starting difficult Valve’s poor shut, stem distortion Repair or replace • (1) Compression pressure Valve spring damage Replace valve spring • Cylinder head gasket’s leak Replace gasket • Wear of piston, piston ring or liner Adjust •...
  • Page 65 Condition Causes Remedies • 4) Overheating Engine oil insufficient or poor Replenish or replace • Cooling water insufficient Replenish or replace • Fan belt loosened, worn, damaged Adjust or replace • Cooling water pump’s function lowered Repair or replace • Water temp.
  • Page 66 Condition Causes Remedies • (4) Others Wear of crankshaft, thrust bearing Replace thrust bearing • Camshaft end play increased Replace thrust plate • Idle gear end play increased Replace thrust washer • Timing gear backlash excessive Repair or replace • Valve clearance excessive Adjust valve clearance •...

  • Page 67: General Information

    8. General Information 8.1. 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.

  • Page 68: Engine Characteristic

    8.2. Engine Characteristic 8.2.1. Toroidal combustion mode (D1146/PU086) The D1146 engine is operated in the toroidal combustion mode that was developed by this company with AVL Co. Australia. The feature of this mode in the fundamental structure is that there are combustion chambers in the centers of piston heads and swirling passages in the cylinder heads.
  • Page 69 8.2.3. Oil gallery cooling type piston (P086TI) Oil gallery cooling is used for the piston of P086TI generator engine. When thermal loading is high, piston cooling by means of an oil gallery in the crown is normally necessary to pre- vent crown cracking and ring sticking.

  • Page 70: Maintenance

    9. Maintenance 9.1. Engine Disassembly 9.1.1. Heed at disassembly • Before disassembly, the part shelf should be prepared for various tools and repair parts. • When assembling, clean empty hand should be used and clean environment maintained. • In case of storing the disassembled parts, each part should not touch each other. •...
  • Page 71 9.1.4. Engine oil • Remove the oil drain cock of oil pan and pour the engine oil into the prepared vessel. Drain cock EA9O4001 9.1.5. Cooling fan • Remove the flange fixing bolts, then take off the flange and cooling fan. EA9M3001 9.1.6.
  • Page 72 9.1.8. Fuel filter • Remove the hollow screws of filter and tear down fuel supply and dis- charge rubber hose. • Remove fuel filter assembling bolts and disassemble the fuel filter. ED7OM009 9.1.9. Breather • Loosen the clamp screw to remove the rubber hose.
  • Page 73 9.1.12. Oil cooler • Loosen the cooling water pump and the rubber hose clamps of connected pipes, and disassemble it. • Remove the oil cooler assembling nuts and disassemble it. 9.1.13. Oil filter • Remove the oil filter assembling bolts and disassemble the oil filter assembly.
  • Page 74 9.1.16. Nozzle • Remove the fuel supply high pressure pipe and its assembling nuts that are connected between fuel injection pump and nozzle and disassemble the pipes. • After installing the special tool f o r removing nozzle temporarily, loosen the holder and then ham- mer up with a hammer which is a special tool so as for nozzle assem- bly to be disassembled.
  • Page 75 9.1.19. Intake manifold • Remove the Intake manifold assem- bling bolts and disassemble it from the cylinder head. • Disassemble the intake manifold gas- ket and scrap it. ED7OM005 9.1.20. Cooling water pipe • Remove cooling water pipe assembling bolts and disassemble the pipe for the cylinder head.
  • Page 76 • Lay the removed bolts orderly not to damage the threads at all and store. Caution : Prevent a collision between the bolt thread each other. • Take out the cylinder head gasket and scrap it. • Remove the foreign residues from the cylinder head surface and block surface. Caution : Try not to make any damage on the contact surfaces.
  • Page 77 9.1.26. Oil pump • Remove the bracket fixing bolts of oil intake pipe. • Remove the pipe assembling bolts of oil pump and disassemble intake and supply pipe. • Remove the oil pump assembling bolts, and disassemble the oil pump. EFM2025I 9.1.27.
  • Page 78 (2) Heat the piston with a electric heater, then take out the piston pin from the piston as tapping it with a round wooden bar. EAMD088I (3) Remove the piston ring with a plier. (4) Clean the piston thoroughly. 9.1.28. Cylinder liner •...
  • Page 79 • Remove the idle gear assembling bolts and disassemble the idle gear pin. 9.1.30. Fuel injection pump • Disassembly the oil hose for lubrica- tion. • R e m o v e t h e i n j e c t i o n p u m p f l a n g e assembling nuts EAMD021I...
  • Page 80 9.1.32. Fly wheel • Remove the flywheel assembling bolts and disassemble it. • The bolt removal is done by the reverse order of assembling and by the steps. EDM2072I 9.1.33. Fly wheel housing • Remove the flywheel housing assem- bling bolts and disassemble the flywheel housing.
  • Page 81 9.1.36. Bearing cap • Remove the bearing cap assem- bling bolts by the step in the reverse order of assembling, and disassemble the bearing cap. (Remove by the same way as the cylinder head bolts’ removal.) • Disassembled bearing caps are kept laid in order.
  • Page 82 9.1.39. Oil spray nozzle (D1146T, P086TI only) • Remove the valve screws of oil injec- tion nozzle and disassemble it. - 78 -...
  • Page 83 9.2. Inspection 9.2.1. Cylinder block • Clean the cylinder block thoroughly, and check for any crack or damage. • If there is any crack or severe damage, replace it and if there is minor one, correct it. • Check for any clogging or corrosion in the oil passage and water passage. •...
  • Page 84 (2) Distortion of lower surface • As shown in figure, measure the cylinder head’s distortion at 6 directions with hor- izontal ruler and clearance gauge. • If the measured value is beyond the limit value, correct it by means of the fine grinding paper or grinding machine.
  • Page 85 Dimension Standard Limit Description Intake valve stem 8.950~ 8.970 mm 8.93 mm Exhaust valve stem 8.935~ 8.955 mm 8.91 mm • Valve seat contacting faces Check the valve seat contact surface for any crack and wear, and if necessary, correct with grinding paper, and if excessive, replace it.
  • Page 86 (3) Valve seat • Contacting face amount As for the valve seat’s wear, measure the width of the contact surface with intake valve seat and exhaust valve seat. If beyond the limit value, replace the valve seat. • Assemble the valve at the valve seat of the cylinder head, and check the amount of depression of the valve from the lower portion of the cylinder head using a dial...
  • Page 87 (4) Valve spring • Visual check Check the appearance of valve spring and if necessary replace the spring. • Valve spring free length Use a vernier caliper to measure the valve spring free length. If the measured value is less than the specified limit, the valve spring must be replaced.
  • Page 88 (5) Assembling cylinder head • Clean the cylinder head thoroughly. • Replace the valve stem seal with new one, and by means of a special tool, press the stem seal into the valve guide of cylinder head. • Coat engine oil to valve stem and valve g u i d e a n d a s s e m b l e t h e v a l v e .
  • Page 89 • Rocker arm shaft diameter With an outside micrometer, measure the rocker arm shaft diameter at the point where the rocker arms have been installed. Replace the rocker arm if the amount of wear is beyond the specified limit. Standard Limit 23.978 ~ 23.959 mm...
  • Page 90 • Visual check of tappet Visually check the face of the tappets in contact with the cam for pitting, scores or cracks, and replace if severely dam- aged. If the amount of cracks or pitting is small, correct with an oil stone or grind- (1) Unevenness (2) Crack (3) Normal...
  • Page 91 9.2.4. Camshaft 1) Camshaft End play • Push the thrust plate toward the cam gear. • With a feeler gauge, measure the clear- ance between the thrust plate and camshaft journal. • If the end play is excessive, replace the thrust plate.
  • Page 92 <Clearance> Camshaft bearing Standard Limit 0.12 ~ 0.17 mm 0.24 mm Replace the bushing if the measured value is beyond the specified limit. EA0M4063 • Run-out Support the camshaft on two V blocks and check for run-out using a dial indi- cator.
  • Page 93 • If the amount of wear is beyond the limit, have the crankshaft ground and install undersize bearings. However, if the amount of wear is within the limit, you can correct the wear using an oil stone or oiled grinding paper of fine grain size. (Be sure to use grinding paper which has been immersed in oil.) EFM2047I...
  • Page 94 (3) Crankshaft run-out • Support the crankshaft on V blocks. • Turn the crankshaft with a dial indicator placed on the surface plate and take the amount of crankshaft run-out. Standard Limit 0.05 mm 0.1 mm 2) Crankshaft bearing and connecting rod (1) Visual check Visually check the crankshaft bearing and connecting rod bearing for scores,...
  • Page 95 • Connecting rod bearing clearance Install the connecting rod bearing in the connecting rod bearing cap, tighten the connecting rod cap bolts to the specified t o r q u e , t h e n m e a s u r e t h e i n s i d e diameter.
  • Page 96 3) Bearing spread and crush • Inspection Check to see that the bearing requires a considerable amount of finger pressure at reassembly operation. Spread = O A - O B EDM2047I • Crankshaft bearing crush Install the bearing and cap in the cylinder block, retighten the bolts to specified torque, unscrew out one bolt completely, then measure the clearance between the...
  • Page 97 • Connecting rod bearing crush Install the bearing and cap in the con- necting rod big end, retighten the bolts to specified torque, unscrew out one bolt completely, then measure the clearance between the bearing cap and connecting rod big end using a feeler gauge. Standard 0.3 ~ 0.5 mm EAMD064I...
  • Page 98 • Using a cylinder bore gauge, measure cylinder liner inside diameter at 3 points (cylinder top ring contacting face, middle, and oil ring contacting face on BDC) in a ˚. direction at an angle of 45 Take the mean value with the largest and smallest values excepted.
  • Page 99 (3) Piston ring side clearance • Fit the compression ring and oil ring in the piston ring groove. Feeler gauge • With a feeler gauge, measure side clearance of each ring, and replace either the ring or piston if the measured value is beyond the specified limit.
  • Page 100 (2) Clearance Measure the clearance between the piston pin and connecting rod bushing, and replace either of them, whichever dam- aged more, if the measured value is beyond the limit. Standard Limit 0.009 ~ 0.015 mm 0.08 mm EA3M2047 (3) Condition check Check the engaged condition of the piston and piston pin.

  • Page 101: Reassembly

    9.3. Reassembly 9.3.1. General precautions • Clean all the disassembled parts, particularly oil and water ports, using compressed air, then check that they are free from restrictions. • Arrange the general and special tools in order for engine assembly operation. •...
  • Page 102 • Apply engine oil to the entire face of the tappets and slide them into the tappet holes on the cylinder block. • Wet the cam bush inside diameter and camshaft with oil, and carefully assemble them while turning the camshaft. Caution : Be careful not to generate a damage to camshaft and bush.
  • Page 103 • Heat the crankshaft gear for at least 10 ˚C minutes to 120 , then apply sealant (Loctite # 641) to the inside wall of the heated crankshaft gear evenly before inserting it to the end of crankshaft. EA8M3014 • Semi-tighten a bolt at both sides of the crankshaft, apply engine oil to journals and pins, then assemble the crankshaft...
  • Page 104 • Install the bearing cap by matching the cylinder block No. with the bearing cap EQM3058I • Apply oil to the entire part of the bearing cap bolts, then tighten in tightening sequence to specified torque. Torque 30 kg • After semi-tightening both bolts evenly, tighten them diagonally to the specified EQM3059I...
  • Page 105 Caution : When the bolts are tightened, remove the guide bar. • The flywheel housing is assembled after the new oil seal was pressed (Coat engine oil over the outside of oil seal) before in the housing by a press. If any peripheral scar was gener- ated due to oil seal at the oil seal contact surface of crankshaft, after inserting about 1 mm shim or thereabout in front of oil seal (Direction toward crankshaft.), measure and adjust.
  • Page 106 • Install a guide bar into a bolt hole on the crank shaft, and lift the flywheel to align the dowel pin with the pin hole on the f l y - w h e e l f o r t e m p o r a r y a s s e m b l y operation.
  • Page 107 9.3.11. Cylinder liner • Stand the cylinder block so that the fly- wheel faces downward. • Thoroughly clean the liner flange fitting surface and bore inside with compressed air to prevent the entry of foreign sub- stances. • After the cleaning operation, make the cylinder liner dried up and push it into the cylinder block by hand.
  • Page 108 • Noticing the direction of the piston, make the longer side (machined with key groove on the bearing) of the connecting rod big end and the mark of ‘ ’ impressed on the inside of the piston face each other in opposite directions. On the piston head surface, the longer side of the connecting rod big end is in opposite direction from the valve seat...
  • Page 109 • Install the bearing in the connecting rod cap and apply oil. Caution : Make sure that the manufacture serial numbers impressed on the connecting rod cap and connecting rod big end are iden- tical, and install the connecting rod cap by aligning it with dowel pin.
  • Page 110 9.3.13. Timing gear case • Mount a new gasket using dowel pin on the cylinder block. • Put the time gear case to the cylinder block by aligning the dowel pin hole of timing gear case with its pin, and then assemble it by tapping lightly with an ure- thane hammer to the right and left (Particularly around dowel pin).
  • Page 111 • Install the idle gear by coinciding the marks impressed on the crank gear, cam Mark "2" gear, fuel injection pump drive gear, and Fuel injection Cranshaft gear idle gear. pump drive gear • Install a thrust washer on the idle gear Idle gear and tighten to specified torque.
  • Page 112 (1) As above adjusting method, Please coincide the indication point( ) at the flywheel housing’s inspection hole with the flywheel’s inspection angle. <Fuel injection timing> Model Timing angle ˚ D1146/PU086/D1146T BTDC 18 PU086T/P086TI BTDC 12 ˚ - 108 -...
  • Page 113 (2) Loosen the drive gear fixing bolt of injection pump a bit. (3) After turning slowly the coupling of injection pump until the fuel will drop from #1 plunger at the rate of a drop for 6 ~ 8 sec., tighten the driving gear fixing bolt of fuel pump.
  • Page 114 9.3.18. Water pump • Mount a new gasket. • Install the water pump on the cylinder block and tighten the assembling bolts with specified torque. Torque 2.2 kg • Connect water pipes and by-pass pipe to the water pump. ED7OM008 •...
  • Page 115 9.3.21. Vibration damper • Insert the vibration damper to the crankshaft, and assemble by tightening the assembling bolts at the specified tightening torque according to bolt tight- ening order. (refer to right figure.) Torque 13 kg 9.3.22. Oil pan EDM2089I •...
  • Page 116 Caution : Align the bolt holes with gasket holes to prevent damage to the gasket and tighten. 9.3.23. Oil filter • Install the oil filter onto the cylinder block, and tighten the fixing bolts. Torque 2.2 kg • I n s t a l l p a c k i n g a n d a s s e m b l e t h e cartridge using a filter wrench.
  • Page 117 • With a valve stem seal fitting jig, assemble the valve stem seal with the valve guide. • After installing valve springs and spring retainer, press the retainer with a jig, then install cotter pin. • Tap the valve stem lightly with a rubber hammer to check that the valve is assembled correctly.
  • Page 118 • Check the inside of combustion chamber for foreign substances, and carefully mount the cylinder head assembly in the block by aligning the dowel pin with the dowel pin hole. Caution : Be careful not to damage the cylinder head gasket. If the dowel pin is not in EA9M3022 alignment, lift the cylinder head again and then remount it.
  • Page 119 • As for the valve clearance, adjust it when in cold. Model Intake Valve Exhaust Valve D1146/PU086 D1146T/PU086T 0.3 mm 0.3 mm P086TI Caution : (1) Crankshaft revolution is done by hands without using a starting motor.
  • Page 120 • Adjust valve clearance with a feeler Valve clearance adjust gauge and tighten the fixing nuts to specified torque. Torque 5.0 kg EA8M3007 9.3.28. Rocker arm assembly • Apply lubricating oil to the rocker arm bush and shaft, and assemble the intermediate bracket with the rocker arm (rocker arm assembly) on the cylinder block using fixing bolts.
  • Page 121 9.3.30. Exhaust manifold • Install the exhaust manifold gasket over the stud bolts by aligning the gasket with the exhaust port on the cylinder head so that the face and back of the gasket can be positioned correctly. • Semi-assemble the exhaust manifold and install the heat resisting plate.
  • Page 122 9.3.33. Alternator • Install the alternator mounting bracket. • Install the alternator with fixing bolts to the mounting bracket. EA9M3004 9.3.34. Fuel filter • Assemble the fuel filter with the intake manifold. • Assemble the fuel feed hose according to the direction of an arrow impressed on the fuel filter head so that fuel can be fed in the sequence of FUEL FEED PUMP FUEL FILTER...
  • Page 123 9.3.36. Injection pipe • Semi-assemble a nut at both ends of the fuel high pressure pipe and tighten them up one by one to specified torque. Torque 3.0 kg • Tighten hollow screws to assemble the fuel return pipe. • Assemble the fuel return hose on the fuel injection pump.

  • Page 124: Breaking-In

    9.3.39. V- Belt • Install the V-belt on the crank pulley, Press here alternator pulley and water pump pulley. 10~15mm • Adjust the V-belt tension using the ten- sion adjusting support. Water pump pulley Alternator pulley Crank pulley V-belt EA9O2006 9.3.40.

  • Page 125: Maintenance Of Major Components

    10. Maintenance of Major Components 10.1. Cooling System 10.1.1. 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.
  • Page 126 Valve lift 8 mm or more (at 85 ˚C Operating temperature 71 ~ 85 3. Cooling fan and belt D1146/T, PU086/T : 590mm - 6 Fan diameter - Number of blades P086TI : 755mm - 7 Fan belt tension 15mm/ deflection by thumb 10.1.3.
  • Page 127 There are 2 kinds of thermostats according to surrounding and operating conditions. One is named by 71 ˚C type and the other is 79 ˚C • Inspecting (1) Check the wax pallet and spring for damage. Ruler (2) Put the thermostat in a container of Thermometer water, then heat the water slowly and check temperature with a thermometer.
  • Page 128 10.1.4. Diagnostics and troubleshooting Complaints Possible causes Corrections • • 1. Engine overheating Lack of coolant Replenish coolant • • Radiator cap pressure valve Replace cap spring weakened • • Fan belt loosened or broken Adjust or replace fan belt •...

  • Page 129: Lubricating System

    10.2. Lubricating System 10.2.1. General descriptions • 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 injec- tion pump in order to ensure normal engine performance.
  • Page 130 10.2.2. Oil pump • Disassembly (1) Disassembly of oil pump drive gear a. Unscrew the screw and disassemble the oil relief valve. b. Unfold the washer for the oil pump drive gear fixing nut and remove the nut. c. Disassemble the drive gear. EQM4006I (2) Remove the oil pump cover fixing nuts and disassemble the oil pump cover.
  • Page 131 (3) Measuring clearance between drive shaft and bushing a. Measure the outside diameters of the drive shaft and driven shaft, and replace if the measured values are less than the limit ( 16.95mm) Standard 16.95 ~ 16.968 mm b. Measure the inside diameter of the pump body bushing to determine the clearance between the bushing and shaft, and compare the measured value with the standard value to determine whether to replace or not.
  • Page 132 10.3. Fuel Injection Pump 10.3.1. General information of fuel system The fuel system consists of the fuel tank, injection pump, injection nozzle, fuel filter, and fuel lines such as pipes and hoses necessary to connect those components. Fuel return pipe Overllow valve (Valve opening) pressure 1.6kgf/cm...
  • Page 133 1) D1146 (1) Injection pump : 65.11101-7269A - Model : KP-PES6AD95B410RS2 (101061-8820 ZEXEL) - Governor : KP-EP/RSV200-1350AQ49C311(105419-3930) - Plunger & barrel : 131153-1720 - Delivery valve : 131110-5120 - Feed pump : KP-FP/KE-ADS(105210-5280) - Prestroke : 4.6 ± 0.05mm (2) Nozzle holder assembly : 65.10101-7050 (9134-153C LUCAS) (3) Nozzle : 65.10102-6026 (9135-143 LUCAS)
  • Page 134 (7) Governor adjustment (D1146) Injection Pump Speed (rpm) EA9M4002 - 130 -...
  • Page 135 2) D1146T (1) Injection pump : 65.11101-7271A - Model : KP-PES6AD95B410RS2 (101061-8820 ZEXEL) - Governor : KP-EP/RSV200-1350AQ49C311(105419-3930) - Plunger & barrel : 131153-1720 - Delivery valve : 131110-5120 - Feed pump : KP-FP/KE-ADS(105210-5280) - Prestroke : 4.6 ± 0.05mm (2) Nozzle holder assembly : 65.10101-7050 (9134-153C LUCAS) (3) Nozzle : 65.10102-6026 (9135-143 LUCAS) (4) Injection pipe : 65.10301-6048 (5) Injection order: : 1 - 5 -3 - 6 - 2 - 4...
  • Page 136 (7) Governor adjustment (D1146T) Injection Pump Speed (rpm) EA9M4002 - 132 -...
  • Page 137 3) P086TI (1) Injection pump : 65.11101-7309 (106674-4120 ZEXEL) - Model : NP-PE6P120/700RS3S (106067-6010 ZEXEL) - Governor : Ghana electric control - Plunger & barrel : 134153 -2020 - Delivery valve : 134110 - 1420 - Feed pump : NP-FP/KD-PS(105237-5470) - Prestroke : 3.9 ±...
  • Page 138 4) PU086 (1) Main Specification Fuel Injection Pump : 65.11101-7269A Model Type : PES6AD Governor Type : RSV Fuel Feed Pump : 105210-4830 Cam Lift : 11 mm Injection Timing : BTDC 18° ± 1° Injection Order : 1-5-3-6-2-4 Rotating Direction : Clockwise (Viewed at driving gear side) (2) Calibration Data Nozzle &...
  • Page 139 (3) Rack Diagram Idling serve spring Stroke start or more than 14 Governor spring set Idling serve. 10.5 Spring setting 370 485 1100 1215 or LESS 1165 Pump speed (RPM) EDM5001I - 135 -...
  • Page 140 5) PU086T (1) Main Specification Fuel Injection Pump : 65.11101-7271A Model Type : PES6AD Governor Type : RSV Fuel Feed Pump : 105210-4830 Cam Lift : 11 mm Injection Timing : BTDC 12° ± 1° Injection Order : 1-5-3-6-2-4 Rotating Direction : Clockwise (Viewed at driving gear side) (2) Calibration Data Nozzle &...
  • Page 141 (3) Rack Diagram 14.0 14.0 or more Booster compensating start : 10 0.5 mm 11.2 10.5 Governor spring setting Idling serve. spring setting Q = 17 1.3MM / st (7.7) (7.0) -0.1 1190 1100 1165 Pump speed (RPM) EDM5003I - 137 -...
  • Page 142 10.3.3. Governor system (P086TI Only) Governor system for fuel injection pump consists of "Integral Actuator" and " Speed Control Unit". 1) Integral Actuator EC2OM316 <Dimension View> Fig. No. Description Q’ty Remark Frame Bearing retainer kit Ass’y Mounting bar SWP connector Mg610320 Front cover T3.2...
  • Page 143 2) Speed control unit for governor system (DWC-2000 SERIES SPEED CONTROL UNIT) <Introduction> This speed control unit performs the electronic function of the engine governing system. The speed control unit senses the pulses from the magnetic speed sensor, compares them with the speed control unit's set point and supplies the appropriate current output to the actuator to control the engine's fuel system.
  • Page 144 The engine speed signal is usually obtained from a magnetic speed sensor mounted in close prox- imity to the teeth of a ferrous ring gear that is driven by the engine. The frequency of the speed sen- sor signal is proportional to the engine speed. The speed control unit will accept any signal if the fre- quency is proportional to engine signal, and in the frequency range of the speed control unit (1K to 7.5K Hz.).
  • Page 145 1) Specification • Performance Isochronous Operation / Steady State Stability ..........±0.25% or better Speed Range/Governor ................. 1K~7.5 K Hz continuous Speed Drift with Temperature ................±0.5% Maximum Idle Adjust CW ....................60% of set speed Idle Adjust CCW .............….…........Less than 1200Hz Droop Range ............…..……......
  • Page 146 Reset Crank Overspeed Crank Test Speed Gain : DWC-2000 Stability : DC24V : 65.11220-7006 Starting GHANA CONTROL Fuel 826-1 Kuro 3-Dong, Duro-Gu Seoul 152-053 KOREA(DONG-IL TECKNO-TOWN) MADE IN KOREA Speed Ramping Idle Idle Speed Trim Droop Droop Autuator Pic-up Battery AUX 10V 10V POWER AUX.
  • Page 147 2) Application and installation information The speed control unit is rugged enough for mounting in a control cabinet or engine mounted enclosure or in a remote console up to 20 meters(65ft.) from the engine. Care should be taken to insure that the speed control unit, mount it vertically so that condensation will not accumulate in the speed control unit.
  • Page 148 • Start engine The speed control unit governed speed setting is factory set at approximately engine idle speed. Crank the engine with DC power applied to the governor system. The actuator will energize to the maximum fuel position until the engine starts. The governor system should control the engine at a low idle speed.
  • Page 149 Method 2 : Start the engine and control at an idle speed for a period of time prior to accelerating to the operating speed. This method separates the starting process so that each may be optimized for the lowest smoke emissions. Replace the connection between Terminals M &...
  • Page 150 • Accessory input The AUXiliary Terminal N accepts input signals from load sharing units, auto synchronizers, and other governor system accessories, DWC accessories are directly connected to this terminal. It is recommended that this connection from accessories be shielded as it is a sensitive input terminal. If the auto synchronizer is used alone, not in conjunction with a load sharing module, a 3M ohm resistor should be connected between Terminals N and P.
  • Page 151 • OVERSPEED shutdown setting DWC-2000 has a Test switch to determine the OVERSPEED set point and test the engine shut- down function. If you want to adjust the OVERSPEED set point at the speed about 10% higher than the RUN set speed, use the Test switch. When the engine is operating at the Run set speed in pushing the Test switch, rotate the Overspeed Adjust.
  • Page 152 • Unsatisfactory performance If the governing system functions poorly, perform the following tests. SYMPTOM TEST PROBABLE FAULT Actuator goes to full fuel. then, disconnect speed sensor at Terminals C & D. • Do not crank. Apply If actuator still at full fuel speed control DC power to the gov- unit deffective.
  • Page 153 • Electromagnetic compatibility (EMC) EMI SUSCEPTIBILITY - The governor system can be adversely affected by large inter- fering sig- nals that are conducted through the cabling or through direct radiation into the control circuits. All DWC-2000 speed control units contain filters and shielding designed to protect the units sensi- tive circuits from moderate external interfering sources.
  • Page 154 10.3.4. Fuel feed pump 1) General descriptions and construction Priming pump Check valve Check valve Outlet Inlet side side Tappet Piston Cam shaft EQM4019I The P-type injection pump is mounted with K-ADS or KP type feed pump. These pumps have the same basic construction a n d o p e r a t i o n , a n d t h e g e n e r a l descriptions of the KP type pump are given below: The figures show its construction (above figure) and operation (following figure).
  • Page 155 Inlet side Outlet side Interruption EQM4020I 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 feed- ing 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.
  • Page 156 2) Disassembly • Clamp the feed pump with a vise and disassemble the plugs (30, 32), strainer (31) and gaskets (35, 36). • Take off the priming pump (25), plug (16), both gaskets (18), spring (15), and check valve (14). •...
  • Page 157 5) Testing (1) Suction capacity test Connect one end of a hose to the inlet Outlet hose side of the feed pump and immerse the other end of it into the fuel tank as illus- Feed pump trated. Hold the feed pump in position about 1 m above the level of fuel in the fuel tank.
  • Page 158 10.3.5. Injection nozzle 1) General descriptions Pressurized fuel delivered from the fuel injection pump is sprayed into the combustion cham- ber past the injection nozzle at proper spray pressure and spray angle, then burnt complete- ly to achieve effective engine performance. (1) At valve closed (2) At valve opened EQM4024I...
  • Page 159 Abnormal Abnormal EFM2057I 7) Testing With the nozzle assembled to a nozzle tester and specified pressure applied, check the nozzle for fuel leakage. EAMC022I Engine Model D1146/PU086 D1146T/PU086T P086TI Opening pressure 214 kg/cm 214 kg/cm 214 kg/cm - 155 -...
  • Page 160 10.3.6. Diagnostics and troubleshooting Complaints Possible causes Corrections • 1. Engine won’t start Fuel pipes clogged or air into Correct 1) Fuel not being pumped pipe fine • out from feed pump Feed pump valve defective Replace • Feed pump piston or Push rod Disassemble, correct sticking •...
  • Page 161 Complaints Possible causes Corrections • 6. Engine output unstable supply of fuel insufficient Check feed pump • Air in fuel Bleed • Water in fuel Replace fuel • Operation of plungers unsmooth Disassemble, correct • Movement of control rack Disassemble, correct sluggish •...

  • Page 162: Turbocharger

    10.4. Turbocharger 10.4.1. Main data and specifications 1) Main data and specifications Specification D1146T/PU086T P086TI Turbocharger Model Allied Signal 466721-13 Allied Signal 466721-16 50Hz: Approx. 0.76 kg/cm 50Hz: Approx. 1.56 kg/cm Air pressure at compressor outlet 60Hz: Approx. 1.00 kg/cm 60Hz: Approx.
  • Page 163 27,30,31 EFM3001I 1. Turbine shaft 15. Seal plate 2 Thrust bush 16. Thrust bearing 3. Oil shut off 17. Journal bearing 4. Fixing nut 18. Screw 5. Seal ring 19. Screw 6. Seal ring 21. Heat dissipator 7. Seal ring 22.
  • Page 164 3) Operating principle The turbocharger is a system designed to make use of the engine exhaust gas energy to charge high-density air into the cylinders, thereby to increase the engine output. 10.4.2. General descriptions The engine output is determined by the fuel delivery volume and engine efficiency.To burn the supplied fuel completely to change into effective power for the engine, the volume of air enough to burn the fuel completely should be supplied into the cylinders.Therefore, the engine output is determined substantially by the cylinder capacity, and a greater volume of...
  • Page 165 2) Compressor The compressor, which is connected to the turbine over the one and same shaft to form a rotat- ing body, takes in and compresses ambient air with rotating force transmitted from the turbine shaft. Then, the compressed air is delivered to the intake stake. This is the operating principle of the compressor.
  • Page 166 10.4.4. Precautions for operation 1) Precautions for operation of engine The following precautions should be observed when starting, operating, or stopping the engine: Operations Precautions Reasons When starting 1) Check oil level 2) Abrupt starting of the engine caus- 2) Crank the engine with starter to the engine es the engine to rotate with oil not check the increase in oil pressure...
  • Page 167 10.4.5. Walk-around check and servicing As the condition of turbocharger depends greatly on how well the engine is serviced, it is very important to maintain the engine in accordance with the specified maintenance procedure. 1) Intake system Pay particular attention to the air cleaner when servicing the intake system. In the case of wet-type air cleaner, if the level of oil surface is lower than specified, clean- ing effect is poor;...
  • Page 168 10.4.6. Periodical checking and servicing Make it a rule to check the turbocharger assembly for condition and contamination periodi- cally. 1) Guide for checking the rotor for rotating condition The inspection of the rotor assembly for rotating condition should be performed by the degree of unusual sound.
  • Page 169 (2) Rotor radial play Dial gauge Magnetic vise Oil outlet Radial play Move the turbine shaft Standard : 0.075~0.11mm in both directions Limit of wear : 0.12mm simultaneously Oil inlet EA8M4004 (3) If the measured axial and radial plays are beyond the limit of wear, replace or repair the turbocharger.
  • Page 170 10.4.7. Diagnostics and troubleshooting Complaints Possible causes Corrections 1. Excessive black smoke 1) Air cleaner element clogged Replace or clean 2) Restrictions in air duct Check and correct 3) Leakage at intake manifold Check and correct 4) Turbocharger seized up and not rotating Disassemble/repair or replace 5) Turbine blades and compressor blades...

  • Page 171: Special Tool List

    11. Special Tool List Part No. Figure Tool Name Injection pump setting ass’y EF.123-014 (for D1146/T,PU086/T) Injection pump setting ass’y EF.123-015 (for P086TI) Oil seal(CR) insert ass’y (Front) EF.123-127 (Up to 2000.Apr) Oil seal(NOK)insert ass’y (Front) EF.123-173 (From 2000.May) Oil seal(CR) insert ass’y (Rear) EF.123-043...
  • Page 172 Part No. Figure Tool Name EF.123-065 Valve spring press EU.2-0647 Crankshaft gear punch EF.120-208 Piston sleeve 60.99901-0027 Feeler gauge T7610001E Snap ring plier T7621010E Piston ring plier EB1M7001 - 168 -...
  • Page 173 Appendix • Tightening torque for major parts Screw Strength Major Parts Tightening Torque Remarks (Diameter x pitch) (grade) 1st : 6.0 kg • 2nd : 180° Cylinder head bolt M14 x 1.5 10.9T 3rd : 150° (Angle method) 1st : 10 kg Connecting rod bearing cap bolt M14 x 1.5 12.9T...
  • Page 174 • Standard bolt tightening torque table Refer to the following table for bolts other then described above. Degree of strength Diameter 10.9 12.9 (4A) (4D) (4S) (5D) (5S) (6D) (6S) (6G) (8G) (10K) (12K) pitch Limit value for elasticity (kg/mm (mm) Tightening torque (kg •...
  • Page 175 • Maintenance specification table Stand value Limit Group Part Inspection Item Correction Remark for assembly for use Inside diameter of 111.222 111~ 111.022 Replace liner (limit 0.2) cylinder liner for wear Need amount of Projection difference Amount of liner Cylinder 0.03~0.08 projection without between adjacent projection...
  • Page 176 Stand value Limit Group Part Inspection Item Correction Remark for assembly for use Radial run-out of journal Correct Measure In horizontal 0.01 and pin with a grinder and vertical directions Outside diameter of 83.966~ Use under sized journal 83.988 bearings 70.971~ respectively(0.25, Outside diameter of pin...
  • Page 177 Stand value Limit Group Part Inspection Item Correction Remark for assembly for use Diameter of intake valve 8.950~ 8.970 0.02 When replacing stem Replace valve & valve, replace Diameter of valve guide 8.935~ 8.955 0.02 valve guide alike exhaust valve stem Clearance Intake 0.030~0.065...
  • Page 178 Stand value Limit Group Part Inspection Item Correction Remark for assembly for use Clearance between 0.035 ~ 0.077 Replace tappet tappet & cyl. block Valve Diameter of tappet 19.94~ 19.965 19.89 Replace tappet Tappet system Replace Tappet face in contact if severely worn or with cam deformed...
  • Page 179 Stand value Limit Group Part Inspection Item Correction Remark for assembly for use Radiator & water pump for corrosion, damage & Correct or replace improper connecting Submerge in water Test for leakage and replace if air (air pressure) (kg/cm bubbles found Radiator Pressure valve for opening pressure (kg/cm...

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