Doosan Engine DX Serie NON Dpf Training

Doosan Common Rail Engines DL06, DL08 & DV11

August, 2011 EMEA Training Team

Contents 1. Common rail system.

2. DL06 / DL08 / DV11 Common rail engines 3. E.C.U’s 4. C.P Pumps 5. Common rail 6. Injectors 7. Sensors 8. Valve clearance adjusting & Maintenance

Common Rail System

Fuel injection is controlled by electrical signal - Fuel injection pressure is unlimited (400 ~ 1600 bar) - Fuel injection timing is unlimited - Fuel injection frequency is unlimited - Fuel injection volume is unlimited The common rail system engine can solve the above mechanical engine limitation problems.

Common rail system engine is able to satisfy the new emission regulations.

Common Rail System

High pressure supply pump : Supplies fuel at high pressure.

ECU & Injector : Determines fuel volume, Injection fuel timing, fuel injection frequency by ECU signal

Common Rail System

1) High pressure supply pump 2) High pressure tube (=Injection pipe) 3) Common rail with pressure limiter valve and rail pressure sensor 4) CR Injector / High pressure connector 5) E.C.U 6) Sensors (Accel. Pedal, Temperature ,Pressure …)

7) Harness (1.Engine 2.Injector 3.Vehicle )

Common Rail System

High Pressure supply pump (CP3)

Rail Pressure Sensor Pressure Pipe

Pressure Limiter Valve

CR Injector

ECU Common Rail

Common Rail System

Pressure limiter valve

High pressure pump CP3

Rail pressure sensor Rail

Gear pump

Flow limiter Filter

Metering unit ZME Other actuators

Other sensors Injector Accelerator pedal

Control unit

Tank

Prefilter

Engine speed (crank) Engine speed (cam)

High pressure Low pressure

Common Rail System

Temperature

Nox (1)

PM (Smoke) (2)

CRS Angle

(1) (2)

Multiple injection and E.G.R. Fuel atomization (High pressure fuel injection)

Common Rail System Multiple Injection

Dispose noxious fumes

Noise Control

Pre/Pilot Injection

Main Injection

Post/After Injection

Common Rail System

Valve Lift (mm)

IEGR - Internal Exhaust Gas Recirculation

Inputs exhaust gas to cylinder head during the exhaust stroke, by opening the intake valve during the exhaust stroke.

1. Prevents excessive supply of oxygen to the cylinder during the suction stroke.

2. Reduces the combustion temperature in the cylinder.

Common Rail System IEGR -Internal Exhaust Gas Recirculation The EGR reduces combustion temperature.

- Combustion stroke 1) Pure air in cylinder only : Combustion temperature in cylinder is too high with pure air only.

2) Pure air + exhaust gas in cylinder : The combustion temperature is lower than the combustion temperature with pure air only, because of less oxygen in the cylinder.

In order to increase exhaust gas 1°C , It requires a lot of calories. It means the exhaust gas consumes lots of energy to increase 1°C temperature.

Common Rail System

2. DL06 / DL08 / DV11

1. Purpose : Euro-III Emission Meet, Euro-IV/V Capable

2. Target Model : DL06 (5.89 ltr) 95~175ps/1900rpm DL08(7.6 ltr) 280~320ps/2200rpm, DV11(11.0 ltr) 350~420ps/1800rpm, 3. Applied technique: 4-Valves Per Cylinder, Electronic Common Rail System, Rear Gear Train, Internal E.G.R.

Common Rail System ■ Heavy Duty Engines for EURO-3 Emission Regulation - Model ● ●

●

:

DL06 & DL08-EURO III

In-Line 6 , Turbo-Intercooled type Bore x Stroke : 100 mm x 125mm (5.89 ltr) 108 mm x 139 mm (7.6 ltr ) Max. Power : 129 kW [ 175 PS] at 1900 rpm 235 kW [ 320 PS ] at 2200 rpm

Δ 4 Valves per Cylinder Δ Electronic Common-Rail Fuel System Δ Low Pollution & Low Consumption of Fuel, Lub. oil

4-Valves per Cylinder Common Rail

Δ High Output and Durability

Common Rail System ■ Heavy Duty Engines for EURO-3 Emission Regulation - Model

:

DV11-EURO III

●

Vee 6,

Turbo-Intercooled type

●

Bore x Stroke : 128 mm x 142 mm(11.0 Liter)

●

Max. Power : 309 kW [ 420 PS ] at 1800 rpm

Δ 4 Valves per Cylinder Δ Electronic Common-Rail Fuel System Δ Low Pollution & Low Consumption of Fuel, Lub. oil Δ High Output and Durability

4-Valves per Cylinder Common Rail

Δ Compact and Light Weight

Common Rail System

Wastegate Turbocharger

Injector Cyl. Head Piston Common rail Con. Rod Cyl. Block

High Pressure Pump Cam Shaft Starter

Crank Shaft Combo Oil Filter

Oil Pan

Common Rail System DL06 / DL08 / DV11

Common Rail System DL08 Engine curve

Suffix Rated power Max torque Rate of fuel consumption

EUPEA (DX300) 200 ps/1900 rpm 93 kg.m/1,300 rpm 155 g/ps.h

Common Rail System Engine serial number DL08

DV11

DL08 4 00001 BA DV11 4 00001 BA Engine Model Production year

Engine code (Engine suffix) Serial number

Common Rail System DL06 & DL08 Engine

No 1 cylinder is fan end

Common Rail System DV11 Engine

No 1 Cylinder is next to the water pump

Common Rail System Cylinder head Hexagonally arranged cylinder head bolts Injector sleeve Ex Ex

4 valves & central injector port

In In

Common Rail System Intake/ Exhaust valve Caliper adjust screw Valve gap adjust screw Caliper

Common Rail System Intake / Exhaust Valve Calipers (DL06 Only)

Ball pin Cap

• Lubricating oil goes through the ball pin and cap to the top contact face of the caliper.

• Lubrication oil is sprayed on the top of the Push rod and adjustment screw directly.

• Intake/ Exhaust valve calipers are NOT the same (Exhaust has larger pad area) • Direction of caliper installation is critical (Oval hole nearest push rod) • The lubrication oil passage (Ø1.0mm)

Common Rail System Intake/ Exhaust valve (II)

Mark should be top position

Mark here

Valve spring Intake valve

Exhaust valve

Common Rail System Head gasket One layer steel gasket Fiber preforated gasket

Cylinder liner

Cylinder liner Part No. Cylinder block

Cylinder block

Current engine gasket

DL/DV Engine gasket * Part number on gasket is top position when installing

Common Rail System Tightening order for head bolts

Tightening torque : refer to the maintenance manual

Common Rail System 4 Valves & New combustion chamber shape ●●ELE ELEControl ControlCommon CommonRail Rail ●●44Valves / Cylinder Valves / Cylinder ●● New NewCombustion CombustionSystem System ●● Central CentralVertical VerticalInjector Injector

High Power

4-Valves

Low Pollution

Common Rail Injection system

Low Fuel Consumption Ratio

New Combustion System

Common Rail System Fuel Injection

Current

New engine

Common Rail System Cam shaft – IEGR (Internal exhaust gas recirculation)

Intake Intake cam cam

IEGR lobe Opens the intake valve a little, to put exhaust gas in to the intake manifold, while the engine exhausts exhaust gas to outside.

- The exhaust gas causes lower temperature in cylinder during compression stroke.

Common Rail System Gear train (Timing gear) •

Assembly of timing gear on engine

1.

Assemble cam shaft timing gear

2.

Assemble CRS shaft timing gear

3.

Assemble step idle gear on body Align ‘0’ mark with CRS timing gear and idle gear Align ‘1’ mark with Cam timing gear and idle gear Gear backlash is 0.074~0.163 (Except oil pump gear backlash)

Common Rail System Gear train

View to fly wheel direction

1.

Crank shaft gear

2/3

Idler gear

4.

Cam shaft gear

5.

Idler gears for Fuel high pressure pump

6.

Fuel high pressure pump

7.

Oil pump

Common Rail System Timing gear (DL08) Timing mark

Cam shaft

Idle gear

C.R.S

Common Rail System Timing gear (DV11) Timing mark

Cam shaft

C.R.S

Common Rail System DL06 engine oil circulation

Oil pan → Oil pump → Oil filter → Oil cooler → Main gallery → Oil spray nozzle → Camshaft / rocker arm / turbo charger / timing gears → Oil pan

Common Rail System DL06 engine oil circulation

Oil Pan

Oil Pan

Oil pan → Oil pump → Oil cooler → Oil filter →Main gallery → Oil spray nozzle → →Oil pan

Rocker arm shaft Cam shaft CRS Oil pan Gear train Turbo charge

Common Rail System DL06 Piston 1. Oil Spray Nozzle

4

The oil from engine main gallery is supplied to the piston oil gallery for piston cooling.

2. Oil Hole

3

An oil passage connects oil from oil spray nozzle to the inside of piston oil gallery

2

3. Oil Gallery Oil hole for cooling piston and combustion chamber.

1

4. Oil Drain Hole Drained oil connects to piston pin on connecting rod for lubrication

Common Rail System DL06 coolant circulation Cylinder Head

Thermostat

Water pump

Radiator

Water pump → Engine oil cooler → Cylinder block → Cylinder head → Thermostat → Radiator → Water pump

Common Rail System DL06 coolant circulation

Water pump → Engine oil cooler → Cylinder block → Cylinder head → Thermostat → Radiator → Water pump

Common Rail System DL06 coolant circulation

Cylinder

Water pump

Oil cooler

Cooling water

The coolant is distributed to engine cylinder block via the oil cooler

Common Rail System Oil lubrication (DL08)

Contaminated hot oil Cleaned hot oil Cleaned cool oil

Common Rail System Cooling system (DL08)

Hot water Cool water

Common Rail System Oil lubrication (DV11)

Contaminated hot oil Contaminated cool oil Cleaned cool oil

Common Rail System Cooling system (DV11)

Hot water Cool water

Common Rail System Fuel system (DL06 & DL08) Common rail

Injector Cylinder head

2nd fuel filter Fuel pressure pump 1st fuel filter E.C.U

Fuel tank

Common Rail System Fuel system (DV11) Common rail Fuel pressure pump

2nd fuel filter

1st fuel filter E.C.U

Fuel tank

Injector Cylinder head

High pressure connector

Common Rail System Turbo Charger (Waste Gate Type)

Closed

Open

Reducing shaft power, avoiding excess air delivery and rotor over speed

Not Closed Crankcase Ventilation)

3. E.C.U

Common Rail System DL06 : ECU Injector connector

Engine connector

Vehicle Connector

Atmospheric Pressure Sensor

• Hardware : Bosch EDC7UC31 • Software : Special software for Doosan engine

Common Rail System E.C.U Vehicle Connector

Engine connector

ATM Sensor Injector connector (Not use)

Common Rail System E.C.U (Tightening order & torque)

1

8

5

4

3

7

6 2 Tightening torque : 1 ± 0.2Kg.m

Common Rail System DL06 : Engine connector harness

Common Rail System DL08 & DV11 Engine connector harness

Common Rail System DL06 : Injector connector harness

Common Rail System DL08 & DV11 Injector connector harness

Common Rail System ECU Control 1) Engine starting * Sensing the coolant temp., fuel temp. and intake air temperature to calculate fuel quantity * Sensing the engine RPM using crankshaft speed sensor on flywheel housing * Calculate the optimal fuel quantity for engine starting

2) Preheating/After heating * Sensing the coolant temp., fuel temp. and intake air temperature to calculate heating or not - Heating function works below 10 degree C * Preheating - Key On position with warning lamp - Heating time depends on coolant temperature * After heating - No warning lamp - Heating time depends on coolant temperature * Preheating (After heating) is not working if battery voltage is lower than 12V.

Common Rail System ECU Control 1) Engine Starting Coolant Temp Fuel Temp Air Temp

Injector

ECU

Engine RPM

ECU decides optimal fuel quantity for engine starting

2) Preheating

Key “on”

Coolant Temp Fuel Temp Air Temp

ECU

Air heater Warning lamp

ECU decides optimal preheating time If battery voltage is lower than 12V, heating is not working

Common Rail System ECU Control 3) After heating

Engine running signal

Coolant Temp

ECU

Fuel Temp

Air heater

Air Temp

ECU decides optimal preheating time If battery voltage is lower than 12V, heating is not working

4) Limp home LCD Panel EPOS

X X

ECU

1000 RPM

ECU Control (4/4) 5) Emergency stop

Emergency engine stop signal

Engine running signal

ECU

Cut Fuel Injection

Common Rail System Before doing electric welding on the machine ...

Very Important If welding occurs on any vehicle (excavator or loading shovel ..) while the harness connectors are connected on the engine ECU, the ECU can be seriously damaged.

Please adhere to the following: 1. Disconnect the battery “Earth” cable ( ‘-’ cable) from the chassis.

2. Disconnect the wiring harness connectors from the engine ECU (& also the “e-Epos”, “Transmission Controller” & “Fan controller” as appropriate for the vehicle) 3. Once the welding is completed.

4. Re-connect the wire harness connectors on to the ECU (etc) 5. Re-connect the battery “Earth” cable ( ‘-’ cable) on to the chassis.

4. CP pump

Common Rail System Fuel system of DL06 & DL08

Common Rail System Fuel schematic drawing (DL06 & DL08) filter

Back Pressure Valve p back CRIN1: 0.3...1 bar erl. p back CRIN2: 0...1 bar rel.

injectors

burst pressure >15bar

DBV rail metering unit

over pressure valve 10.5...13 bar

bypass valve 0.1 bar

p suction 0.5...1.0 bar abs

cooling plate

handprimer

prefilter <=100mm with water separator

lubrication

KÜV zero delivery drain

p back CP3 < 1.2 bar abs KÜV: two step overflow valve DBV: pressure limiter valve

: high pressure : low pressure

Common Rail System Fuel high pressure pump DL06 & DL08 (CP3.3 Pump)

Common Rail System Fuel high pressure pump DL06 & DL08 (CP3.3 Pump) 60ml fuel here

When assembling the CP pump to the engine, 60ml of fuel must be put in the pump before starting up the engine and pay attention to assembly of fuel hose connections

Common Rail System Fuel high pressure pump DL06 & DL08 (CP3.3 Pump)

Fuel drain hole

Small amount of CP pump lubricating fuel can leak from fuel drain hole in order to prevent the unwanted mixing of engine oil and fuel.

Common Rail System Fuel high pressure pump DL06 & DL08 (CP3.3 Pump) From pre-filter T = 22±2

T : Torque (Nm) Return to fuel tank T = 25±2

From fuel filter T = 25±2

To fuel filter T = 22±2

Metering Unit

T = 110±10

For tightening bolt M8 T = 30±5

To rail (high press.)

T = 20.5±2.5

When assembling a new CP pump on to the engine, 60ml clean fuel must be filled in pump for initial lubrication !!

Common Rail System Fuel high pressure pump DL06 & DL08 (CP3.3 Pump) Gear Pump

High Pressure Low Pressure

Metering Unit

Fuel Lubricating System

Common Rail System Gear pump (CP3.3 Pump)

Common Rail System Fuel high pressure pump DV11 (CP3.4 Pump)

Common Rail System Fuel high pressure pump DV11 (CP3.4 Pump)

Common Rail System Fuel high pressure pump DV11 (CP3.4 Pump)

Fuel high pressure pump DV11 (CP3.4 Pump)

Gear pump

High Pressure Low Pressure Oil

Metering Unit

Oil Lubricating System * First assemble, Input 40ml Engine Oil

Common Rail System DV11 - Low & High pressure circuit CP3.4 p back CRIN1: 0,3...1 bar rel. p back CRIN2: 0...1 bar rel.

filter burst pressure >15bar

injectors DBV rail metering unit

over pressure valve 10,5...13 bar

p suction 0,5...1,0 bar abs

handprimer

bypass valve 0,15 bar

cooling plate prefilter with water separator

ÜV

zero delivery drain

p back CP3 < 1,2 bar abs

ÜV: overflow valve DBV: pressure limiter valve

: high pressure : low pressure

Common Rail System Gear pump

Common Rail System Metering unit location

DL08

DV11

Common Rail System CP Pump Part Number

Engine

Doosan Part No.

Spec.

Lubrication

DL06

65.10501-7005A

Euro3, Tier3

Fuel

DL08

65.10501-7001A

Euro3, Tier3

Fuel

DV11

65.10501-7002A

Euro3, Tier3

Engine Oil

Common Rail System Metering unit

Coil resistance : 2.6 ~ 3.5Ω

Open : Below 8 Volt

Closed : Above 8 Volt

Supply of fuel from the gear pump to the high pressure CP pump is controlled by the ECU

5. Common rail

Common Rail System Common rail

Fuel Inlet from Supply pump

Fuel Outlets to Injectors

Rail Mounting Flange

Common rail

Common Rail System Rail for DL06 / DL08 / DV11 DL06 & DL08 - 1 Rail

Pressure limiter valve

From CP3

3 4

5

6

1 2

To Tank

6

5

Left

4

To Tank

3

2

1

Rail pressure sensor

Right From CP3

DV11 - 2 Rails

Common Rail System Maintenance of common rail Common rail maintenance • Fuel sealing by plastic deformation.

• Do not re use common rail pipe when the pipe is disassembled.

(Fuel leakage can be a problem) • Keep clean common rail, high pressure pipe and fuel high pressure pump when disassembled.

Common Rail System Rail pressure sensor RDS3

Sensor Pin

DL08/DV11

DL06

Description

1

CN2-20

CN212

Ground

2

CN2-27

CN214

Pressure Signal

If the rail pressure sensor fails, the E.C.U makes the CP pump 400~500 3 CN2-12 CN2- pressure + 5 V Supply 13 bar, for limp home function.

Location of the Rail Pressure Sensor

DL06

DL08

DV11

Common Rail System Common rail pressure relief valve

• Setting pressure : 1950 bar • The valve must be changed if the following conditions have been met: - Over 5 hours working under limp home condition - Over 50 times valve opening.

• Fuel sealing is by plastic deformation with the common rail.

• It can be re used, if the contact face is not damaged.

Common Rail System Common rail pressure relief valve

If the Engine is working correctly this valve is never open.

If the valve does not open due to a mechanical problem under high fuel system pressure in the common rail (Over 1750 bar for a long time), the ECU will cut the fuel supply off, so stopping the engine. (Fuel cut off by metering valve)

Common Rail System Maintenance of rail pressure sensor Common rail maintenance • Sensor sealing with common rail by plastic deformation.

• Sensor can be re used if sensor sealing face is not damaged.

• Keep sensor clean when disassembled from common rail.

• If water separator condition is poor, water may enter the fuel system and cause damage to the rail pressure sensor.

• When disassembled from the common rail, don’t allow the sensor connector to become damaged (Most sensor problems are caused by use of incorrect tools)

6. Injector

Common Rail System Injector Part Number

Engine

Doosan Part No.

Remark

DL06

65.10401-7004A

Euro3, Tier3

DL08

65.10401-7001C

Euro3, Tier3

DV11

65.10401-7002C

Euro3, Tier3

Common Rail System Injector

Common Rail System Injector Tightening torque 0.15  0.025 kgm

Fixing groove Fuel return to tank

High pressure fuel

Injector coil resistance • DL06 : 0.22Ω ~ 0.29Ω • DL08 & DV11 : 0.31Ω ~ 0.42Ω

Common Rail System Fuel Inlet Magnet Nut Terminal

Push Rod High Pressure Bore

Nozzle Retaining Nut

Intermediate Pin

Control Chamber

Magnet Core

Nozzle

Injector Body

Armature

Fuel Drain

Before assembling injector & connector, the O-rings must be lubricated

Common Rail System

Spring Coil

Ball

Armature Control Chamber

Ball Orifice

Supply Orifice

Common Rail System

Fuel injection

Common Rail System Doosan Engine: 1 Pilot + 1 Main Injection

Common Rail System Injector Part No. Doosan Part No.

Bosch Part No.

Engine

Doosan Part No.

Remark

DL06

65.10401-7004A

Euro3, Tier3

DL08

65.10401-7001C

Euro3, Tier3

DV11

65.10401-7002C

Euro3, Tier3

Common Rail System

Before assembling injector & connector, the O-rings must be lubricated.

Do not re-use the O-rings, when the injector and connector are disassembled the O- ring must be changed

Common Rail System Maintenance injector Maintenance of injector • HPC sealing with engine cylinder head is by plastic deformation • Don’t re use the HPC, if the HPC is disassembled from the injector, the HPC must be changed.

(Failure to change the HPC can cause fuel to leak between the injector and the HPC contact point, resulting in a decrease in engine power)

Common Rail System High pressure connector (HPC)

The HPC can only be assembled on the cylinder head in one position due to this pin.

The O-ring must be lubricated with clean engine oil, when assembling the HPC to the cylinder head.

Common Rail System High pressure connector (HPC) Maintenance of HPC • You Must follow the correct injector assembly sequence and tightening torques.

• You Must keep the injector holes and fuel return line clean when disassembled.

• Before assembling the HPC on the cylinder head, you must lubricate the O rings.

Common Rail System

Remove caps only when necessary to allow assembly on the engine (Keep all holes covered as long as possible)

7. Sensor

Common Rail System Sensor Location (DL06)

1.

CRS sensor

2.

Common rail press. sensor

3.

Common Rail press. relief valve

4.

Fuel temp. sensor

5.

Metering units

6.

Oil press.& Temp. sensor

Common Rail System Sensor Location (DL06) 7.

Boost press. sensor

8.

Coolant temp. sensor

9.

Air heater

10. A/C compressor 11. Starter 12. Cam sensor

Common Rail System Sensors Coolant Coolant Temperature Temperature sensor sensor

Fuel Fuel Temperature Temperature sensor sensor

Boost Boost press./Temperature press./Temperature sensor sensor

Engine Engine oil oil press./ press./ Temp.

Temp. sensor sensor

CRS CRS sensor sensor

Cam Cam sensor sensor

ECU ECU

Common Rail System Coolant Temperature Sensor : DL06

Common Rail System Coolant Temperature Sensor : DL08 & DV11

DL08 DV11

Common Rail System Fuel Temperature Sensor : DL06

Common Rail System Coolant/Fuel Temperature Sensor

• Sensor type : NTC Sensor • Sensor resistance • 25℃ : 2.5 ㏀ ± 6 % .100℃ : 0.186 ㏀ ± 2 %

Common Rail System Boost Pressure / Temperature Sensor : DL06

Common Rail System Boost Pressure / Temperature Sensor : DL08 & DV11

DL08

DV11

Common Rail System Boost Pressure & Temperature Sensor

• Temperature sensor type : NTC sensor

Pressure sensor type : Piezo sensor

Common Rail System Boost Pressure & Temperature Sensor

• Temperature sensor resistance 25℃ : 2.5 ㏀ ± 6 %. 100℃ : 0.186 ㏀ ± 2 % • Pressure sensor normal range : 0.5 V ~4.5 V

Oil Pressure / Temperature Sensor location: DL06

Oil Pressure / Temperature Sensor location: DL08 & DV11

DL08 DV11

Common Rail System Engine Oil Pressure & Temperature Sensor

• Temperature sensor resistance 25℃ : 2.5 ㏀ ± 6 %. 100℃ : 0.186 ㏀ ± 2 % • Pressure sensor normal range 0.5 V ~4.5 V

Common Rail System Crankshaft Speed Sensor : DL06

Common Rail System Crankshaft Speed Sensor : DL08 & DV11

DL08 DV11

Common Rail System Camshaft Speed Sensor : DL06

Common Rail System Camshaft Speed Sensor : DL08 & DV11

DL08

DV11

Common Rail System C.R.S / Cam Sensor

Cam sensor

• Sensor type : Magnetic pick up • Sensor resistance at 20℃ : 860Ω ± 10 % • Air gap : 1.0mm (Fly wheel and Cam gear) - No need adjusting gap.

• CRS and Cam sensor are currently the same part No. • Keep off the pollution and rust on harness contact point.

Air gap

C.R.S/ Cam shaft speed sensor *Sensor resistance : 20°C : 860Ω ± 10 % *Air gap : 1.0mm ± 0.5 (Flywheel and Cam gear) (No need to adjust gap)

Air gap

Cam gear Flywheel

C.R.S/ Cam shaft speed sensor

* C.R.S Sensor : 1. Sensing engine R.P.M for display.

2. Sensing C.R.S Angle.

3. Sensing piston location.

4. Decision on injection timing. * Cam Sensor : 1. Sensing OT point of No1 cylinder.

2. Sensing engine R.P.M

8. Valve clearance adjustment & Maintenance

Common Rail System DL06 & DL08 : Valve gap adjusting (1)

DL06 & DL08 : Valve gap adjusting (2)

Valve Gap

Valve

Intake

Exhaust

Valve gap (X)

0.3mm

0.4mm

At cold condition

Common Rail System DL06 : Valve gap adjusting (3) • Method 1

• Method 2 Valve-Overlapped cylinder

1

5

3

6

2

4

Adjusting cylinder (Intake/Exhaust valve)

6

2

4

1

5

3

- Engine rotation : Counter-clockwise (view from flywheel)

Common Rail System DL08 Adjusting Valve Clearance (I) Cylinder No

Adjust Cylinder No 1 Cylinder T.D.C Point (OT point 0º)

1

2

EX

IN

●

●

EX

3 IN

EX

4 IN

EX

●

No 5 Cylinder T.D.C Point (Turn flywheel 180º) No 6 Cylinder T.D.C Point Turn flywheel 180º (Total 360º) No 2 Cylinder T.D.C Point Turn flywheel 180º (Total 540º)

5 IN

EX

●

●

6 IN

EX

IN

●

●

●

●

●

●

Engine turning : Count clock wise viewed from flywheel

●

Common Rail System DL08 Adjusting Valve Clearance (II)

Overlap cylinder

1

5

3

6

2

4

Adjusting cylinder (In/ Ex valve)

6

2

4

1

5

3

Valve

Intake

Exhaust

Valve gap

0.3mm

0.4mm

At cold condition

Common Rail System DV 11 Valve Clearance (I)

Water pump

Common Rail System DV 11 Valve Clearance (II) Adjusting screw & nut

Measure valve gap here

Valve Valve gap (mm)

Intake

Exhaust At cold condition

0.4

0.5

Common Rail System DV11 Adjusting valve clearances (I) Cylinder No

1

2

Adjust Cylinder

EX

IN

EX

No 1 Cylinder T.D.C Point (OT point 0º)

●

●

●

3 IN

EX

4 IN

EX

IN

6 EX

●

Turn flywheel 90º

No 5 Cylinder T.D.C Point Turn flywheel 270º (Total rotation 360º)

IN

5 IN

EX

●

●

●

●

Turn flywheel 90º (Total rotation 450º) Engine turning : Count clock wise viewed from flywheel

●

●

●

●

Common Rail System Adjusting valve clearances (II)

Overlap cylinder

1

4

2

5

3

6

Adjusting cylinder (In/ Ex valve)

5

3

6

1

4

2

Valve

Intake

Exhaust At cold condition

Valve gap

0.4mm

0.5mm

End of Document

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