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
EUPEA (DX300)
Rated power
200 ps/1900 rpm
Max torque
93 kg.m/1,300 rpm
Rate of fuel consumptio n
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 Intakecam 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
The coolant is distributed to engine cylinder block via the oil cooler
Cooling water
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 Vehicle Connector
Engine connector
• Hardware : Bosch EDC7UC31 • Software : Special software for Doosan engine
Atmospheric Pressure Sensor
Common Rail System E.C.U Vehicle Connector
ATM Sensor (Not use)
Engine connector
Injector connector
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 optimalheating fuel quantity for engine starting 2) *Preheating/After * 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
4. CP pump
Common Rail System Fuel system of DL06 & DL08
Common Rail System Fuel schematic drawing (DL06 & DL08)
Back Pressure Valve p back CRIN1: 0.3...1 bar erl. p back CRIN2: 0...1 bar rel.
filter
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) T : Torque (Nm) Return to fuel tank T = 25±2
From prefilter T = 22±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
65.104017004A
Euro3, Tier3
DL08
65.104017001C
Euro3, Tier3
DV11
65.104017002C
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
65.104017004A
Euro3, Tier3
DL08
65.104017001C
Euro3, Tier3
DV11
65.104017002C
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 b
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
Turn flywheel 90º (Total rotation 450º)
EX
IN
6 EX
●
Turn flywheel 90º
No 5 Cylinder T.D.C Point Turn flywheel 270º (Total rotation 360º)
IN
5 IN
EX
●
●
●
●
●
●
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
136
