Daewoo D1146, D1146, D1146TI, DE08TIS, D1146TI Service Manual

...

MAINTENANCE MANUAL

Diesel Engine

D1146 D1146TI

65.99897-8056 Feb. 2001

DE08TIS

PS-MMA0415-E1A

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

FOREWORD

This maintenance manual is designed to serve as a reference for DAEWOO Heavy Industries Ltd's (here after DAEWOO’s) customers and distributors who wish to gain basic product knowledge on DAEWOO's D1146, D1146TI and DE08TIS Diesel engine. This economical and high-performance diesel engine (6 cylinders, 4 strokes, in-line, direct injection type) has been so designed and manufactured to be used for the overland transport or industrial purpose. That meets all the requirements such as low noise, fuel economy, high engine speed, and durability. To maintain the engine in optimum condition and retain maximum performance for a long time, CORRECT OPERATION and PROPER MAINTENANCE are essential. In this manual, the following symbols are used to indicate the type of service operations to be performed.

Removal Adjustment

Installation Cleaning

Disassembly Pay close attention-Important

Reassembly Tighten to specified torque

Align the marks Use special tools of manufacturer's

Directional Indication Lubricate with oil

Inspection Lubricate with grease

Measurement

During engine maintenance, please observe following instructions to prevent environmental damage;

z Take old oil to an old oil disposal point only. z Ensure without fail that oil and diesel fuel will not get into the sea or rivers and

canals or the ground.

z Treat undiluted anti-corrosion agents, antifreeze agents, filter element and

cartridges as special waste.

Printed in Jan. 2001 PS-MMA0415-E1A

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

z The regulations of the relevant local authorities are to be observed for the

disposal of spent coolants and special waste.

If you have any question or recommendation in connection with this manual, please do not hesitate to contact our head office, dealers or authorized service shops near by your location for any services.

For the last, the content of this maintenance instruction may be changed without notice for some quality improvement. Thank you.

DAEWOO Heavy Industries & Machinery LTD.

Feb. 2001

Printed in Jan. 2001 PS-MMA0415-E1A

MAINTENANCE MANUAL

CONTENTS

1. GENERAL INFORMATION

1.1 General Repair Instructions 1

1.2. Engine Specific Character 2

1.3. Engine Specifications 4

1.4. Engine Assembly 8

2. MAJOR MAINTENANCE

2.1. Preventive Maintenance 13

2.2. Diagnosis and Remedy 22

2.3. Engine Inspection 32

3. MAINTENANCE

3.1. Engine Disassembly 33

3.2. Inspection and Measurement on Major Parts 48

3.3. Reassembly 69

3.4. Breaking in 96

D1146/D1146TI/DE08TIS

4. MAINTENANCE OF MAJOR COMPONENTS

4.1. Cooling System 98

4.2. Lubrication System 102

4.3. Fuel Injection Pump 106

4.4. Turbocharger 122

5. Special Tool List 132

● Appendix 134

● WORLDWIDE NETWORK

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D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

1. GENERAL INFORMATION

1.1. General Repair Instructions

1. Before performing service operation, disconnect the grounding cable from the battery for reducing the chance of cable damage and burning due to short-circuiting.

2. Use covers for preventing the components from damage or pollution.

3. Engine oil and anti-freeze solution must be handled with reasonable care as they cause paint damage.

4. The use of proper tools and special tools where specified is important to efficient and reliable service operation.

5. Use genuine DAEWOO parts necessarily.

6. Used cotter pins, gaskets, O-rings, oil seals, lock washer and self-lock nuts should be discarded and new ones should be prepared for installation as normal function of the parts can not be maintained if these parts are reused.

7. To facilitate proper and smooth reassemble operation, keep disassembled parts neatly in groups. Keeping fixing bolts and nut separate is very important as they vary in hardness and design depending on position of installation.

8. Clean the parts before inspection or reassembly. Also clean oil ports, etc. using compressed air to make certain they are free from restrictions.

9. Lubricate rotating and sliding faces of parts with oil or grease before installation.

10. When necessary, use a sealer on gaskets to prevent leakage.

11. Carefully observe all specifications for bolts and nuts torques.

12. When service operation is completed, make a final check to be sure service has been done property.

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D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

1.2. Engine Specific Character

1.2.1. Toroidal combustion mode (D1146)

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. This swirling passages when intake stroke generates the strong swirling motion in the combustion chambers by giving the intake air a big moment, and when compression stroke, the special piston’s shapes causing very complicated and distorted flows by means of eddy current and squashed flows will make the air and fuel mix more smoothly. Also, when explosion stroke, a considerable output increase came to be expected with the accomplishment of nearly perfect combustion by the more smooth mixing of air and fuel which was injected through multi-nozzles in the combustion chamber. This engine by means of Toroidal Combustion Mode has the specific character such as quiet and stable revolutional motion, multi-purpose application, economical fuel and oil consumption, etc.

1.2.2. OMEGA combustion bowl (D1146TI, DE08TIS)

The OMEGA combustion bowl is a unit designed to perform high efficiency, low emission combustion. As the rim around the combustion bowl port of the upper of the piston has been machined in a smaller size than the interior of the combustion bowl, strong swirl is produced in the combustion bowl and strong squish flow makes the fuel be mixed more sufficiently with air. Due to the application of OMEGA combustion system and optimal utilization of intake and

M1041A

exhaust port configuration within the cylinder head, the D1146TI, DE08TIS diesel engines discharge very low level of hazardous exhaust gases such as smoke, nitrogen oxide, hydrocarbon, or carbon monoxide and thus ensure high performance and low fuel consumption.

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D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

1.2.3. Oil gallery cooling type piston (DE08TIS)

Oil gallery cooling is used for the piston of DE08TIS diesel engine. When thermal loading is high, piston cooling by means of an oil gallery in the crown is normally necessary to prevent crown cracking and ring sticking. The design of the gallery, the design and location of the oil spray nozzle and the quantity of oil flowing in the gallery are critical in order to achieve the desired temperature reduction. The cross section shape of the gallery should be designed to achieve sufficient oil movement to maximize cooling efficiency.

M1255

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MAINTENANCE MANUAL

1.3. Engine Specifications

1.3.1. Specification

Engine Model Items

Engine type

Combustion chamber type Direct injection type Cylinder liner type Replaceable dry liner Timing gear system Gear driven type No. of piston ring Compression ring 2, oil ring 1 No. of cylinder-bore x stroke (mm) Total piston displacement (cc) 8,071 Compression ratio 17.5 : 1 16.8 : 1 18.5 : 1 Engine dimension (length x width x height) (mm) 1,253x811.5x934.5 1,253x812.5x1,009 1,253x812.5x1,009 Engine weight (kg) 730 745 745 Rotating direction (viewed from flywheel) Counter clockwise Fuel injection order 1 – 5 – 3 – 6 – 2 – 4 Fuel injection timing (B.T.D.C static) Injection pump type Zexel in-line “AD” type Zexel in-line “P” type

Governor type

Injection nozzle type Multi-hole type (5 hole) Fuel injection pressure (kg/cm2) 210 214 160/220

Compression pressure (kg/cm2) 28 (at 200 rpm) Intake and exhaust valve clearance (at cold) (mm) 0.3

Intake valve

Exhaust valve

Lubrication method Full forced pressure feed type Oil pump type Gear type driven by crankshaft Oil filter type Paper element type Cartridge type Lubricating oil capacity (max./min.) (lit) 15.5/12 or 20/17 Oil cooler type Water cooled Water pump Centrifugal type driven by belt Cooling Method Fresh water forced circulation Cooling water capacity (engine only) (lit) 14

Thermostat type Air compressor type & capacity (cc) Belt driven type, 220 or 300

Alternator voltage – capacity (V – A) 24 – 45 or 24-150 Starting Motor voltage – output (V - kW) 24 – 4.5 Air heater capacity (V – A) 22 – 95 (2.1kW) Battery capacity (V - AH) 24 - 150

Open at Close at Open at Close at

D1146 D1146TI DE08TIS

4 cycle in-line,

Water-cooled type

Naturally aspirated

6 – 111 × 139

15° 9° 3°

Mechanical governor

type(RLD)

16° (B.T.D.C) 36° (A.B.D.C) 46° (B.B.D.C) 14° (A.T.D.C)

Wax pallet type

(79 ∼ 94 °C or 83 ∼ 95 °C )

4 cycle in-line,

Water-cooled type

Turbo charged & intercooled

Mechanical

governor

type(RLD-J)

Multi-hole type

(7 hole)

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1.3.2. Engine power

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Engine model Performance

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

Production tolerance : ±5%

Model Suffix

EACBA EACBB EACBE

D1146

EACBH

EACBI

EACBK

EAPBA 9 205/2,200 75/1,400 600-650

D1146TI

EAPCA 9 215/2,300 82/1,400 600-650

Injection

timing

(BTDC°)

15 182/2,500 57.5/1,600 600-650 2750

Power

(PS/rpm)

Torque

(kg.m/rpm)

Low idle

(rpm)

High idle

(rpm)

2370

2,470

2250

2,350

Remark

EURO-I

ECPBA ECPCA

DE08TIS

ECPBB ECPCB

3 225/2,300 82/1,200 600-650 2,530

3 240/2,300 90/1,200 600-650 2,530

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

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EURO-II

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1.3.3. Performance curve (DE08TIS – 225PS)

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

Performance ISO 1585(SAE J1349)

Output (max.) 165 kW (225PS) / 2,300 rpm Torque (min) 804 N.m (82 kg.m) / 1,200 rpm Fuel consumption (min) 192 g/kW.h (141 g / PS.h)

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1.3.4. Performance curve (DE08TIS – 240PS)

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

Performance ISO 1585(SAE J1349)

Output (max.) 176 kW (240PS) / 2,300 rpm Torque (max.) 882 N.m (90 kg.m) / 1,200 rpm Fuel consumption (min.) 192 g/kW.h (141 g / PS.h)

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1.4. Engine Assembly

1.4.1. Engine sectional view (longitudinal)

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

8 9

11 12

14 15

16 17

24 25 26

1 Water pump 2 Piston 3 Air compressor 4 Intake valve 5 Exhaust valve 6 Breather

7 Cylinder head cover 8 Exhaust valve spring 9 Cylinder head 10 Intake valve spring 11 Cylinder block 12 Push rod 13 Flywheel housing 14 Ring gear 15 Tappet 16 Cam shaft 17 Fly wheel 18 Oil seal (Rear) 19 Oil seal (Front) 20 Crank shaft pulley 21 Crank gear 22 Vibration damper 23 Oil pump 24 Oil suction pipe 25 Oil pan 26 Crank shaft

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1.4.2. Engine sectional view (cross)

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

13 14

6 7

8 9

1 Fuel injection pipe 9 Turbo charger 2 Fuel filter 10 Fuel injection pump 3 Fuel injection nozzle 11 Timing gear case 4 Intake manifold 12 Oil filler cap 5 Air heater 13 Connecting rod 6 Rocker arm 14 Oil spray nozzle 7 Rocker arm bracket 15 Oil filter 8 Exhaust manifold 16 Oil cooler

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1.4.3. Engine Assembly Views

(1) D1146 (bus)

3 4 5 6 7

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

17 18

1 Flywheel housing 8 Oil filler cap 16 Water pump 2 Intake manifold 9 Oil level gauge 17 Exhaust manifold 3 Breather 10 Oil pan 18 Cylinder head cover 4 Air pipe 11 Oil drain plug 19 Crank shaft pulley

(Air cleaner to intake manifold)

12 Oil filter 20 Vibration damper 5 Fuel filter 13 Fuel injection pump 21 Oil cooler 6 Power steering pump 14 Air compressor pulley 22 Starter 7 Air compressor 15 Thermostat 23 Cooling water pipe

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MAINTENANCE MANUAL

(2) DE08TIS (Truck)

34 5

9 10

678

11 12

20 21

15 16

29 30

23 24 25

26 27

Magnetic pick-up sensor

12 Cooling fan 21 Exhaust elbow 2 Flywheel housing 13 Cooling fan guide 22 Crank shaft pulley 3 Intake manifold 14 Air compressor pulley 23 Vibration damper 4 Fuel filter 15 Thermostat 24 Mounting bracket 5 Air pipe 16 Water pump 25 Oil cooler

(Intercooler to intake manifold)

17 Alternator 26 Starter relay 6 Fuel injection pipe 18 Air pipe 27 Starter 7 Air compressor

(Turbocharger to intercooler)

28 Breather 8 Air con. compressor 19 Air pipe 29 Water delivery pipe 9 Oil pan

(Air cleaner to turbocharger)

30 Air heater relay 10 Fuel injection pump 20 Turbocharger 31 Cooling water pipe 11 Oil filter

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D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

(3) DE08TIS (Bus)

192

3 4 5 6 7

12 13 14

18 19 20

28 29

1 Intake manifold 10 Oil level gauge 20 Water pump 2 breather 11 Flywheel housing 21 Exhaust manifold 3 Air pipe 12 Drain plug 22 Belt

(Intercooler to intake manifold)

13 Oil pan 23 Mounting bracket 4 Fuel injection pipe 14 Oil filter 24 Oil cooler 5 Air pipe 15 Fuel injection pump 25 Turbocharger

(Turbocharger to intercooler)

6 Fuel filter 17 Idle gear pulley 27

16 Vibration damper 26 Starter

Cooling water pipe

7 Power steering pump 18 Air compressor pulley 28 Fly wheel 8 Air compressor 19 Thermostat 29 Pilot bearing 9 Oil filler cap

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D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

2. Major Maintenance

2.1. Preventive Maintenance

The preventive maintenance means that the operator performs the servicing of engine to obtain long life and best performance from DAEWOO diesel engine.

2.1.1. Cooling Water

z Regarding the cooling water that is to be used for engine, the soft water not the hard

water must be used.

z The engine cooling water can be used diluting it with antifreezing solution 40% and

the additive for rust prevention (DCA4) 3 ～ 5 %.

z The density of above solution and additive must be inspected every 500 hours to

maintain it properly.

NOTE : The proper density control of antifreezing solution and rust preventing additive will be able to prevent the rusting effectively and maintain the stable quality of engine. For the improper control might give the fatal damage to the cooling water pump and cylinder liners, detail care is needed.

z Since D1146, D1146TI and DE08TIS (diesel engine of D1146 series) cylinder liner is

dry type, particularly the cooling water control should be applied thoroughly.

z The density of antifreezing solution and additive for rust prevention is able to be

confirmed by the cooling water test kit. (Fleetguard CC2602M or DAEWOO

60.99901-0038)

z How to use the cooling water test kit

(1) When the cooling water temp. of engine is in the range of 10 ～ 55 °C,

loosen the plug for cooling water discharge and fill the plastic cup about a half.

NOTE : In taking the cooling water sample, if the water in auxiliary tank were taken, it is hard to measure the accurate density. Take the cooling water sample

necessarily loosening the cooling water discharge plug.

(2) At the state of a test paper soaked in the sampled water, after taking the paper

out through water agitation, shake off the water.

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MAINTENANCE MANUAL

(3) Wait for about 45 sec. till the color change of test paper.

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

change.

(4) Make the numerical value by comparing the test paper which hue has

changed with the color list of label on storage bottle.

(5) By comparing the hue changed into yellowish green or so with the green color

indication of test paper storage bottle, confirm the density. (Then, the density indication must be in the hue range of 33% to 50%).

(6) The brown at the middle of test paper and the lower pink color indication

represent the additive state for rust prevention, and the proper range is that the meeting numerical value of brown (vertical) and pink color (horizontal) locates in the range of 0.3 to 0.8 at the color list of label on the test paper storage bottle.

(7) In case of less than 0.3, replenish the additive for rust prevention (DCA4), and

in case of more than 0.8, pour out the cooling water about 50% and then readjust the density after refilling with clean fresh water.

z Amount of Anti-freeze in winter

Ambient

Temperature (°C)

Over -10

-10

-15

-20

-25

-30

-40

Cooling water (%) Anti-freeze (%)

85 80 73 67 60 56 50

15 20 27 33 40 44 50

2.1.2. Fan belt

deteriorated.

z Check the fan belt for belt tension.

If belt tension is lower than the specified limit, adjust the tension by relocating the alternator. (specified deflection: 10 ∼ 15 mm when pressed down with thumb)

z Use a fan belt of specified dimensions, and replace if damaged, frayed, or

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2.1.3. Engine oil

z Check oil level with the oil level gauge and replenish if necessary.

z Check the oil level with the engine cooled. If the engine is warm, allow time for 5

∼ 10 minutes for oil drain into the crankcase before checking oil level. The oil level must be between Max and Min. lines on the gauge.

z Engine oil should be changed at the specified intervals.

Oil filter cartridge should be changed simultaneously.

- First oil change : 1,000km(50 hr) operating First oil change

(city bus, dump truck)

(express bus, cargo truck)

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

After 1,000km (50hr)

operation D1146/TI every 10,000km Short-distance operation vehicle DE08TIS every 20,000km D1146/TI every 15,000km Long-distance operation vehicles DE08TIS every 30,000km

z The following oils are also recommended

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

2.1.4. Oil filter

z Check for oil pressure and oil leaks, and

repair or replace the oil filter if necessary.

z Change the oil filter cartridge simultaneously

at every replacement of engine oil.

Engine

model

D1146 D1146TI

DE08TIS

Recommend oil

Remark

SAE No. API No.

SAE 15W40 above CD or CE

SAE15W40 SAE10W40

ACEA-E2 or ACEA-E3

(API CH-4)

Oil filter head

Oil filter (Cartridge)

G1081

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2.1.5. Fuel filter

z Drain water in cartridge with loosening

the

cock under filter manually (6) from time to

time.

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

2.1.6. Air cleaner.

z In case that elements are deformed,

damaged or if the air cleaner has a crack,

replace it.

z By the definite interval, the elements must be

cleaned and replaced.

2.1.7. Intercooler

G1019

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

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Air fl

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

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Air/air intercooler with radiator (combined radiator)

ow by cooling fan

Hot air by turbo charger compressor

Cooled air to intake manifold (max. 50°C)

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2.1.8. Valve clearance adjust procedure

z After letting the #1 cylinder's piston

come at

the compression top dead center by turning

the crankshaft, adjust the valve clearances.

z Loosen the lock nuts of rocker arm

adjusting screws and push the feeler gauge

of specified value between a rocker arm and a valve stem and adjust the clearance with adjusting screw respectively and then tighten with the lock nut.

z As for the valve clearance, adjust it when in

cold, as follows.

Model

D1146 D1146TI DE08TIS

Intake Valve Exhaust Valve

0.3 mm 0.3 mm

1) Rotate the crankshaft to overlap the intake and the exhaust valves of #6, then #1 cylinder become the compression state of top dead center.

2) Therefore adjust the valve clearance corresponding to “ ” of lower figure.

At this time there are no force on the push rods of #1 cylinder.

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MAINTENANCE MANUAL

3) Rotating the crankshaft by one revolution, #6 cylinder become the compression state of top dead center.

4) Thereafter adjust the valve clearances corresponding to “

” of lower figure.

5) After reinsuring the valve clearances, retighten if necessary.

z No. 1 cylinder is located at the side where

flywheel was installed.

Flywheel

Intake Valve Exhaust Valve Cylinder No. Cooling Fan

2.1.9. Cylinder compression pressure

z Stop the engine after warming up,

and

take out nozzle holder assembly.

G1048

G1067

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MAINTENANCE MANUAL

z Install the special tool (compression gauge adapter) at the nozzle holder hole, and connect the compression pressure gauge there.

Standard value 28kg/cm

over Limit value 24kg/cm2 Difference between each cylinder

Within ± 10 %

♦ Condition : Water temperature 20°C,

Engine rotation 200rpm (10 rotations)

G1068

2.1.10. Injection nozzle

z Install a nozzle on the nozzle tester.

z If the inspected injection pressure is less than the specified value, adjust using

the adjusting shims.

Engine Model D1146 D1146TI DE08TIS

Opening pressure

z Check the atomizing state and replace it if abnormal.

2.1.11. Fuel injection pump

z Check the housing crack, damage etc. and replace it if abnormal.

210 kg/cm

214 kg/cm

1st : 160 kg/cm

2nd : 220 kg/cm

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z Check if the idle operation and speed regulating lever's sealing is removed.

z The adjustment and testing of fuel injection pump should necessarily be done at

the test bench.

2.1.12. Battery

z Inspect for any leakage of electrolytic solution owing to battery crack, and

replace

the battery in case of poor condition.

z Inspect for amount of electrolytic solution, and replenish if insufficient. z Measure the gravity of electrolytic solution, if less than specified value (1.12 ～

1.28), replenish.

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

2.1.13. Air removal of fuel system

The suction room of fuel injection pump has the function of air removal continuously during the operation through a relief valve.

In case that the suction room lacks fuel at all, for instance, in case of new installation of injection pump, after loosening the air removing screws of cartridge filter respectively, remove the air by operating the manual pump of fuel supply pump until bubble will disappear.

2.1.14. Fuel supply pump

Every time of engine oil replacement, the fuel strainer installed at the fuel supply pump should be removed and cleaned.

2.1.15. Turbocharger

The turbocharger needs not arty special equipment. Every time of engine replacement, a leakage or clogging of oil pipes should be

inspected. Air cleaner should be maintained carefully for nut or foreign material not to get in. Periodic inspection should be applied on the compressed air and exhaust gas

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pipes, For leaking air will bring the overheat engine, an immediate repair must be done. During the operation that is surrounded by the dust and oil mixed air, frequent cleaning must be done on the impellers. Tear down the impeller casing (attention: be careful not to bend) and must clean with non-acid solvent solution. If necessary, use plastic scraper If impeller is severely polluted, dip the impeller into solution and may be better to clean it with stiff brush. Then one thing to beware is to dip only impeller part and so do not support by impeller but bearing housing.

2.1.16. Starting motor

In case of engine maintenance, clean pinion and ring gear thoroughly putting in the fuel, and coat them with grease.

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

Also, In case of washing engine (room) and so forth, inspect the wiring state being careful for water not to get in.

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2.2. Diagnosis and Remedy

z The following description summarizes the probable cause of and remedy for

generall failure by item.

z Immediate countermeasures should be taken before a failure is inflamed if any

symptom is detected.

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

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D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

Operating state

1. Overload

2. Radiator core clogged

3. Continuous over-run

Check fresh Radiator tank cap

Inspect Radiator

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D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

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D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

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MAINTENANCE MANUAL

Causes according to operating conditions

1. Overload

2. Freqent use of low geae position at high speed

3. Freqent use of high geae position at low speed

4. Clutch slip

5. Too low tire inflation pressure

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