Engine Training Text

Mar 2009
Overseas Product Support Team
Doc. No. ENG.001
E/G Model & Machine Model

E/G Model Machine Model

DB58 Series S140LC-V, S220LC-V, S225LC-V, S255LC-V, S225LC-7
D1146 Series S290LC-V
DE08 Series 300LC-V, S300LC-7
DE12 Series S330LC-V, 3340LC-V, S34-LC-7, S470LC-V, S500LC-V

Ma c h i n e Mo d e l S140LC-V S220LC-V S225LC-V S255LC-V S225LC-7 S290LC-V

Engine Model DB58T DB58TI DB58TIS DB58TIS DB58TI D1146TI

Suffix EATEK EAOEA ECOEB ECOEA EAOEL EAPEA

Machine Model S300LC-V S330LC-V S340LC-V S340LC-7 S470LC-V M400-V M500-V

S300LC-7 S500LC-V (CUMMINS)
Engine Model DE08TIS DE12T DE12TIS DE12TI DE12TIS DE12TIS QSM11
Suffix ECPEA EBHEA ECIEC EBIEF ECIEA ECILC

DE12TIS

Tier – Ⅱ
Intercooler

Turbo Charger

E/G Model
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E/G Suffix & Spec

• Valve Clearance, Injection Timing, Nozzle Injection Pressure

Machine Model S140LC-V S220LC-V S225LC-V S255LC-V S225LC-7 S290LC-V

I,E Valve (mm) 0.4 0.4 0.4 0.4 0.4 0.3

(at cold)
Injection Timing 13 13 11 11 13 9
(BTDC)
Injection (㎏/㎠) 220 185 190 190 205 214

Machine Model S300LC-V S330LC-V S340LC-V S340LC-7 S470LC-V M400-V

S300LC-7 S500LC-V
I,E Valve (mm) 0.3 0.3 0.3 0.3 0.3 0.3
(at cold)
Injection Timing 3 14 5~6 14 14 5~6
(BTDC)
Injection (㎏/㎠) 160/220 220 160/220 220 160/220 160/220

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E/G Assembly

• Engine sectional view

3
Engine Model and Serial Number (DB58 Series)

4
Engine Model and Serial Number (D, DE Series)

5
Cylinder No

DB58 Series

D1146, DE Series

6
Valve Clearance Adjust

7
Timing mark position

DB58 Series

D1146, DE Series

8
Injection Timing Adjustment (DE1146, DE08 Series)

9
Lubrication System (DB58 Series)

10
Lubrication System (DE12 Series)

11
Oil Spray Nozzle (DE12 Series)

12
Oil level check & Change

DB58T/TI/TIS

13
Fuel System (DB58 Series)

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Fuel System (DE12 Series)

1. Fuel filter
1a. Fuel water drain
2. Air bleeding screw
3. Injection nozzle
4. Overflow tube
5. Fuel pipe (filter -> Injection pump)
6. Overflow valve
7. Fuel injection pipe
8. Fuel pipe (feed pump -> filter)
9. Fuel tank
10. Fuel return pipe
11. Suction pipe
12. Feed pump
13. Injection pump

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Fuel Filter

16
Cooling System

17
Radiator & Cap

18
Radiator Cap

• Compression • Vacuum

Pressure valve Vacuum valve Vacuum valve Pressure valve

High pressure Low pressure

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Antifreeze

20
Fan Belt Tension

• V-Belt Type

Type A-Grade B-Grade C-Grade D-Grade F-Grade

Width (mm) 13 17 23 32 38
Thickness (mm) 9 11 15 20 24
Length Thickness center line length

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Cylinder head bolt torque (Kg-m)

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Cylinder head bolt torque (DB58 Series)

(Unit : Kg-m)

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Cyl’ Head Bolt loosen & Tighten Order (DB58 Series)

• Head Bolt Loosen Order • Head Reassembly

24
Cylinder head bolt torque (DE12 Series)

(Unit : Kg-m)

• Head gasket position (‘TOP’ mark facing upward)

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Engine DB58 Series Cyl’ Liner & Piston Grade Mark

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Engine DB58 Series Cyl’ Liner & Piston Grade Mark

Parts Mark position Mark Means

Cyl’Liner •Liner : Outer Face •1,2

- 1A, 1B - Liner Outer Dia
- 2A, 2B •A,B
- Liner Inner Dia

•Piston : Head Face

Piston
- A, B

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Cylinder Liner Type -> Dry Type

Replacement

Assembly

28
Cylinder Head Parts

29
Valve Stem Seal ass’y

30
E/G Oil Consumption

Atmospheric pressure

Suction Exhaust

31
Piston Ring Gap

• Piston ring gap Inspection (DB58 Series)

32
Cyl’ Head Bolt Tighten (D1146, DE08 Series)

33
Fly wheel

34
Fly wheel

35
Engine part (Cyl’ Head & Block)

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Engine Parts (Crank shat, Piston & Valve parts)

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Engine Oil Cooler & Water pump, Cooling Fan

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Intake & Exhaust Pipe & Turbo Charger

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Fuel System parts

40
Trouble shooting

• Torque wrench use the 4 point bolt (Certainly) • Valve Clearance large
- Cyl’ Head Bolt - Noise
- Crank shaft cap Bolt - Black Smoke
- Connecting Rod Cap Bolt - Over Heating

- Fly wheel Bolt - E/G Overload

• E/G Oil mixing on coolant • Valve Clearance Small

- Head gasket Damaged - Push rod bending
- Oil Cooler damage - Tappet & Cam fast wear
- Piston Head Damage
• Coolant mixing on E/G oil
- E/G Overload
- Head gasket Damaged
- Head & Block Coolant plug leakage • Valve Clearance less and less
- Cyl’ Head valve face damage
• Fuel mixing on E/g oil
- Injection Nozzle tip open stick • Valve Clearance less and less
- I/P Plunger & Barrels damage - Cyl’ Head valve face damage
- Feed pump seal damage
• C.R.S & Con Rod bearing wear
• Oil mixing on fuel - Noise
- Feed pump seal damage - Oil pressure down

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Trouble shooting

• Thrust bearing wear • Oil Consumption much

- Noise - Piston ring & Liner wear

- Piston pin side wear - Valve stem seal wear

- Blow by gas with out
• Blow smoke (= Fuel)
- Leakage (Seal & Gasket wear)
- Fuel supply much
- Nozzle Injection pressure down • Fuel Consumption much
- Nozzle tip open stick - Piston ring & Liner wear
- Power down
• White smoke (= Oil)
- Oil combustion • E/g Oil pressure down
- Oil pump problem
• Black smoke
- Rocker arm sticking
- Air Cleaner stopped
- Piston & Liner sticking
- Air Supply insufficiency
- Oil pipe line crack or gasket leakage
- Cyl’ Compression pressure down
- Oil pump relief valve open stick
- Fuel Injection much
-> Nozzle Injection pressure down
• Damper rubber wear
- E/G vibration
- Turbo charger problem
- Valve clearance large

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Trouble shooting
• Over heating
- Radiator core stopped
- Coolant insufficiency
- Radiator Mounting side Sponge removal
- Radiator Shroud removal
- Cooling Fan turn assembly
- Fan belt tension loosen
- Thermostat problem
• Turbo charger problem
- E/G starter after rapidity acceleration
-> E/G start after 5 minute acceleration
- Overload work after rapidity stop
-> Idle after 5 minute stop
• Oil spray nozzle pipe broken
- Piston overheating
- Piston & Liner sticking

• Injection timing at fast • How to you different the piston stick?

- Knocking - Case1 : overheating
- Overheating
- Case2 : E/G Oil insufficiency

• Injection timing at late

- Block smoke
- Overload
- Acceleration at late

• Overflow valve problem

- E/G don’t start
- E/g don’t acceleration

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