Beruflich Dokumente
Kultur Dokumente
August, 2011
EMEA Training Team
Contents
1. Common rail system.
2. DL06 / DL08 / DV11 Common rail engines
3. E.C.Us
4. C.P Pumps
5. Common rail
6. Injectors
7. Sensors
8. Valve clearance adjusting & Maintenance
Common Rail System
Common rail system engine is able to satisfy the new emission regulations.
Common Rail System
3) Common rail with pressure limiter valve and rail pressure sensor
5) E.C.U
Pressure Pipe
ECU CR Injector
Common Rail
Common Rail System
Metering
unit ZME
Accelerator
pedal
Control unit
Engine
speed
(crank)
Tank Engine
Prefilter High pressure
speed
(cam) Low pressure
Common Rail System
Temperature
Nox
(1)
PM (Smoke)
(2)
CRS Angle
Multiple Injection
Main Injection
Noise Control
Post/After
Pre/Pilot Injection Injection
Common Rail System
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
- Combustion stroke
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
Wastegate
Turbocharger
Injector
Cyl. Head
Piston
Common rail
Con. Rod High Pressure Pump
Cyl. Block Cam Shaft
Starter
Crank Shaft
Oil Pan
Common Rail System
DL08 DV11
DL08 4 00001 BA
DV11 4 00001 BA
Engine Model Engine code (Engine suffix)
Production year Serial number
Common Rail System
DV11 Engine
Cylinder head
Hexagonally arranged
cylinder head bolts
Injector sleeve
Ex
In
Ex
In
Caliper
Common Rail System
Ball pin
Cap
Lubricating oil goes through the ball pin and Intake/ Exhaust valve calipers are NOT the same
cap to the top contact face of the caliper. (Exhaust has larger pad area)
Lubrication oil is sprayed on the top of the Direction of caliper installation is critical
Push rod and adjustment screw directly. (Oval hole nearest push rod)
The lubrication oil passage (1.0mm)
Common Rail System
Mark here
Valve spring
Intake valve Exhaust valve
Common Rail System
Head gasket
Cylinder
Cylinder liner
liner
Part No.
Cylinder block
Cylinder block
Current engine gasket
ELE
ELEControl
ControlCommon
CommonRailRail
44Valves / Cylinder
Valves / Cylinder
New
NewCombustion
CombustionSystem
System
Central
CentralVertical
VerticalInjector
Injector
High
4-Valves Power
Low Fuel
Low Consumption
Pollution Ratio
Common Rail
Injection system
New Combustion System
Common Rail System
Fuel Injection
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
7. Oil pump
Timing mark
Cam Idle
shaft gear
C.R.S
Common Rail System
Timing mark
Cam shaft
C.R.S
Common Rail System
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 Piston
1. Oil Spray Nozzle
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
Thermostat
Radiator
Water
pump
Water pump Engine oil cooler Cylinder block Cylinder head Thermostat
Radiator Water pump
Common Rail System
Water pump Engine oil cooler Cylinder block Cylinder head Thermostat
Radiator Water pump
Common Rail System
Cylinder
Water
pump
Cooling water
Oil cooler
Hot water
Cool water
Common Rail System
Hot water
Cool water
Common Rail System
Fuel pressure
pump
Fuel tank
Common Rail System
High pressure
connector
Fuel tank
Common Rail System
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
Hardware : Bosch
Injector connector Vehicle EDC7UC31
Software : Special software
Connector for Doosan
engine
E.C.U
Vehicle
Connector Engine connector
ATM Sensor
(Not use) Injector connector
Common Rail System
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
2) *Preheating/After
Calculate the optimalheating
fuel quantity for engine starting
* 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
ECU Injector
Air Temp
Engine RPM
2) Preheating
Key on
Coolant Temp
Fuel Temp ECU Air heater
ECU Control
Coolant Temp
Air heater
Fuel Temp ECU
Air Temp
4) Limp home
LCD Panel X
ECU 1000 RPM
EPOS X
ECU Control (4/4)
5) Emergency stop
Engine running signal
Emergency
engine stop signal ECU Cut Fuel Injection
Common Rail System
Very Important
DBV
rail
metering unit
over
pressure bypass
valve valve
10.5...13 bar 0.1 bar lubrication
p suction KV
0.5...1.0 bar abs cooling
plate zero delivery drain
prefilter
<=100mm with
hand-
water separator p back CP3 < 1.2 bar abs
primer
KV: two step overflow valve : high pressure
DBV: pressure limiter valve : low pressure
Common Rail System
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
Metering
Unit
Gear pump
Metering Unit
High Pressure
Low Pressure Oil Lubricating System
Oil
* First assemble, Input 40ml Engine Oil
Common Rail System
DBV
rail
metering unit
over
pressure bypass
valve valve
10,5...13 bar 0,15 bar
V
p suction
0,5...1,0 bar abs
zero delivery
cooling
drain
plate
hand-
primer prefilter
with water p back CP3 < 1,2 bar abs
separator
V: overflow valve : high pressure
DBV: pressure limiter valve : low pressure
Common Rail System
Gear pump
Common Rail System
DL08 DV11
Common Rail System
Metering unit
Coil resistance :
2.6 ~ 3.5
Open : Closed :
Below 8 Volt 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
6
5
3 4
1 2 To Tank
Left
4
6 5
To Tank
2 1
3
Rail pressure sensor
Right
From CP3
DV11 - 2 Rails
Common Rail System
Keep clean common rail, high pressure pipe and fuel high pressure pump when
disassembled.
Common Rail System
Rail pressure sensor RDS3
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, dont allow the sensor connector to
become damaged (Most sensor problems are caused by use of incorrect tools)
6. Injector
Common Rail System
Doosan Part
Engine Remark
No.
65.10401-
DL06 Euro3, Tier3
7004A
65.10401-
DL08 Euro3, Tier3
7001C
65.10401-
DV11 Euro3, Tier3
7002C
Common Rail System
Injector
Common Rail System
Injector
Tightening torque
0.15 0.025 kgm
Fixing groove
Fuel Inlet
Fuel Drain
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
Doosan Part
Engine Remark
No.
65.10401-
DL06 Euro3, Tier3
7004A
65.10401-
DL08 Euro3, Tier3
7001C
65.10401-
DV11 Euro3, Tier3
7002C
Common Rail System
Maintenance injector
Maintenance of injector
Dont 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
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
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
1. CRS sensor
5. Metering units
9. Air heater
11. Starter
Sensors
Coolant
Coolant Temperature
Temperature sensor
sensor
Fuel
Fuel Temperature
Temperature sensor
sensor
Boost
Boost press./Temperature
press./Temperature sensor
sensor ECU
ECU
Engine
Engine oil
oil press./
press./ Temp.
Temp. sensor
sensor
CRS
CRS sensor
sensor
Cam
Cam sensor
sensor
Common Rail System
DL08
DV11
Common Rail System
DL08 DV11
Common Rail System
Temperature sensor type : NTC sensor Pressure sensor type : Piezo sensor
Common Rail System
DL08
DV11
Common Rail System
DL08
DV11
Common Rail System
DL08 DV11
Common Rail System
Cam sensor
Air gap
Sensor type : Magnetic pick up
Sensor resistance at 20 : 860 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.
C.R.S/ Cam shaft speed sensor
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
Valve
Gap
Method 2
Valve-Overlapped
1 5 3 6 2 4
cylinder
Adjusting cylinder
6 2 4 1 5 3
(Intake/Exhaust valve)
Cylinder No 1 2 3 4 5 6
EX IN EX IN EX IN EX IN EX IN EX IN
Adjust Cylinder
No 1 Cylinder T.D.C Point
(OT point 0)
Overlap cylinder 1 5 3 6 2 4
Adjusting cylinder
6 2 4 1 5 3
(In/ Ex valve)
Water pump
Common Rail System
Cylinder No 1 2 3 4 5 6
Adjust Cylinder EX IN EX IN EX IN IN EX IN EX IN EX
Turn flywheel 90
Turn flywheel 90
(Total rotation 450)
Overlap cylinder 1 4 2 5 3 6
Adjusting cylinder
5 3 6 1 4 2
(In/ Ex valve)
136