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    TB 80 Engine

    Uploaded by

    Ronald
    The document provides detailed information about the S8000 engine, including: 1) Diagrams and pictures showing the engine components such as the turbocharger, intake manifold, fuel injection pump, and other parts. 2) Specifications and requirements for the engine such as the emission standards it complies with, particulate matter filters, and use of exhaust gas recirculation to reduce emissions. 3) Maintenance procedures such as adjusting valve clearances, fuel pump timing, selection of the proper head gasket, cylinder head tightening, and servicing the air filter and fuel system.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    TB 80 Engine

    Uploaded by

    Ronald
    93 views51 pages
    The document provides detailed information about the S8000 engine, including: 1) Diagrams and pictures showing the engine components such as the turbocharger, intake manifold, fuel injection pump, and other parts. 2) Specifications and requirements for the engine such as the emission standards it complies with, particulate matter filters, and use of exhaust gas recirculation to reduce emissions. 3) Maintenance procedures such as adjusting valve clearances, fuel pump timing, selection of the proper head gasket, cylinder head tightening, and servicing the air filter and fuel system.

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    TB 80 engine

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    The document provides detailed information about the S8000 engine, including: 1) Diagrams and pictures showing the engine components such as the turbocharger, intake manifold, fuel injection pump, and other parts. 2) Specifications and requirements for the engine such as the emission standards it complies with, particulate matter filters, and use of exhaust gas recirculation to reduce emissions. 3) Maintenance procedures such as adjusting valve clearances, fuel pump timing, selection of the proper head gasket, cylinder head tightening, and servicing the air filter and fuel system.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    93 views51 pages

    TB 80 Engine

    Uploaded by

    Ronald
    The document provides detailed information about the S8000 engine, including: 1) Diagrams and pictures showing the engine components such as the turbocharger, intake manifold, fuel injection pump, and other parts. 2) Specifications and requirements for the engine such as the emission standards it complies with, particulate matter filters, and use of exhaust gas recirculation to reduce emissions. 3) Maintenance procedures such as adjusting valve clearances, fuel pump timing, selection of the proper head gasket, cylinder head tightening, and servicing the air filter and fuel system.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 51

    S8000 Engine

    Engine View
    Engine View

    Turbo Charger

    Intake Manifold
    LDA
    Rotary Fuel Injection
    pump

    Fuel Lift pump

    Crank Pulley

    KSB
    Fuel filter Pre & Micro
    3
    Left side view

    Turbocharger
    Waste gate control

    Exhaust Manifold

    Lube oil filter

    Lube oil Cooler


    Front & Rear View

    5
    Side & Front Sectional View

    6
    Views

    7
    Engine Identification
    S8000 Engine Specifications
    BACKGROUND BS-III
    Bharat stage III emission standards as instituted by the government of
    Republic of India(Bharat) that regulate the output of air pollutants.

    One of the main reason for air pollution is the emission of exhaust gases
    of vehicles and engines used in various applications.

    The main constituents of exhaust gases are Nitrogen Oxide(NOX), Carbon


    Monoxide(CO), Hydrocarbon(HC), Particulate Matter(PM), Oxides of
    Sulphur, Soot & Smoke.

    To arrest the emission of exhaust gases, Bharat Stage III compliance


    engines have been introduced
    What is PM?

    • "Particulate matter," also known as particle pollution or PM, is a complex mixture


    of extremely small particles and liquid droplets.

    • Particle pollution is made up of number of components, including acids such as


    nitrates and sulfates, organic chemicals, metals, and soil or dust particles

    • particles that are 10 μ in diameter or smaller pass through the throat and nose
    and enter the lungs. affect the heart and lungs and cause serious health effects.
    EGR:

    The Exhaust gas is recirculated to combustion chamber by opening the


    Exhaust valve during induction stroke or by opening the intake valve during
    Exhaust Stroke (FPT 3.9)

    The neutral exhaust gases neither burns nor support combustion

    It dilutes the peak combustion chamber temperature this in turn reduces the
    NOx formation

    This is done by making special arrangement in engine camshaft. An


    additional lobe (Tiner) is made at the camshaft so that a secondary lift is
    given to inlet valve for opening during exhaust stroke.
    The tiner on the inlet cam lobe keeps inlet valve open for some time
    during the exhaust stroke, so that a small amount (27-30%)of exhaust
    gas mix with fresh inlet air and reduces the NOX gases to be exhausted
    into the atmosphere.
    Waste gate Turbocharger

    Waste gate : To controls the extra pressure into the cylinder one waste gate
    valve is provided that allows the exhaust gases to bypass. When the boost
    pressure in intake is too high.
    Compressor Wheel
    Compressor outlet Compressor inlet
    Oil inlet

    Compressor Cover

    Bearing Housing

    Turbine Wheel Wastegate hose

    Wastegate
    bracket

    Turbine outlet
    Turbine Housing

    Turbine inlet
    After Cooler

    • After coolers are widely known in automotive use as an air-to-air or air-to-liquid


    cooler for forced induction (turbocharged or supercharged) internal combustion
    engines to improve their volumetric efficiency by increasing intake air charge
    density through nearly isobaric (constant pressure) cooling.

    • Volumetric efficiency is a ratio (or percentage) of the quantity of air that is trapped
    by the cylinder during induction over the swept volume of the cylinder under static
    conditions. VE can be improved in a number of ways, most effectively this can be
    achieved by compressing the induction charge
    Additional Components in Fuel system LDA

    Starting the engine - At low


    temperatures

    When starting a cold engine at


    temperatures below 5 °C (41 °F),
    open the throttle fully. Turn the key
    to “ON” until the engine starts,
    then release the key. If the engine
    fails to start, wait for one minute
    and repeat the starting procedure.

    KSB
    KSB – (Kaltstartbeschleuniger) Cold starting timing advance system is
    used to advance the timing in cold starting and at low speed cold
    running. A lever is pulled which turns cam that pushes timing piston to
    provide about 5.5 degree advance at no load.

    LDA – (Laden Druck Angleichung) controls the injected fuel quality at


    middle and high engine speeds in relation to boost from the
    turbocharger.
    The LDA reacts to charge pressure entering at (14) from the exhaust gas
    generated by the turbocharger and adapts the full load delivery to the charge
    air pressure. The LDA functions by means of a pipe from the engine inlet
    manifold that allows boost pressure to push on a diaphragm acting against
    spring. As the diaphragm moves it influences the action of governor to allow
    more fuelling the air acts against the diaphragm(6) compressing spring (7).
    The control cone (9) acts against guide pin (4) causing the reverse lever (3) to
    pivot about M1 which in turns acts against the tensioning lever (12) resulting
    in the control collar moving towards the full load position.
    Adjustment of Valve Tappet Clearance
    Tappet setting can be done as per following figure.
    1. Firing order of S 8000 Turbo Super engine (1-3-4-2)

    • Rotate the engine anticlockwise from flywheel side and Match the flywheel on PMS1 compression
    stroke and adjust 1st & 2nd valve tappet clearance (0.30 mm) .
    • Rotate the flywheel further anticlockwise 180° and adjust the 5th & 6th valve tappet clearance
    • Rotate the flywheel further anticlockwise 180° and adjust the 7th & 8th valve tappet clearance
    • Rotate the flywheel further anticlockwise 180° and adjust the 3rd & 4th valve tappet clearance
    Valve clearance setting Adjustment

    Special tool No: 291883

    Adjust valve clearance setting with each piston in turn at Top Dead Centre
    and rockers free to move. Use special tool No: 291883 for Adjustment.

    Intake valve clearance : 0.30 mm

    Exhaust valve clearance : 0.30 mm


    Gear Timing

    Fuel
    Pump Camshaft

    Idle
    Idle

    Crank
    Shaft
    Before removing the timing gear use a dial indicator on feeler gauge to
    measure the
    backlash between each set of gears.

    2. Rotate the gears and check the backlash at four equal points on the gears.
    Renew if the backlash exceeds 0.160 mm.
    Pump Timing

    KSB
    Fig 1 Fig 2

    -
    +

    Fig 3 Fig 4
    FUEL INJECTION PUMP
    Pump Timing

    • Give supply to KSB direct from the battery or heat the engine up to 40 degree to active KSB (Next
    Slide Fig 1)
    • Wait for approximate 3 minute to fully open the KSB (Next Slide Fig 2).
    • Bring first piston at PMS1 (TDC) mark by rotating the engine in clockwise direction(from pulley end)
    in compression stroke
    • Fit adopter SST No.9971500
    • Insert dial gauge fully and see total travel ( Next Slide Fig 3.)
    • Pre load the dial gauge
    • Set needle at 0 and move the flywheel anticlockwise (from pulley end) till needle stops
    • Set needle at 0 mark & rotate engine clockwise (from pulley end) till PMS1 (TDC) mark aligns with
    pointer
    • At that time needle should travel and stop at 1mm mark.
    • Any deviation in this specification required pump timing adjustments
    • Adjust timing by loosening three FIP mounting bolts
    • Move pump up for advance & down for retard
    Selection of Head Gasket

    Pistons that are replaced must be of the same type that were removed and have the same
    identification letters, and numbers, as embossed on the piston

    1. Upon re--assembly with the piston at Top Dead Centre, ensure that piston stand out from
    engine block is 0.355 -- 0.761 mm.
    2. Use Gasket “A” if Standout is ≤ 0.762 mm Gasket Thickness: 1.35 mm
    3. Use Gasket “B” if standout is > 0.763 mm Gasket Thickness: 1.55 mm

    NOTE: With most new Pistons, a machining allowance is provided on the crown of the piston
    and the necessary amount must be removed in a lathe to give clearance quoted above. Some
    pistons may be available that do not require topping
    Ensure words ALTO on top.
    Cylinder Head Tightening

    Stage 1 Stage 2 Stage 3


    40 NM 130º 140⁰
    4.1 Kg-mtr.
    With torque Wrench Turn through Turn through
    (With angular torqueing
    tool
    Oil Circuit Diagram
    Coolant circuit
    Air filter maintenance

    Servicing instructions
    A. Clean primary element: When service indicator
    shows red band.
    B. Replace primary element: When servicing indicator
    shows red band even after cleaning or after two
    cleaning intervals if holes or tears are found in element.
    C. Replace safety element: when replacing primary
    element.
    NOTE: Do not tap or hammer element on ground.
    Maintenance on Fuel system
    Maintenance in lubrication system

    Oil Change: Every 500 Hour


    51

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