65.

99892-8051

Operation Manual
GENERATOR DIESEL ENGINE

DE12T
POLUS

P126TI

FOREWORD
This manual has been prepared to help you use and maintain the DE12T/ P126TI generator diesel
engines in a safe and correct manner.

These economical and high-performance diesel engines (OMEGA combustion system) have been
designed and manufactured for generator application. They meet all the requirements such as low
noise, fuel economy, high engine speed, and durability.

Nonetheless, to obtain the best performance and long life of an engine, it is essential to operate it
appropriately and to carry out periodic checks as instructed in this manual. We strongly urge you to
thoroughly read this manual from cover to cover and to acquaint yourself fully with all the information
contained in this manual.

Please contact your authorized DAEWOO dealer for the answers to any questions you may have
about your DE12T/ P126TI generator engines features, operation, or manuals.

In order to operate the engine in the optimal conditions and to maintain its best performances, the
contents in this instruction are to be thoroughly understood and observed.
In addition refer to the INSTALLATION manual about DAEWOO generator engine installation instructions.
All warranty claims to be addressed to;

Engine Export Team,

DAEWOO Heavy Industries LTD.
DAEWOO Center 541
Namdaemun-ro 5-ga, Chung-gu
Seoul, Korea
TEL : (82-2-726-3205~8), FAX: (82-2-726-3168)

Or to your local DEALER or DISTRIBUTOR.

DAEWOO Heavy Industries LTD.

July. 1999

CONTENTS

1. General information ................................................................................................................... 1

1.1. Engine specification

1.2. Engine assembly

2. Safety regulations...................................................................................................................... 6
2.1. General notes

2.4. Regulations designed to prevent pollution

2.2. Regulations designed to prevent accidents

2.5. Notes on safety in handling used engine oil

2.3. Regulations designed to prevent damage

3. Technical information.............................................................................................................. 10
3.1. Engine model and serial number

3.7. Intercooler

3.2. Engine type

3.8. Fuel system

3.3. Engine timing

3.9. Cooling system

3.4. Valves

3.10. V-belt tension check and adjust

3.5. Lubrication system

3.11. Turbocharger

3.6. Air cleaner

3.12. Electrical equipment

4. Commissioning and operation ............................................................................................... 26

4.1. Preparation

4.4. Operation in winter

4.2. Breaking-in

4.5. Tuning the engine

4.3. Inspection after starting

5. Inspection and maintenance .................................................................................................. 30

5.1. Periodical inspection and maintenance

5.5. Fuel system

5.2. Lubrication system

5.6. Injection nozzle maintenance

5.3. Cooling system

5.7. Turbocharger

5.4. Air intake system

6. Checking and setting .............................................................................................................. 42

6.1. Adjustment of valve clearance

6.4. Cylinder compression pressure

6.2. Adjustment of injection timing

6.5. V-belts

6.3. Tightening the cylinder head bolts

Appendix.................................................................................................................................... 49

WORLDWIDE NETWORK

1. General information
1.1. Engine specification
Engine Model

DE12T

Items

P126TI

Water-cooled, 4 cycle in-line

type
Turbo charged & intercooled
Direct injection type

Water-cooled, 4 cycle in-line

type Turbo charged

Engine type
Combustion chamber 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

4 - 123 x 155

(cc)

11,051

Compression ratio

17.1 : 1

Engine dimension (length x width x height)

Engine weight

(mm) 1,365.5 x 870 x 1,046

(kg)

1,383 x 870 x 1,207

910

Rotating direction (from flywheel)

Counter clockwise

Fuel injection order

1-5-3-6-2-4

Fuel injection timing (B.T.D.C static)

12

Injection pump type

Zexel in-line P type

Governor type
Injection nozzle type
Fuel injection pressure

(kg/cm )

Compression pressure

(kg/cm )

Mechanical governor type(RSV)

Electric governor type(GAC)

Multi-hole type (5 hole)

Multi-hole type (5 hole)

220

1st : 160, 2nd : 220

28 (at 200 rpm)

50Hz
60Hz
50Hz
60Hz
60Hz
(1,500rpm) (1,800rpm) (1,500rpm) (1,800rpm) (1,800rpm)

Condition

280PS
(206kW)

336PS
(247kW)

Prime

205PS
(151kW)

245PS
(180kW)

328PS
(241kW)

378PS
(278kW)

356PS
(262kW)

Stand by

226PS
(166kW)

270PS
(199kW)

370PS
(272kW)

405PS
(298kW)

392PS
(288kW)

Continuous
Power (ISO 3046)

Intake and exhaust valve clearance (at cold) (mm)

Intake valve
Exhaust valve

P126TI-I

0.3

Open at

18 (B.T.D.C)

Close at

34 (A.B.D.C)

Open at

46 (B.B.D.C)

Close at

14 (A.T.D.C)

Lubrication method

Full forced pressure feed type

Oil pump type

Gear type driven by crankshaft

Oil filter type

Lubricating oil capacity (max./min.)

Full-flow, Cartridge type

(lit)

Oil cooler type

Water cooled

Water pump

Gear driven impeller type

Cooling Method
Cooling water capacity (engine only)

Pressurized circulation
(lit)

Thermostat type
Alternator voltage - capacity
Starting Motor voltage - output

23/20

19
Wax pallet type (83 ~ 95 C)

(V - A)

24 - 45

(V - kW)

24 - 6.0

-1-

1.2. Engine assembly

1.2.1. Engine sectional view (Longitudinal)

10

11

12

13

14 15

16

17

18
EA8M1002

1. Cooling fan

7. Piston pin

13. Crankshaft

2. Exhaust valve

8. Piston

14. Oil pan

3. Valve spring

9. Combustion chamber

15. Connecting rod

4. Oil filter

10. Crankshaft pulley

16. Camshaft

5. Tappet

11. Vibration damper

17. Flywheel housing

6. Push rod

12. Oil pump

18. Flywheel

-2-

1.2.2. Engine sectional view (Cross)

10

11

12

4
5
6

EA8M1003

1. Intake manifold

7. Injection nozzle assembly

2. Fuel filter

8. Rocker arm

3. Oil cooler

9. Cylinder head cover

4. Injection pump

10. Exhaust manifold

5. Cylinder block

11. Piston ring

6. Oil filter

12. Turbocharger

-3-

1.2.3. Engine assembly views

1) DE12T

1 2

3 12 4

27

13 18
5

22

23
16

8
17

6
15

9 11 10
19

25
24

14

20 21 26
EA8M1004

1. Cooling fan

10. Flywheel housing

19. Thermostat

2. Cooling water pipe

11. Flywheel

20. Injection pump

3. Oil filler cap

12. Exhaust manifold

21. Oil level gauge

4. Cylinder head cover

13. Injection nozzle assembly

22. Mounting bracket

5. Turbocharger

14. Oil filter

23. Vibration damper

6. Oil drain valve

15. Fuel filter

24. Water pump

7. Alternator

16. Oil cooler

25. Fan drive

8. Oil pan

17. Intake manifold

26. Crankshaft pulley

9. Starter

18. Injection pipe

27. Breather

-4-

2) P126TI

7
14 15 16 17 18

12

6
19

13

9 10 11

24
22
23

25

20 21
EA8M1005

1. Cooling fan

8. Oil pan

18. Injection pipe

2. Cooling water pipe

9. Starter

19. Thermostat

3. Air pipe

10. Flywheel housing

20. Injection pump

11. Flywheel

21. Oil level gauge

12. Exhaust manifold

22. Mounting bracket

13. Injection nozzle assembly

23. Vibration damper

5. Turbocharger

14. Oil filter

24. Water pump

6. Oil drain valve

15. Breather hose

25. Fan drive

7. Air pipe

16. Oil cooler

(Intercooler

Intake manifold)

4. Air pipe
(Air cleaner

(Intercooler

Turbocharger)

Intake manifold)

17. Intake manifold

-5-

2. Safety regulations
2.1. General notes
Day-to-day use of power engines and the service products necessary for running them
presents no problems if the persons occupied with their operation, maintenance and care are
given suitable training and think as they work.

This summary is a compilation of the most important regulations. These are broken down into
main sections which contain the information necessary for preventing injury to persons,
damage to property and pollution. In addition to these regulations those dictated by the type of
engine and its site are to be observed also.

Important :

If, despite all precautions, an accident occurs, in particular through contact with caustic
acids, fuel penetrating the skin, scalding from oil, antifreeze being splashed in the eyes
etc., consult a doctor immediately.

2.2. Regulations designed to prevent accidents

2.2.1. During commissioning, starting and operation
Before putting the engine into operation for the first time, read the operating instructions
carefully and familiarize yourself with the critical points, If you are unsure, ask your
DAEWOO representative.

For

reasons of safety we recommend you attach a notice to the door of the engine room

prohibiting the access of unauthorized persons and that you draw the attention of the
operating personal to the fact that they are responsible for the safety of persons who enter
the engine room.

The

engine must be started and operated only by authorized personnel. Ensure that the

engine cannot be started by unauthorized persons.

When

the engine is running, do not get too close to the rotating parts. Wear close-fitting

clothing.

Do not touch the engine with bare hands when it is warm from operation risk of burns.
Exhaust gases are toxic. Comply with the installation instructions for the installation

of

DAEWOO generator diesel engines which are to be operated in enclosed spaces. Ensure
that there is adequate ventilation and air extraction.

Keep vicinity of engine, ladders and stairways free of oil and grease.
Accidents caused by slipping can have serious consequences.

-6-

2.2.2. During maintenance and care

Always carry out maintenance work when the engine is switched off. If the engine has to be
maintained while it is running, e.g. changing the elements of change-over filters, remember
that there is a risk of scalding. Do not get too close to rotating parts.

Change the oil when the engine is warm from operation.

Caution :

There is a risk of burns and scalding. Do not touch oil drain valve or oil filters with bare
hands.

Take into account the amount of oil in the sump. Use a vessel of sufficient size to ensure that
the oil will not overflow.

Open the coolant circuit only when the engine has cooled down. If opening while the engine
is still warm is unavoidable, comply with the instructions In the chapter entitled Cooling.

Neither tighten up nor open pipes and hoses (lube oil circuit, coolant circuit and any additional
hydraulic oil circuit) during the operation. The fluid which flow out can cause injury.

Fuel is inflammable. Do not smoke or use naked lights in its vicinity. The tank must be filled
only when the engine is switched off.

Keep service products (anti-freeze) only in containers which can not be confused with drinks
containers.

Comply with the manufacturers instructions when handling batteries.

Caution :

Accumulator acid is toxic and caustic. Battery gases are explosive.

2.2.3. When carrying out checking, setting and repair work

Checking, setting and repair work must be carried out by authorized personnel only.
Use only tools which are in satisfactory condition. Slip caused by the worn open-end wrench
could lead to Injury.

When the engine is hanging on a crane, no-one must be allowed to stand or pass under it.
Keep lifting gear in good condition.

When checking injectors, do not put your hands under the jet of fuel.
Do not inhale at atomized fuel.

When working on the electrical system disconnect the battery earth cable first. Connect it up
again last in prevent short circuits.

2.3. Regulations designed to prevent damage to engine and premature wear

1) Never demand more of the engine than it was designed to yield for its intended purpose.
Detailed information on this can be found in the sales literature. The injection pump must not
be adjusted without prior written permission of DAEWOO.

-7-

2) If faults occur, find the cause immediately and have it eliminate in order to prevent more
serious of damage.
3) Use only genuine DAEWOO spare parts. DAEWOO will accept no responsibility for damage
resulting from the installation of other parts which are supposedly just as good.
4) In addition to the above, note the following points.

Never

let the engine run when dry, i.e. without lube oil or coolant. Use only DAEWOO-

approved service products (engine oil, anti-freeze and anticorrosion agent).

Pay

attention to cleanliness, The Diesel fuel must be free of water. See Maintenance and

care.

Have the engine maintained at the specified intervals.

Do not switch off the engine immediately when it is warm, but let it run without load for about
5 minutes so that temperature equalization can take place.

Never put cold coolant into an overheated engine. See Maintenance and care.
Do not add so much engine oil that the oil level rises above the max. marking on the dipstick.
Do not exceed the maximum permissible tilt of the engine. Serious damage to the engine may
result if these instructions are not adhered to.

Always ensure that the testing and monitoring equipment (for battery charge, oil pressure, and
coolant temperature) function satisfactorily.

Comply with instructions for operation of the alternator. See Commissioning and operation.
Do not let the water pump run dry. If there is a risk of frost, drain the water when the engine
switched off.

2.4. Regulations designed to prevent pollution

2.4.1. Engine oil, filter element, fuel filter

Take old oil only to an oil collection point. Take strict precautions to ensure that oil does not
get into the drains or into the ground.

The drinking water supply may be contaminated.

Oil and fuel filter elements are classed as dangerous waste and must be treated as such.
2.4.2. Coolant

Treat undiluted anti-corrosion agent and / or antifreeze as dangerous waste.

When disposing of spent coolant comply with the regulations of the relevant local authorities.
2.5. Notes on safety in handling used engine oil
Prolonged or repeated contact between the skin and any kind of engine oil decreases the skin.
Drying, irritation or inflammation of the skin may therefore occur. Used engine oil also contains
dangerous substances which have caused skin cancer in animal experiments. If the basic
rules of hygiene and health and safety at work are observed, health risks are not to the
expected as a result of handling used engine oil.

-8-

Health precautions

Avoid prolonged or repeated skin contact with used engine oil.

Protect your skin by means of suitable agents (creams etc.) or wear protective gloves.
Clean skin which has been in contact with engine oil.
- Wash thoroughly with soap and water, A nailbrush is an effective aid.
- Certain products make it easier to clean your hands.
- Do not use petrol, Diesel fuel, gas oil, thinners or solvents as washing agents.

After washing apply a fatty skin cream to the skin.

Change oil-soaked clothing and shoes.
Do not put oily rags into your pockets.
Ensure that used engine oil is disposed of properly.
- Engine oil can endanger the water supply -

For this reason do not let engine oil get into the ground, waterways, the drains or the sewers.
Violations are punishable. Collect and dispose of used engine oil carefully.
For information on collection points please contact the seller, the supplier or the local
authorities.

-9-

3. Technical information
3.1. Engine model and serial number
Engine Number
The engine model and serial number is
located on the engine as illustrated. These
numbers

are

required

when

requesting

warranty and ordering parts. They are also

referred to as engine model and serial
number because of their location.

EA8O3001

Engine serial No. (example 1 : DE12T)

EBHGA900001

BORE

mm

STROKE

mm

STAND-BY

VOLUME

cc

PRIME

YEAR

Serial No.

MODEL

Production Year(19x9)

SPEED

Engine Model Suffix

1500/1800

rpm

SERIAL NUMBER

DAEWOO HEAVY INDUSTRIES LTD.

EA9O2002

< Name Plate : General >

Engine serial No. (example 2 : P126TI)

EDIGA900001
IMPORTANT ENGINE INFORMATION
THIS DAEWOO HEAVY-DUTY DIESEL MODEL
IS CERTIFIED TO OPERATE ON
EPA AND CARB STANDARDIZED ENGINE FAMILY DESIGNATION IS
TUNE-UP SPECIFICATIONS AND ADJUSTMENTS

Serial No.

DAEWOO HEAVY INDUSTRIES LTD.

ENGINE AND MATERIAL DIV.
6, MANSECOK-DONG, DONG-GU
INCHEON, KOREA

TYPE 2-D DIESEL FUEL.

Production Year(1999)
Engine Model Suffix

EA9O2003

< Name Plate : EPA & CARB >

- 10 -

3.2. Engine type

The Engines DE12T/ P126TI are in-line vertical water-cooled 6-cylinder four-stroke diesel
engines with direct injection. DE12T is turbo-charged engine, and P126TI model is turbocharged and inter-cooled engine.

3.2.1. Cylinder block

The cylinder block is a single piece of alloy cast iron. To increase its stiffness, it is extended
to a level below the crankshaft center line. The engine has replaceable dry cylinder liners
and individual cylinder heads with struck-in valve seat rings and replaceable valve guides,

3.2.2. Piston con-rod / crankshaft

The forged crankshaft is a ingrate type (Counterweight is integrated with crank shaft body).
Radial oil seal on crankshaft and flywheel are provided to seal the flywheel housing inside
penetrations.
The con-rods (connecting rods) are die-forged, diagonally split and can be removed through
the top of the cylinders together with the pistons. Crankshaft and connecting rods run in
steel-backed lead bronze ready-to fit type bearings.

- 11 -

3.3. Engine timing

Camshaft, oil pump and injection pump are driven by a gear train arranged at the front end.

Injection pump gear

(Z = 72)

Camshaft gear
(Z = 72)

Water pump gear

(Z = 29)

Idle gear
(Z = 52)
Crankshaft gear
(Z = 36)
Oil pump idle gear
(Z = 31)
Oil pump drive gear
(Z = 32)

EA8O3002

3.4. Valves
The overhead valves are actuated via chilled cast iron tappets, push rods and rocker arms
from the camshaft.

- 12 -

3.5. Lubrication system

The engine is equipped with force-feed lubrication.
The pressure is produced by a gear pump whose drive gear is in direct mesh with the
crankshaft gear at the front end of cylinder block.
The oil pump draws the oil from the oil sump and delivers it through the oil cooler and oil filter
to the main distributor gallery and from there to the main bearings, big-end bearings and
camshaft bearings as well as to the small-end bearings and the rocker arms.
The injection pump and the turbocharger are also connected to the engine lubricating system.
The cylinder walls and timing gears are splash-lubricated.
Each cylinder has an oil jet provided for cooling the underside of the pistons.
The lube oil is cleaned in a full-flow oil filter.

OPENING PRESSURE
4.0 ~ 5.0 kg/cm2

RELIEF VALVE

BY - PASS VALVE
1.8 ~ 2.3 kg/cm2

CAM SHAFT BEARING

OIL FILTER

IDLE GEAR SHAFT

BY - PASS VALVE
5.0 ~ 6.0 kg/cm2

TURBO CHARGER

CYLINDER BLOCK MAIN GALLERY

ROCKER ARM SHAFT

OIL SPRAY VALVE

1.5 ~ 1.8 kg/cm2

OIL COOLER
SPRAY NOZZLE

CRANK JOURNAL

IDLE GEAR FACE

INJECTION PUMP

VALVE ROCKER ARM

RELIEF VALVE
10 + 1.5 kg/cm2

CRANK PIN

OIL PUMP

TAPPET

VALVE

OIL STRAINER

EA8O3003

3.5.1. Recommend of lubricating oil

Initial factory fill is high quality break-in oil for API Service CD. During the break-in period (50
hours), frequently check the oil level. Somewhat higher oil consumption is normal until piston rings
are seated. The oil level should be maintained in the safe range between the Min. and Max.
marks on the dipstick. The safe range between the marks represents approximately 3 liters. To
obtain the best engine performance and engine life, grade of engine oil is recommended. Engine
oils are specified by API Service, letter designations and SAE viscosity numbers. If the
specified motor oil is not available, use a reputable brand of engine oil labeled for API Service
CD and SAE viscosity 30 or 15w40. Refer to oil identification symbol on the container.
Engine oil should be changed at the specified intervals. (800hr)

- 13 -

Engine oil viscosity - ambient temperature

SAE 20, 20W

Single
grade
Ambient -30 C
temp
(-20 F)

SAE 30

SAE 10W

-15 C
(-0 F)

Multi
grade

SAE 40, 50

-0 C
(-32 F)

15 C
(60 F)

25 C 30 C
(80 F) (90 F)

SAE 10W - 30

SAE 15W - 40

SAE 10W - 40, 20W - 40, 20W - 50

SAE 5W - 20
EA4M1008

3.5.2. Oil cooler

An oil cooler is provided between the oil filter and the cylinder block. This cooler is a flat tube
type with turbulence inserts and operated by the coolant.

3.5.3. Oil filter

Check for oil pressure and oil leaks, and
repair or replace the oil filter if necessary.
Change the oil filter cartridge simultaneously
at every replacement of engine oil.

Oil filter (Cartridge)

Oil filter head

EQM4010I

- 14 -

3.6. Air cleaner

In case that elements are deformed, damaged
or if the air cleaner has a crack, replace it.
By the definite interval, the elements must be
cleaned and replaced.

- Cleaning of air cleaner element: Every 200

hours.
- Changing of air cleaner element: Every 600
hours.

EFM1002I

3.7. Intercooler
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.

Air/air intercooler
with downstream
radiator
(Combined radiator)

Cooling air
Hot charge air
from compressor
Recooled charge air
to intake pipe (max. 50 C)
EA5O4003

- Cleaning of intercooler fins: Every 600 hours.

- 15 -

3.8. Fuel system

The fuel is delivered by the fuel feed pump via the fuel filter to the injection pump and from
there to the injection nozzles.
The fuel is sprayed into the cylinders through nozzles fitted in screw-fit injection nozzle holders
in the cylinder heads.
Excessively delivered fuel and leak fuel from the nozzle flow through the return pipe back to
the tank.
A strainer is arranged ahead of the fuel feed pump.

4
1a

3
6

13
8
12
10
9

11

EA8O3004

1. Fuel filter

7. Delivery pipe

1a. Full water drain plug

8. Fuel pipe (manual pump

2. Air bleeding screw (for fuel filter)

9. Fuel tank

3. Injection nozzle

10. Fuel return pipe

4. Overflow tube

11. Suction pipe

5. Fuel pipe (filter

injection pump)

12. Feed pump

6. Overflow valve

13. Injection pump

- 16 -

filter)

3.8.1. Injection pump

The in-line injection pump is driven via gears from the crankshaft. It is connected to the force
feed lubricating system of the engine and consequently maintenance-free. The governor
flange-mounted on the pump casing is a variable range governor designed to keep the
speed set by the speed control unit constant under conditions of varying load.

Governor system for fuel injection pump consists of Integral Actuator and Speed Control
Unit.

1) Integral Actuator

2) Speed control unit for governor system

The ESD5550 Series speed control unit is an all electronic device designed to control engine
speed with fast and precise response to transient load changes. This closed loop control, when
connected to a proportional electric actuator and supplied with a magnetic speed sensor signal,
will control a wide variety of engines in an isochronous or droop mode. It is designed for high
reliability and built ruggedly to withstand the engine environment.
Simplicity of installation and adjustment was foremost in the design. Non-interacting
performance controls allow near optimum response to be easily obtained.
The primary features of the ESD5550 Series speed control unit are the engine STARTING
FUEL and SPEED RAMPING adjustments. The use of these features will minimize engine
exhaust smoke experienced prior to attaining engine operating speed.
Other features include adjustable droop and idle operation, inputs for accessories used in multiengine or special applications, protection against reverse battery voltage, transient voltages,
accidental short circuit of the actuator and fail safe design in the event of loss of speed sensor
signal or battery supply.
Engine model

P126TI

GAC governor model

ACE 175A

Speed control unit model

ESD5550

- 17 -

6.00 (152)
5.25 (133)

O 0.27 (7)

C2
ON
SOFT COUPLING
OFF

C1 OFF
LEAD CIRCUIT
ON

OVERSPEED
OVERNORS
MERICA

GA

1 2 3

RESET TEST
OVERSPEED

ORP

SPEED CONTROL UNIT

SPEED

MODEL : ESD5550
S/N

GAIN
STABILITY

6.00 (152)

6.05 (165)

MADE IN AGAWAM, MA U.S.A

STARTING
FUEL

SPEED
RAMPING

CAUTION
PICK-UP

E3

DEAD TIME
COMPENSATION
JUMPER

DROOP

ENGINE SPEED CONTROL

COMPONENT WHEN INSTALLING
OR SERVICING REFER TO
PRODUCT PUBLICATION

ACTUATOR

E2
E1

_
+
BATTERY

IDLE
AUX

10V
OUTPUT

A B C D E F G H J K L M N P

OPTIONAL ACTUATOR
CABLE SHELDING TO
MEET CE DIRECIVE

ACCESSORY POWER
SUPPLY
ACCESSORY INPUT

ADD JUMPER FOR 12V

BATTERY OR ACTUATOR
CURRENTS ABOVE 5A
GROUND REFERENCE

ACTUATOR
CW

MAGNETIC
PICK-UP
_

BATTERY

1.03 (26)

CLOSE FORDROOP
SPED TRIM
CONTROL - 5K

S1

CLOSE FOR IDLE

FUSE
15A MAX

SPECIFIC ACTUATOR PUBLICATION FOR PROPER

* SEE
WIRING OF ACTUATOR BASED ON BATTERY VOLTAGE

EA6M4004

- 18 -

3.8.2. Fuel filter

This fuel filter has two functions not only oil
filtering but also water separating.

Before entering the suction chamber of the

injection pump, the fuel is cleaned in a

strainer of fuel feed pump and a fuel filter.

5
2

Drain water in cartridge with loosening the

cock under filter manually (6) from time to
time.
The fuel filter should be replaced at every

EA2O4009

1,200 hours.

3.8.3. Fuel requirements

DAEWOO marine diesel engines was designed to use Number 2-D diesel fuel or equivalent
that meets specification DIN 51601-DK. For maximum fuel economy, Number 2-D fuel
whenever possible. When temperatures are below -7C(20F), use Number 1-D fuel. If
Number 1-D fuel is not available, the mixture of one kerosene to two gallons of Number 2-D
fuel can be used. Once kerosene has been added, the engine should be run for several
minutes to mix the fuel.

3.8.4. How to select fuel oil

Fuel quality is an important factor in obtaining satisfactory engine performance, long engine
life, and acceptable exhaust emission levels. DAEWOO engines are designed to operate on
most diesel fuels marketed today. In general, fuels meeting the properties of ASTM
Designation D975 (grades 1-D and 2-D) have provided satisfactory performance.
The ASTM 975 specification, however, does not in itself adequately define the fuel
characteristics needed for assurance of fuel quality.
The properties listed in the fuel oil selection chart below have provided optimum engine
performance. Grade 2-D fuel is normally available for generator service. Grade 1-D fuel
should not be used in pleasure craft engines, except in an emergency.

- 19 -

Fuel oil selection chart

General Fuel

ASTM

No. 1

No. 2

Classification

Test

ASTM 1-D

ASTM 2-D

D 287

40 ~ 44

33 ~ 37

0.815 ~ 0.855

D 93

100 (38)

125 (52)

131 (55)

D 445

1.3 ~ 2.4

1.9 ~ 4.1

1.8 ~ 10

D 2500

See Note 1)

See Note 1)

See Note 1)

D 129

0.5

0.5

0.15

D 524

0.15

0.35

0.1

D 2274

1.5

1.5

Ash, wt%, Max.

D 482

0.01

0.01

Cetane Number, Min. +)

D 613

45

45

350(177)

375(191)

DIN 51601
Gravity,API

#)

Flash Point
Min. F (C)
Viscosity, Kinematic
CST 100 F (40 C )
Cloud Point F

#)

Sulfur Content
wt%, Max.
Carbon Residue
on 10%, wt%, Max.
Accelerated Stability
Total Insolubles
mg/100 ml, Max.

#)

Distillation

> 45

D 86

Temperature, F(C)
IMP, Typican

#)

10% Typical

#)

385(196)

430(221)

50% Typical

#)

45(218)

510(256)

90%

500 (260) Max. 625(329) Max.

+)

End Point

680(360)

#)

550(288) Max.

675(357) Max.

0.05

0.05

Water & Sediment

D 1796

0.05

%, Max.

#) Not specified In ASTM D 975

+) Differs from ASTM D 975
Note : 1.The cloud point should be 6C(10F) below the lowest expected fuel

temperature to prevent clogging of fuel fitters by crystals.

- 20 -

3.9. Cooling system

The engine has a liquid-cooling system. The fresh water pump is a maintenance-free by gear
from the crankshaft.
Depending on the agreed extent of delivery and the design of the engine, the coolant circuit
can be equipped with temperature monitors which, in the event of loss of coolant, shut the
engine down.

Check the coolant level of the expansion tank by removing the expansion tank filler cap, and
add coolant if necessary.

When injecting antifreeze solution, first drain out the old coolant from the cylinder block and
radiator, and then clean them with cleaning solution.

Be sure to mix soft water with antifreeze solution.

Water pipe
Thermostat

Reserve tank

R
a
d
i
a
t
o
r

Cylinder head

Cylinder block

Water pump

EJM4001I

- 21 -

3.9.1. Coolant pressure cap

Check the pressure valve opening pressure
using a expansion tank cap tester. Replace
the filler cap assembly if the measured valve
Rediater Cap

does not reach the specified limit. (pressure

valve opening pressure : 0.9 kg/cm2)

Note : Because it is dangerous to open

Rediater

the pressure cap quickly when

coolant is hot, after lowering the
inside pressure of the tank by
slow-opening at first open it fully.

EA5O3002

3.9.2. Anti-freeze
The anti-freeze, 50% of the whole coolant,
is always to be used to prevent the cooling system from the corrosion. And in winter the
amount of anti-freeze shown in the following table should be used in accordance with the
ambient temperature.
As the individual freezing points corresponding to the proportions of antifreeze in the table
are subject to change slightly according to the kind of antifreeze, you must follow the
specifications provided by the antifreeze manufacturer.

Ambient

Cooling water (%)

Anti-freeze (%)

Over -10

85

15

-10

80

20

-15

73

27

-20

67

33

-25

60

40

-30

56

44

-40

50

50

Temperature (C)

As the ratio of antifreeze in the mixture decrease each time new coolant is added to make up
for the loss coolant resulting from engine operation, Check the mix ratio with every
replenishment of coolant, and top up as necessary.

- 22 -

3.10. V-belt tension check and adjust

By the finger-pressure the belt is pressed by

here
Press hear

10mm ~ 15mm between the fan pulley and

15mm

the alternator pulley in normal condition. For

Fan
Pulley

Alternator
Pulley

the adjustment of the tension, loosen the

adjusting bolts which support the alternator,
adjust the tension and tighten the bolts

V-belt

again.

Crank Pulley

EA8O3005

3.11. Turbocharger
The exhaust gases of the engine are passed through the turbine rotor of the turbocharger. Air
compressor impeller mounted on the same shaft draws in fresh air and delivers it at a higher
pressure to the cylinders.
The turbocharger is naturally air-cooled. Lubrication of the main bearing is by oil under
pressure from the engine lubricating system.

5
A

C
EA6O3004

1. Compressor casing

A. Air inlet

2. Turbine casing

B. Gas outlet

3. Compressor wheel

C. Gas inlet

4. Impeller

D. Oil supply

5. Turbine

E. Oil return

- 23 -

3.12. Electrical equipment

3.12.1. Alternator
The alternator is fitted with integral silicon rectifiers. A transistorized regulator mounted on
the alternator body interior limits the alternator voltage. The alternator should not be
operated except with the regulator and battery connected in circuit to avoid damage to the
rectifier and regulator.

24V x 45A
P-TAB : KET GP 890545
TACHOMETER CHARGE INDICATOR
ALDO SYSTEM FREQUENCY = RPM

M6 x 1.0 THREAD
BATTERY TERMINAL

10

"L" Terminal
"R" Terminal

CONNECTOR HOUSING
KET MG 620042
TERMINAL
KET ST 740254

EA8O3006

The

alternator

is

maintenance-free,

nevertheless, it must be protected against

dust and, above all, against moisture and

To Battery +
Regulator

water.
RRLL = 150~250 OHM

Operate the alternator according to the

instructions given in the chapter.

EA8O3007

- 24 -

3.12.2. Starter motor

The sliding-gear starter motor is flanged to the rear of the flywheel housing on the left-hand
side. As parts of every engine overhaul, the starter pinion and ring gear should be cleaned
with a brush dipped in fuel and then a coat of grease should be applied again.

24V x 6.0kW

TERMINAL S/W
M5 x P0.8

TERMINAL "B"
M10 x P1.5

24V x 6.0kW

EA8O3008

Always protect starter motor against moisture.

Warning : Always

disconnect

the
S/W

battery earth cable before

starting work on the electrical
system. Connect up the earth
cable

last,

as

there

Motor
S/W

is

otherwise a risk of short-

S/W
KS

circuits.
2.5A(20oC 24V)
EA8O3009

- 25 -

4. Commissioning and operation

4.1. Preparation
At the time of initial commissioning of a new or overhauled engine make sure to have
observed the Technical Information for the installation DAEWOO generator engines.

Oil filler neck on cylinder head cover

Before daily starting of the engine, check the fuel, coolant and oil level, replenish if
necessary.
The notches in the dipstick indicate the highest and lowest permissible oil levels
The oil required in the sump is specified in the Engine Specification.

Note : The oil required to fill the oil fillers and pipes depends upon the engine and use and

must be determined individually at the time of initial commissioning. (Make the Max
and Min. marks of the determined quantity on the oil level gauge.)

Cleanliness
Ensure outmost cleanliness when handling fuels, lubricants and coolants.

4.2. Breaking-in
4.2.1. Operation of a new engine (Break-In)
Because the sliding surfaces of a new engine are not lapped enough, the oil film can be
destroyed easily by overload or overspeed and the engine life-time may be shortened.
Therefore the following things must be obeyed by all means.

Up to the first 2,000km (150 hours)

Engine

should be run at fast idling until the temperature of the engine becomes normal

operating condition.

Overload or continuous high speed operation should be avoided.

High speed operation with no load should be prevented.
Abrupt start and stop of the engine should be avoided.
Engine speed must be under 70% of its maximum speed.
Maintenance and inspection must be accomplished thoroughly.

- 26 -

4.2.2. Check points for break-in

During the break-in (the initial running of the engine) period, be particularly observant as
follows:
a) Check engine oil level frequently. Maintain oil level in the safe range, between the min.
and max. marks on dipstick.

Note : If you have a problem getting a good oil level reading on dipstick, rotate dipstick 180

and re-insert for check.

b) Watch the oil pressure warning lamp. If the lamp blinks, it may be the oil pick-up screen is
not covered with oil. Check oil dipstick. Add oil to the oil pan, if required. Do not overfill. If
level is correct and the status still exists, see your DEALER for possible switch or oil pump
and line malfunction.

Note : Oil pressure will rise as RPM increases, and fall as RPM decreases. In addition, cold

oil will generally show higher oil pressure for any specific RPM than hot oil. Both of
these conditions reflect normal engine operation.

c) Watch the engine water temperature gauge and be sure there is proper water circulation.
The water temperature gauge needle will fluctuate if water level in expansion tank is too
low.
At the end of the break-in period, remove break-in oil and replace the oil filter. Fill oil pan
with recommended engine oil. Refer to following table.
<Engine Oil capacity>
Oil pan (only)
DE12T

23 liter

P126TI

23 liter

4.2.3. Operating after break-in

When starting a cold engine, always allow the engine to warm up gradually. Never run the
engine at full throttle until the engine is thoroughly warmed up. Be sure to check the oil level
frequently during the first 50 hours of operation, since the oil consumption will be high until
the piston rings are properly seated.

- 27 -

4.3. Inspections after starting

During operation the oil pressure in the engine lubrication system must be monitored. If the
monitoring devices register a drop in the lube oil pressure, switch off the engine immediately.
And the charge warning lamp of the alternator should go out when the engine is running.

Do not disconnect the battery or pole terminals or the cables!

If, during operation, the battery charge lamp suddenly lights up, stop the engine immediately
and remedy the fault in the electrical system!

Engine should be stopped if the color, the noise or the odor of exhaust gas is not normal.
Confirm the following things through warning lamps and gauge panel.
4.3.1. Pressure of lubricating oil
The normal pressure comes up to 1 kg/cm2 (1.0 bar) at idling and 3 ~ 5 kg/cm2 (3.0 ~ 4.9
bar) at maximum speed. If the pressure fluctuates at idling or does not reach up to the
expected level at high speed, shut down the engine immediately and check the oil level and
the oil line leakage.

4.3.2. Temperature of cooling water

The cooling water temperature should be 78 ~ 85C in normal operating conditions.
Abnormally high cooling water temperature could cause the overheating of engine and the
sticking of cylinder components. And excessively low cooling water temperature increases
the fuel consumption, accelerates the wears of cylinder liners and shortens the engine lifetime.

4.4. Operation in winter time

Pay special attention to the freezing of cooling water and the viscosity of lubricating oil.

4.4.1. Prevention against the freeze of cooling water

When not using anti-freeze, completely discharge the whole cooling water after engine
running. The freeze of cooling water causes the fatal damages of the engine. Because the
anti-freeze is used to prevent cooling water from freeze, consult The amount of anti-freeze.

4.4.2. Prevention against excessive cooling

Drop of thermal efficiency caused by excessive cooling increases fuel consumption, therefore
prevent the engine from excessive cooling. If the temperature of coolant does not reach to
normal condition (78 ~ 85C) after continuous operation, examine the thermostat or the other
cooling lines.

4.4.3. Lubricating oil

As cold weather leads to the rise of oil viscosity, engine speed becomes unstable after
starting. Therefore the lubricating oil for winter should be used to prevent this unstability.
Refer to Lubricating System section.

- 28 -

4.5. Tuning the engine

The purpose of an engine tune-up is to restore power and performance thats been lost
through wear, corrosion or deterioration of one or more parts or components. In the normal
operation of an engine, these changes can take place gradually at a number of points, so that
its seldom advisable to attempt an improvement in performance by correction of one or two
items only. Time will be saved and more lasting results will be obtained by following a definite
and thorough procedure of analysis and correction of all items affecting power and
performance.
Economical, trouble-free operation can better be ensured if a complete tune-up is performed
once every years, preferably in the spring. Components that affect power and performance to
be checked are:

Components affecting fuel injection ;

Nozzle, delivery valve, fuel filter, water separator, etc.

Components affecting Intake & exhaust ;

Air filter, inter-cooler, turbo, silencer, etc.

Components affecting lubrication & cooling ;

Air & oil filter, anti- freeze, etc.

- 29 -

5. Maintenance and care

5.1. Periodical inspection and maintenance
In order to insure maximum, trouble-free engine performance at all times, regular inspection,
adjustment and maintenance are vital.

Daily inspections in below figure should be checked every day.

The maintenance should be executed thoroughly at regular internals.
(refer to appendix General Engine Inspection Cycle.)

5.2. Lubrication system

5.2.1. Exchanging of lubrication oil
Engine oil and the oil filter are important factors affecting engine life. They affect ease of
starting, fuel economy, combustion chamber deposits and engine wear. Refill and drain oil
pan every 50 hours of operation or 6 months whichever occurs first. At the end of the breakin period (50 hours), change the oil sump oil and replace the oil filter.

5.2.2. Oil level

Check the oil level in the engine sump daily
with a dipstick.

The notches in dipstick must indicate the

oil level between the max. and the min.
permissible.

The

oil level should be checked with the

engine horizontal and only after it has

been shut down for about 5 minutes.

Examining

the

viscosity

and

the

EA4O4001

contamination of the oil smeared at the

dipstick

replace

the

engine

oil

if

necessary.

Caution : Do not add so much engine oil that the oil level rises above the max. marking on

the dipstick. Over lifting will result in damage to the engine.

- 30 -

5.2.3. Oil exchange procedure

While the oil is still hot, exchange oil as
follows:

Take out the oil dip dipstick.

Remove the drain valve from oil pan and
the drain plug form oil filter head, then
drain out the engine oil into a container.

Drain Plug
EA8O5001

Reassemble

the drain valve with the oil

pan and the drain plug with oil filter head

after draining out the engine oil.

EA2O4001
EA2O4001

Refill

with new engine oil at the oil filler

neck on the head cover and the lubricating

oil in accordance with the oil capacity of
the engine through oil filler. Be careful
about the mixing of dust or contaminator
during the supplement of oil. Then confirm
that oil level gauge indicates the vicinity of
its maximum level.

For a few minutes, operate the engine at

EA7O5003

idling in order to circulate oil through

lubrication system.

Thereafter shut down the engine. After waiting for about 10 minutes measure the quantity of
oil and refill the additional oil if necessary.

- 31 -

5.2.4. Replacement of oil filter cartridge

At the same times of oil exchanges, replace
the oil filter cartridge.

Drain

engine oil by loosening the drain

plug on the filter head.

Cartridge

Caution : Dont forget tightening the

drain

plug

after

having

drained engine oil.

Loosen

the oil filter by turning it counter-

clockwise with a filter wrench.

With a rag wipe clean the fitting face of the

filter body and the oil filter body so that
new oil filter cartridge can be seated
Drain plug

properly.

EA7O5004

Lightly oil the O-ring and turn the oil filter

until sealing face is fitted against the O-ring. Turn 1-1/4 turns further with the filter wrench.

Note : It is strongly advisable to use DAEWOO genuine oil filter cartridge for replacement.

5.3. Cooling system

The coolant must be changed at intervals of 1,200 hours operation or six months whichever
comes first. If the coolant is being fouled greatly, it will lead an engine overheat or coolant blow
off from the expansion tank.

5.3.1. Coolant draining

a) Remove the pressure cap.
b) Open the drain valve at the radiator lower
part to drain the coolant as the right figure.

Drain Valve
EA5O4002

- 32 -

c) Loosen the coolant drain plug.

Loosen the coolant drain plug of the cylinder
block.

EAMD001I

Caution : When removing the pressure filler cap while the engine is still hot, cover the cap

with a rag, then turn it slowly to release the internal steam pressure This will
prevent a person from scalding with hot steam spouted out from the filler port.

5.3.2. Cleaning of the cooling inside system circuit (by authorized specialist personnel)
When the cooling system circuit are fouled with water scales or sludge particles, the cooling
efficiency will be lowered.
Investigations have shown that in many cases the poor condition of the coolant and /or the
cooling system accounts for damage to the water pump mechanical seal, The poor condition of
the cooling system is normally due to use of unsuitable or no anti-freezing agents and corrosion
inhibitor or defect, not early enough replaced covers for filler neck and working valves.
If twice in a short time the water pump of an engine develops leases or the coolant is heavily
contaminated (dull, brown, mechanically contaminated, grey or black sings of a leakage on
the water pump casing) clean the cooling system prior to removing that water pump as
follows.
a) Drain coolant.
b) Remove thermostats, so that the whole cooling system is immediately flown through when
cleaned.
c) Fill the cooling system with a mixture of potable water and 1.5% by volume of cleaner.
(Henkel P3T5175)
d) Warm up engine under load. After a temperature of 60C is reached, run engine for a
further 15 minutes.
e) Drain cleaning fluid.
f) Repeat steps c) and d).
g) Flush cooling system.
h) Replace drain plug by drain plug with a bore of 8mm diameter.
i) Fill cooling system with hot water.
j) Run engine at idle for 30 minutes. At the same time continuously replenish the water
leaking from the bore in drain plug by adding fresh water.

Periodically clean the circuit interior with a cleaner.

- Cooling system cleaning interval: Every 1,200 hours.

- 33 -

5.3.3. Intercooler
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.

Air/air intercooler
with downstream
radiator
(Combined radiator)

Cooling air
Hot charge air
from compressor
Recooled charge air
to intake pipe (max. 50 C)
EA5O4003

Cleaning
In order to maintain the heat transfer efficiency of the intercooler, it is necessary to clean it
at regular intervals.

Cleaning of intercooler fins : Every 600 hours.

- 34 -

5.4. Air intake system

1. Connection port, fouling indicator

2. Cleaner housing

5 6

3. Clamp
4. Element
5. Hexagon nut
6. Cover
7. Dust bowl

EA6O5012

5.4.1. Maintenance (only when engine is switched off)

Empty the dust bowl (7) regularly. The bowl should never be filled more than halfway with
dust.
On slipping off the two clamps (3), the dust bowl can be removed. Take off the cover (6) of
the dust bowl and empty.
Be careful to assemble cover and bowl correctly.
There is a recess in the cover rim and a lug on the collector which should register. Where the
filter is installed horizontally, watch for top mark on cleaner bowl.

5.4.2. Changing filter element

Caution : Do not allow dirt to get into the

clean air end.

On removing the hexagon nut, take out the
dirty cartridge and renew or clean.
Wipe the cleaner housing with a damp
cloth, in particular the sealing surface for
the element.
EA6O5013

Notice : Unless the maximum number of

cleanings (up to 5 x) have been

done, the filter cartridge should
be renewed every two years or
4,000 hours operation.

- 35 -

5.4.3. Cleaning filter elements

By compressed air (Wear goggles)

For the purpose, the air gun should be
fitted with a nozzle extension which is bent
90 at the discharge end and which is long
enough to reach down inside to the bottom
of the element.
Moving the air gun up and down, blow out
the element from the inside (maximum
500kPa - 5 bar) until no more dust comes

EA6O5014

out of the filter pleats.

By washing
Before washing, the element should be
precleaned by means of compressed air,
as described above.
Then

allow

the

element

to

soak

in

lukewarm washing solvent for 10 minutes,

and then move it to and for in the solvent
for about 5 minutes.
Rinse thoroughly in clean water, shake out

EA6O5015

and allow drying at room temperature. The

cartridge must be dry before it is reinstalled.
Never use steam sprayers, petrol (gasoline), alkalis or hot liquids etc. to clean the filter elements.

Knocking out dirt by hand

In emergencies, when no compressed air or cleaning agent is available, it is possible to
clean the filter cartridge provisionally by hitting the end disk of the cartridge with the ball of
ones thumb.
Under no circumstances should the element be hit with a hard object or knocked against a
hard surface to loosen dirt deposits.

Checking the filter cartridge

Before reinstalling the cartridge, it must be
checked for damage e.g. to the paper
pleats and rubber gaskets, or for bulges
and dents etc. in the metal jacket.
Cracks and holes in the paper pleating can
be established by inspecting the cartridge
with a flashlight.
Damaged cartridges should not be reused
under any circumstances. In cases of doubt,
discard the cartridge and install a new one.

- 36 -

EA6O5016

5.5. Fuel system

5.5.1. Fuel filter

After every 1,200 hour of operation, drain

the water and sediment from the fuel-

water separator.

Shut

off the engine. Use your hand to

open the drain valve

Turn

the

valve

6 .
counter

clockwise

3
4

5
2

approximately 2 ~ 3 turns until draining

occurs. Drain the filter sump of water until
close fuel is visible.

EA2O4009

Turn the valve clockwise to close the drain

valve. Do not over tighten the valve,
overtightening can damage the threads.

5.5.2. Replacement of fuel filter

Clean the area around the fuel filter head

3 .

Remove

the fuel filter

by turning it

counter-clockwise with filter wrench.

(Discard the used filter.)

Remove the fuel filter thread adapter seal

ring

Use

4 .
a clean lint free cloth to clean the

gasket surface of the fuel filter head

Install
4

3 .

EA7O5008

the new thread adapter seal ring

supplied with the new filter.

Use clean oil to lubricate the filter seal 5 , and fill the new filter with clean fuel.
Install the filter on the filter head 3 .
Tighten the filter until the gasket contacts the filter head surface.
Tighten the filter on additional one-half to three-fourths of a turn with the filter wrench, on as
specified by the filter manufacturer.

Notice : Mechanical over tightening of the filter can distort the thread or damage the filter

element seal.

- 37 -

5.5.3. Fuel system checks

Fill the tank with the recommended fuel. Keeping tanks full reduces water condensation and
helps keep fuel cool, which is important to engine performance.
Make sure fuel supply valves (if used) are open.
To insure prompt starting and even running, the fuel system must be primed with the fuel
feed pump manually before starting the engine the first time, or after a fuel filter change.
Refill at the end of each days operation to prevent condensation from contaminating the fuel.
Condensation formed in a partially filled tank promotes the growth of microbial organisms
that can clog fuel filters and restrict fuel flow.
If the engine is equipped with a fuel water separator, drain off any water that has
accumulated. Water in fuel can seriously affect engine performance and may cause engine
damage. DAEWOO recommends installation of a fuel water separator on generator
units.

5.5.4. Fuel Contamination and water trap

In the generator environment, the most likely fuel contaminants are water and microbial
growth (black slime). Generally, this type of contamination is the result of poor fuel handling
practices.
Black slime requires water in the fuel to form and grow, so the best prevention is to keep
water content to a minimum in storage tanks.
If diesel fuel which contains moisture is used the injection system and the cylinder liners /
pistons will be damaged. This can be prevented to same extent by filling the tank as soon as
the engine is switched off while the fuel tank is still warm (formation of condensation is
prevented). Drain moisture from storage tanks regularly. Installation of a water trap upstream
of the fuel filter is also advisable.

Notice : A galvanized steel tank should never be used for fuel storage, because the fuel oil

reacts chemically with the zinc coating to form powdery flakes which can quickly
clog the fuel filters and damage the fuel pump and injection nozzles.

5.5.5. Priming pump strainer cleaning

Clean the priming pump strainer every 200
operation hours.
The strainer is incorporated in the priming
pump inlet side joint bolt.
Clean the strainer with the compressed air
Strainer(Inner)

and rinse it in the fuel oil.

EA7O5009

- 38 -

5.5.6. Bleeding the fuel system

After the cleaning of the fuel filter or after the
engine stop by the lack of fuel, the bleeding
of the fuel system must be executed by all
means.
Bleed the system by manually operating the
priming pump with fuel filter outlet joint bolt
and injection pump bleeder screw loosened.

Priming pump

Press the feed pump cap repetitively until

the fuel without bubbles comes out from

EA9O4005

the bleeding valves.

After the whole air is pulled out, close the

valve of the filter.

Confirm

the resistance of fuel delivery by the repetition pressing of the feed pump cap,

Pressure and turn the feed pump cap simultaneously to close it.

5.5.7. Injection pump

Check the fuel injection pump housing for cracks or breaks, and replace if damaged.
Check and see if the lead seal for idling control and speed control levers have not

been

removed.

No alterations must be made to the injection pump. If the lead seal is damaged the warranty
on the engine will become null and void.

We strongly recommended that any faults developing in the injection pump should be taken
care of by authorized specialist personnel.

5.6. Injection Nozzle Maintenance (by authorized specialist personnel)

The injectors are designed to spray the fuel
delivered by the injection pump directly into
the spherical combustion chamber in the
piston crown.
The injector consists of the nozzle and the
nozzle holder.
A copper seal fitted to the injector ensures
gas-tight seating and good heat dissipation.
The opening pressure of the nozzle is
adjusted

by

means

of

shims

at

the

compression spring.

- 39 -

EA0M3003

Normal

Abnormal

Abnormal

EFM1006I

Install a nozzle to a nozzle tester.

Check injection pressure, and adjust the nozzle using the adjusting shim if the pressure does
not meet the specified limit.

Check nozzle spray patterns and replace if damaged.

DE12T
Injection Nozzle pressure

220kg/cm2

P126TI
1st : 160kg/cm2
2nd : 220kg/cm2

Caution : The injection lines are designed for high operating pressures and should thus be

handled with particular care.

When mounting the pipes to the engine take care of good fitness.
Do not bend pipes to permanent deformation (not for replacing the nozzles either).
Do not mount any heavily bent pipes.
Avoid bending the pipes at the ends by more than 2 to 3 degrees.
In case of faults in the injection system which might have resulted in excessive operating
pressures, not only the failed part but also the injection line has to be replaced.

5.7. Turbocharger
5.7.1. Maintenance (by authorized specialist personnel)
The turbochargers do not call for any specific maintenance.
The only points to be observed are the oil pipes which should be checked at every oil
change for leakage and restrictions.
The air cleaners should be carefully serviced.
Furthermore, a regular check should be kept on charge air exhaust gas pipes. Any leakages
should be attended to at once because they are liable to cause overheating of the engine.
When operating in highly dust or oil-laden atmospheres, cleaning of the air impeller may be
necessary from time to time. To this end, remove compressor casing (Caution : Do not
skew it!) and clean in a non-acid solvent, if necessary using a plastic scraper.
If the air compressor should be badly fouled, it is recommended that the wheel be allowed to

- 40 -

soak in a vessel with solvent and to clean it then with a stiff brush. In doing so, take care to
see that only the compressor wheel is immersed and that the turbocharger is supported on
the bearing casing and not on the wheel.

5.7.2. Special hints

It is recommended that the radial and axial
clearances of the rotor be checked after

Magnetic vise

Turbine wheel chamber

every 3,000 hours operation.

This precaution will enable any wear of the
Measuring of axial clearance bearings to be
detected in good time before serious

Move the turbine

shaft to axial
direction

damage is caused to the rotor and bearings.

Dial gauge

Wear limit : 0.20mm

Measuring rotor axial clearance

Axial clearance

EA4M2017

0.2 mm

Measuring radial clearance

Radial clearance

0.65 mm

Dial gauge
Magnetic vise
Oil
Outlet

Move the turbine shaft

in both directions
simultaneously

Radial play
Limit of wear : 0.57mm

Oil inlet

EA4M2018

- 41 -

6. Checking and setting

6.1. Adjustment of valve clearance
6.1.1. General information
The valve clearances are to be adjusted at the times of the following situations.

After initial 50 hours operation.

When the engine is overhauled and the cylinder heads are disassembled.
When severe noise comes from valve train.
When the engine is not normally operated, even though there is no trouble in the fuel system.
The valve clearance of the cold engine are as follows.
- Intake valves

: 0.3mm

- Exhaust valves : 0.3mm

6.1.2. Adjusting order of the valve clearance

1) After letting the #1 cylinders piston come at the compression top dead center by turning
the crankshaft, adjust the valve clearances.
2) 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.
3) As for the valve clearance, adjust it when in cold, as follow.
Model

Intake Valve

Exhaust Valve

0.3 mm

0.3 mm

DE12T
P126TI
- By cranking the engine, let #6 cylinders valves overlap.
- In time, adjust the valve clearance corresponding to
- Adjust the valve clearance corresponding to

of lower lists.

of lower lists.

- After reinsuring the valve clearances, retighten if necessary.

4) No. 1 Cylinder is located at the side where flywheel was installed.

- 42 -

Flywheel

Intake Valve

Exhaust Valve

Cooling
Cylinder Fan
Fan

Cylinder No.

EA8O6001

6.1.3 Method of adjusting the valve clearance

1

1) Loosen the lock-nuts

using a ring

spanner.
4

2) Insert a thickness gauge of 0.3mm

between valve stem

and rocker arm

1

3 .
3) Turn the adjusting bolts

using a screw

driver until the gauge can be pulled out

with some restriction.
4) After the adjustment fix the adjusting bolt
not to rotate and tighten the lock-nut at the
same time.
5) Measure the clearance one more time
and if necessary adjust again.

- 43 -

3
2

EA0O4014

6.2. Adjustment of injection timing

6.2.1. Method of adjusting injection timing

Turn

the flywheel until No. 1 piston is

placed in the OT position of notch marks

on the flywheel, and then turn again the

Timing
Check hole

flywheel clockwise until showing the notch

mark of the right figure corresponding to
the injection timing is aligned with the
pointer ( ) on the flywheel housing.

Fuel injection timing

(B.T.D.C static)

DE12T

P126TI

12

12

Injection timing
notch mark

Flywheel
ring gear

EA8O6002

Turn the timer until the notch mark of the

indicator plate attached to the fuel injection
pump is aligned with the notch mark of the

Notch
mark

timer.

EA9O5002

- 44 -

 Tighten the coupling fixing bolts and nuts

to specified torque.
6.0 kgm

Torque

EAMD021I

Tighten the drive shaft connecting flange fixing bolts to specified torque.
Torque

7.5 ~ 8.5 kgm

Install the oil delivery pipe and return pipe.

6.3. Tightening the cylinder head bolts

The cylinder head bolts are to be tightened

in the sequence shown in the illustrations,
First tighten the bolts slightly, then slightly
more again and finally tighten with a torque
wrench.

<Cylinder Head Bolts>

Specification

EAMD102I

Type 1

Type 2

TY
12.9T

TY
10.9T

M14x1.5x153

M14x1.5x150

24.5 kg.m

6 kg.m +180+150

8
Torque

12

13
1

11

14
7

10
EAMD103I

The tightening by excessive torque may cause the damages of the cylinder head gaskets, the
flanges of cylinder liners and the cylinder head bolts, therefore obey the regular torque.

- 45 -

6.4. Cylinder compression pressure

1) Stop the engine after warming it up, then
remove the nozzle assemblies.

EA9O5003

2) Install a special tool (gauge adapter) in

nozzle holder hole and connect the
compression

pressure

gauge

to

the

adapter.

3) Cut off fuel circulation, rotate the starter,

then measure compression pressure of
each cylinder.
EA9O5004

Standard

24~28 kg/cm2

Limit

24 kg/cm2 or less

Allowance among cylinders

L10% or less

- Testing conditions : at water temperature of 20 C and speed of 200 rpm (10 turns)

- 46 -

6.5. V-belts
The tension of the V-belts should be checked after every 2,000 hours of operation.
(1) Change the V-belts if necessary
If in the case of a multiple belt drive, wear or differing tensions are found, always replace the
complete set of belts.
(2) Checking condition
Check V-belts for cracks, oil, overheating and wear.
(3) Testing by hand

Press here

The tension is correct if the V-belts can be

15mm

pressed in by about the thickness of the Vbelt. (no more midway between the belt

Fan
Pulley

Alternator
Pulley

pulleys)
A more precise check of the V-belt tension is
possible only by using a V-belt tension tester.

V-belt

Crank Pulley

EA8O3005

(4) Measuring tension

1

Lower indicator arm (1) into the scale.

Apply

tester to belt at a point midway

between two pulleys so that edge of

contact surface (2) is flush with the Vbelt.

Slowly depress pad (3) until the spring

can be heard to disengage. This will
cause the indicator to move upwards.
If pressure is maintained after the spring

EA6O6011

has disengaged a false reading will be

obtained!
2

Reading of tension

Read of the tensioning force of the belt

at the point where the top surface of

the indicator arm (1) intersects with the
scale.

Before

taking readings make ensure

that the indicator arm remains in its

position.

EA6O6012

- 47 -

Tensioning forces on the tester

Type

new installation

Drive belt width

When servicing after

long running time

Installation

After 10 min.
running time

9.5 mm

50 kg

45 kg

40 kg

11.8 mm

55 kg

50 kg

45 kg

15.5 mm

75 kg

70 kg

60 kg

20.2 mm

75 kg

70 kg

60 kg

M
A

* : Adopted in DE12T and P126TI

(5) Tensioning and changing V-belt

Remove fixing bolts. (1)

Remove lock nut. (2)
Adjust nut (3) until V-belts have correct
tensions.

(2)

Retighten lock nut and fixing bolts.

(3)
(1)

To change the V-belts loosen mounting

bolts (1) and lock nut (2) and push
tension

pulley

inwards

by

turning

adjusting nut (3).

EA8O6004

- 48 -

 Appendix
1. General engine inspection cycle
: Check & adjust
Inspection

Daily

: Replace

Every

Every

Every Every Every

50hrs

200hrs

600hrs

800hrs 1200hrs

Remark

Check for leakage(hoses, clamp)

Check the water level
Cooling

Change the coolant water

System

Every
2,000hrs

Adjust the V-belt tension

Clean the radiator
Check for leakage
Check the oil level gauge
Lubrication
System

Change the lubricating oil

1st

Replace the oil filter cartridge

1st

Check the leakage for intercooler

(hoses, clamp)
Intake &

Clean and change

Exhaust

the air cleaner element

System

Clean the inter-cooler air fins

clean
Every
2,000hrs

Clean the turbo-charger

Check the leakage fuel line
Clean the fuel strainer
of fuel feed pump
Remove sediment from fuel tank
Fuel
System

Drain the water in separator

Replace the fuel filter element
Check fuel Injection timing

When
necessary

Check the injection nozzles

When
necessary

Check the state of exhaust gas

Check the battery charging
Engine
Adjust

When
necessary

Check the compression pressure

Adjust Intake/Exhaust
valve clearance

1st

- 49 -

When
necessary

2. Diagnosis and remedy

1. Engine Starting Impossible

Starting motor operation poor

Starting motor revolution

Inspection of battery electorlytic

Ilquid amount & gravity
Normal

Too low

Fuel

Inspect air cleaner

Inspect amount of fuel

Normal

Ajustment
Recharging
Inspection of loose electric
wring & short

Normal

Engine

Retigten
Replace

Polluted
Replace or
clean element

Check compression
pressure

Repair
Replace

Inspection of starting switch

Inspect of
other parts

Repair
Replace

Check valve
clearance

Inspection of starting relay

Normal

Replace
Normal

Adjust

Inspection of magentic switch

Normal

Check cylinder
head gasket

Repair
Replace

Replace

Inspect fuel
injection

No injection

Normal
Continuous
operation after
air removal

Inspect
injection
timing
Normal

Adjust

Inspect injection
nozzle (injection
pressure injection
state etc.)
Normal

Normal
Starting motor
disassembly

None
Replenish

Too low
Normal

Normal

Normal

Engine disassembly
(valve assembly piston
cylinder liner etc.)

Repair
Replace

Injection pump
disassembly

Inspect supply pump operation

Normal
Injection pump
dasassembly

Inspect supply pump valve strainer

Clean
replace

Air mixture in fuel

Normal

Retighten connection
parts. Replace gasket

Inspect fuel filter

Air removal

Element polluted
Overflow valve poor

Continuous air mixing

Replace

- 50 -

Supply pump
disassembly

2. Engine Overheated
Operating state
1. Overload
2. Radiator core clogged
3. Continuous over-run

Fuel unit

Cooling unit
Check coolant

Inspect fuel quality

Normal

Fuel excessive supply

Too low
Poor

Check fan belt

tension wear
or damage etc.

Repair
Replace

Replenish
Normal
Check fresh
water tank cap

Replace

Exteranl

Internal
Engine
disassembly

Normal

Abnormal

Adjust
repair
injection
pump

Repair
Replace

Replace

Normal

Inspect heat
exchanger

Check injection nozzle

Inspect cooling
water leakage

Retighten
Replace

Normal

Check thermostat

Clean and replace

with specilied fuel

Damage

Normal

Check cooling
water pump

Clean cooling
water passage

Normal

Repair
Replace
Repair
Replace

Engine
disassembly

- 51 -

3. Output Insufficient

Engine

Installation improper

Fuel unit

Check for coupling

alignemnt

Others

Check for air mixing

in fuel

Inspect air cleaner

Inspect fuel supply pump

Normal

Normal

Inspect engine control

rod, link, cable, etc.

Clean Replace

Adjust or replace
coupling

Clean Relpace
Inspect air leakage
of air piping line

Inspect fuel filter over folw valve

Adjust

Normal
Normal

Normal

Retighten
Replace

Replace
Check valve clearance

Inspect injection pipe

Adjust

Normal
Normal

Repair Replace

Inspect injection nozzle

injection pressure
atomizing state
Normal

Adjust Replace

Inspect cylinder head

gasket for damage
Replace

Normal

Engine disassembly
(valve assembly)

Check injection timing

Normal

Adjustment

Disassemble engine or
injection pump

Check Turbocharger
Normal

Repair
Replace

Disassemble injection
pump or engine

- 52 -

Inspect air leakage

of Intercooler

4. Oil pressure lowered

Check if oil pressure
gauge indicates wrongly
Check oil amount

Too low

Normal

Use recommended oil

(replenish)

Check cooling
temperature
Too high

Normal

Refer to engine overhea

Inspect oil quality

Normal

Check oil relief

valve

Normal

Retighten
Replace

Water & fuel mixed

in oil
Disassemble engine
or injection pump

Disassemble
engine

- 53 -

Improper

Replace with
recommended oil

5. Fuel Consumption Excessive

Inspect fuel leakage

Causes according to Use Conditions

1. Overload
2. Govemor's Arbitrary Adjustment
3. Full Speed Operation for Long time
4. Sudden Speed Change from Low to
High Speed

Normal
Inspect injection nozzle
(injection pressure
atomizing state etc.)

Oil leakage
Adjust Replace
Retighten Replace

Normal
Check injection timing

Adjust

Normal
Inspect compressed
pressure

Check valve
clearance

Normal
Disassemble
injection pump

Adjust

Normal

Inspect head gasket

Replace

Normal

Disassemble engine
(valve assembly piston
cylinder liner etc.)

- 54 -

Repair Replace
Cylinder liner
Piston ring Piston

6. Oil Consumption Excessive

Cause according to use conditions
1. Excessive oil infusing
2. Continuous operation in low or
extremely cold state

Inspect oil leakage

Inspect air cleaner
Normal

Oil leakage

Check oil quality

External
Retighten
Replace

Replace with
specified oil

Engine disassembly
(piston cylinder liner)

Clean Replace
Internal
Check compressed
pressure

Normal

Disassemble
cylinderhead
(valve stem seal)

7. Engine Knocking
Inspect combustion of fuel & oil
(carbon residue exhaust gas)

Confirm

Unconfirmed
Inspect compressed
pressure

Disassemble
engine
Too low

Normal
Check valve clearance and
cylinderhead gasket for damage

Inspect injection
pump
Normal
Check fuel quality

Adjust

Replace
Adjust

Normal

Disassemble
engine

Use specified fuel

- 55 -

8. Battery Discharge

Battery

Wiring Switch

Check electrolytic
liquid amount

Inspect cut wire

shorts and loose
connections

Generator
Check fan belt
tension & damage

Repair Replace

Normal
Electrolytic
liquid's
standard
Replenish

Battery room
damage

Battery self
discharge

Battery over
charging

Replace

Charging

Inspect generator
Voltage regulator

Normal

Abnormal

Check charged stated

Adjust
Replace

Discharging

Disassemble
generator Voltage
regulator

- 56 -

Condition
1) Starting difficult
(1) Compression pressure

2) Idle operation abnormal

3) Engine output insufficient

(1) Continuous output
insufficient

Causes

Remedies

Valves poor shut, stem distortion

Repair or replace

Valve spring damage

Replace valve spring

Cylinder head gaskets leak

Replace gasket

Wear of piston, piston ring or liner

Adjust

Injection timing incorrect

Adjust

Air mixing at injection pump

Remove air

Valve clearance incorrect

Adjust

Valve tightness poor

Repair

Cylinder head gaskets leak

Replace gasket

Wear, stick, damage of piston ring

Replace piston ring

Injection timing incorrect

Adjust

Fuel injection amount insufficient

Adjust injection pump

Nozzle injection pressure

Adjust or replace

improper or stuck

Supply pumps function lowered

Repair or replace

Fuel pipe system clogged

Repair

Air suction amount insufficient

Clean or replace air

cleaner

(2) Output insufficient

Supercharger poor

Repair or replace

Compression pressure

Disassemble engine

when in acceleration

insufficient

Injection timing incorrect

Adjust

Fuel injection amount insufficient

Adjust injection pump

Injection pump timers function

Repair or replace

insufficient

Nozzle infection pressure, infection

Repair, replace

angle improper

Supply pumps function lowered

Repair or replace

Air intake amount insufficient

Clean or replace air

cleaner
4) Overheating

Engine oil insufficient or poor

Replenish or replace

Cooling water insufficient

Replenish or replace

Fan belt loosened, worn, damaged

Adjust or replace

Cooling water pumps function lowered

Repair or replace

Water temp. regulators operation poor

Replace

Valve clearance incorrect

Adjust

Exhaust systems resistance increased

Clean or replace

- 57 -

Condition
5) Engine noisy

Cause

Remedies

For noises arise compositely such asrota

ting parts, lapping parts etc., there is nec
essity to search the cause of noises accu
rately.

(1) Crankshaft

As the wear of bearing or crankshaft

Replace bearing &

progress, the oil clearances increase.

grind crankshaft

Lopsided wear of crankshaft

Grind or replace

Oil supply insufficient due to oil

Clean oil passage

passage clogging

Stuck bearing

Replace bearing &

Grind

(2) Con rod and

Con rod bearing

Lopsided wear of con rod bearing

Replace bearing

Lopsided wear of crank pin

Grind crankshaft

Connecting rod distortion

Repair or replace

Stuck bearing

Replace &
grind crankshaft

Oil supply insufficiency as clogging

Clean oil passage

at oil passage progresses

(3) Piston, piston pin &
piston ring

(4) Others

Piston clearance increase as the wear

Replace piston &

of piston and piston ring progresses

piston ring

Wear of piston or piston pin

Replace

Piston stuck

Replace piston

Piston insertion poor

Replace piston

Piston ring damaged

Replace piston

Wear of crankshaft, thrust bearing

Replace thrust

bearing

Camshaft end play increased

Replace thrust plate

Idle gear end play increased

Replace thrust
washer

Timing gear backlash excessive

Repair or replace

Valve clearance excessive

Adjust valve
clearance

6) Fuel Consumption
Exttive

Abnormal wear of tappet, cam

Replace tappet, cam

Supercharger inner part damaged

Repair or replace

Injection timing incorrect

Adjust

Fuel injection amount excessive

Adjust injection
pump

- 58 -

Condition

Cause

Remedies

7) Oil Consumption
Excessive
(1) Oil level elevated

Clearance between cylinder iner &

Replace

piston

Wear of piston ring, ring groove

Replace piston,
piston ring

Piston rings damage, stick, wear

Replace piston ring

Piston ring openings disposition

Correct position

improper

Piston skirt part damaged or

Replace piston

abnormal wear

(2) Oil level lowered

(3) Oil leak

Oil rings oil return hole clogged

Replace piston ring

Oil rings contact poor

Replace piston ring

Looseness of valve stem & guide

Replace in set

Wear of valve stem seal

Replace seal

Cylinder head gaskets leak

Replace gasket

Looseness of connection parts

Replace gasket,
repair

Various parts packing poor

Replace packing

Oil seal poor

Replace oil seal

- 59 -

DAEWOO HEAVY INDUSTRIES &

MACHINERY LTD. AROUND THE WORLD

CARDIFF
(U.K.)

FRAMERIES
(Belgium)

DUSSELDORF
(Germany)

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(France)

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(China)

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(U.S.A)

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(China)
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(Japan)
(China)

CLEVELAND
(U.S.A)
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(U.S.A)

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(U.S.A)

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(Taiwan R.O.C)
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(Colombia)
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(Brazil)
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(South Africa)

SYDNEY
(Australia)

Head Office

Daewoo Heavy Industries America Cleveland Office

Hwasu-Dong 7-11, Dong-Gu, Incheon, Korea.

Tel : 82-32-760-1114 Fax : 82-32-762-1546

4530 Renaissance Parkway, Warrensville Heights, OH 44128,

U.S.A
Tel : 1-216-595-1212 Fax : 1-216-595-1214

Seoul Office
8th floor Daewoo Heavy Industries & Machinery Bidg, 14-34,
Youido-Dong, Youngdungpo-Gu, Seoul, Korea
Tel : 82-2-2167-3114 Fax : 82-2-785-2677

Daewoo Rep. C/O Boeing Co.

ASIA & OCEANIA

EUROPE

Daewoo Heavy Industries Australia Pty. Ltd

Euro Daewoo U,K Ltd

Suite 5, Level 4,20 Charles St., Parramatta NSW 2150, Australia

Tel : 61-2-9633-4544 Fax : 61-2-9633-5266

Daewoo Machinery Co., Ltd

P.O.Box 3707 M/S 39-AH, Seattle, WA 98124-2207, U.S.A

Tel : 1-425-266-0478 Fax : 1-425-266-0518

Daewoo House, Unit 6.3 Nantgarw Park, Cardiff

CF47QU, U.K. / Tel : 44-1443-84-2273 Fax : 44-1443-84-1933

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Taiwan R.0.C
Tel : 886-3-327-5576 Fax : 886-3-327-3013

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Xinjiang Daewoo Machinery Co., Ltd

Euro Daewoo S. A

No, 178, Hetanbei Road, Wurumuqi, Xinjiang, China

Tel : 86-991-463-2217 Fax : 86-991-461-8641

1A Rue Achille Degrace 7080 Frameries Belgium

Tel : 32-65-61-3231 Fax : 32-65-61-3238

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Euro Daewoo S. A France

No.87 Gongxing Road, Tanggu, Tianjin, china

Tel : 86-222-521-0540 Fax : 86-222-521-0714

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Tel : 33-1-3016-2140
Fax : 33-1-3016-2144

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#28, Wuzhishan Road, Eco. & Tech, Development Zone,
Yantai, Shandong, China
Tel : 86-535-638-2000 Fax : 86-535-638-2004

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Germany / Tel : 49-2173-8509-20 Fax : 49-2173-8509-60

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Minato-Ku, Tokyo, Japan
Phone : 81-3-3433-8400 Fax : 81-3-3433-8648

AV Tres Andradas 519- Jd. Piratininga - CEP

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Daewoo Heavy Industries America N.J. Office

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Tel : 1-973-618-2500 Fax : 1-973-618-2501

60C Electron Road Isando 1600, Johannesburg, South Africa

Phone : 27-11-974-2095 Fax : 27-11 -974-2778

65.99897-8050

Maintenance Manual
GENERATOR DIESEL ENGINE

DE12T
POLUS

P126TI

FOREWORD

This maintenance manual is designed to serve as a reference for DAEWOO Heavy Industries Ltds
(here after DAEWOOs) customers and distributors who wish to gain basic product knowledge on
DAEWOOs DE series generator diesel engines (DE12T and POLUS P126TI)
These economical and high-performance diesel engines (6 cylinders, 4 strokes, in-line, direct injection type) have been so designed and manufactured to be used for the generator application. They
meet 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 manufacturers

Directional Indication

Lubricate with oil

Inspection

Lubricate with grease

Measurement

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

Take old oil to an old oil disposal point only.

Ensure without fail that oil and diesel fuel will not get into the sea or rivers and canals or the ground.
Treat undiluted anti-corrosion agents, antifreeze agents, filter element and cartridges as special waste.
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 LTD.

July. 1999

CONTENTS
1. GENERAL INFORMATION .........................................................................................................1
1.1. General repair instructions

1.3. Engine assembly

1.2. Engine characteristics

1.4. Engine specifications

2. MAJOR MAINTENANCE.............................................................................................................8
2.1. Preventive maintenance

2.3. Engine inspection

2.2. Diagnosis and remedy

3. DISASSEMBLY AND REASSEMBLY OF MAJOR COMPONENTS ........................................28

3.1. Disassembly

3.3. Reassembly

3.2. Inspection

3.4. Breaking-in

4. MAINTENANCE OF MAJOR COMPONENTS..........................................................................81

4.1. Cooling system

4.3. Fuel injection pump

4.2. Lubricating system

4.4. Turbocharger

5. SPECIAL TOOL LIST..............................................................................................................127

Appendix..................................................................................................................................130

Worldwide Network

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
relaible 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
design depending on position of lnstallation.
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.

-1-

1.2. Engine characteristics

1.2.1 OMEGA combustion bowl
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 exhaust port configuration within the
cylinder head, the POLUS P126TI and
DE12T (DE12 series) generator 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.

EA8M1001

1.2.2. Oil gallery cooling type pistion(P126TI)

Oil gallery cooling is used for the piston of
P126TI generator 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 spary nozzel 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.

-2-

1.3. Engine assembly

1.3.1. Engine sectional view (longitudinal)

10

11

12

13

14 15

16

17

18
EA8M1002

1. Cooling fan

7. Piston pin

13. Crankshaft

2. Exhaust valve

8. Piston

14. Oil pan

3. Valve spring

9. Combustion chamber

15. Connecting rod

4. Oil filter

10. Crankshaft pulley

16. Camshaft

5. Tappet

11. Vibration damper

17. Flywheel housing

6. Push rod

12. Oil pump

18. Flywheel

-3-

1.3.2. Engine sectional view (cross)

10

11

12

4
5
6

EA8M1003

1. Intake manifold

7. Injection nozzle assembly

2. Fuel filter

8. Rocker arm

3. Oil cooler

9. Cylinder head cover

4. Injection pump

10. Exhaust manifold

5. Cylinder block

11. Piston ring

6. Oil filter

12. Turbocharger

-4-

1.3.3. Engine assembly views

1) DE12T

1 2

3 12 4

27

13 18
5

22

23
16

8
17

6
15

9 11 10
19

25
24

14

20 21 26
EA8M1004

1. Cooling fan

10. Flywheel housing

19. Thermostat

2. Cooling water pipe

11. Flywheel

20. Injection pump

3. Oil filler cap

12. Exhaust manifold

21. Oil level gauge

4. Cylinder head cover

13. Injection nozzle assembly

22. Mounting bracket

5. Turbocharger

14. Oil filter

23. Vibration damper

6. Oil drain valve

15. Fuel filter

24. Water pump

7. Alternator

16. Oil cooler

25. Fan drive

8. Oil pan

17. Intake manifold

26. Crankshaft pulley

9. Starter

18. Injection pipe

27. Breather

-5-

2) P126TI

7
14 15 16 17 18

12

6
19

13

9 10 11

24
22
23

25

20 21
EA8M1005

1. Cooling fan

8. Oil pan

18. Injection pipe

2. Cooling water pipe

9. Starter

19. Thermostat

3. Air pipe

10. Flywheel housing

20. Injection pump

11. Flywheel

21. Oil level gauge

12. Exhaust manifold

22. Mounting bracket

13. Injection nozzle assembly

23. Vibration damper

5. Turbocharger

14. Oil filter

24. Water pump

6. Oil drain valve

15. Breather hose

25. Fan drive

7. Air pipe

16. Oil cooler

(Intercooler

Intake manifold)

4. Air pipe
(Air cleaner

(Intercooler

Turbocharger)

Intake manifold)

17. Intake manifold

-6-

1.4. Engine specifications

Engine Model

DE12T

Items

P126TI

P126TI-I

Water-cooled, 4 cycle in-line

type
Turbo charged & intercooled
Direct injection type

Water-cooled, 4 cycle in-line

type Turbo charged

Engine type
Combustion chamber 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

4 - 123 x 155

(cc)

11,051

Compression ratio

17.1 : 1

Engine dimension (length x width x height)

Engine weight

(mm) 1,365.5 x 870 x 1,046

(kg)

1,383 x 870 x 1,207

910

Rotating direction (from flywheel)

Counter clockwise

Fuel injection order

1-5-3-6-2-4

Fuel injection timing (B.T.D.C static)

12

Injection pump type

Zexel in-line P type

Governor type

Mechanical governor type(RSV)

Electric governor type(GAC)

Injection nozzle type

Multi-hole type (5 hole)

Multi-hole type (5 hole)

220

1st : 160, 2nd : 220

Fuel injection pressure

(kg/cm )

Compression pressure

(kg/cm )

28 (at 200 rpm)

50Hz
60Hz
50Hz
60Hz
60Hz
(1,500rpm) (1,800rpm) (1,500rpm) (1,800rpm) (1,800rpm)

Condition

280PS
(206kW)

336PS
(247kW)

Prime

205PS
(151kW)

245PS
(180kW)

328PS
(241kW)

378PS
(278kW)

356PS
(262kW)

Stand by

226PS
(166kW)

270PS
(199kW)

370PS
(272kW)

405PS
(298kW)

392PS
(288kW)

Continuous
Power (ISO 3046)

Intake and exhaust valve clearance (at cold) (mm)

Intake valve
Exhaust valve

0.3

Open at

18 (B.T.D.C)

Close at

34 (A.B.D.C)

Open at

46 (B.B.D.C)

Close at

14 (A.T.D.C)

Lubrication method

Full forced pressure feed type

Oil pump type

Gear type driven by crankshaft

Oil filter type

Lubricating oil capacity (max./min.)

Full-flow, Cartridge type

(lit)

Oil cooler type

Water cooled

Water pump

Gear driven impeller type

Cooling Method
Cooling water capacity (engine only)

Pressurized circulation
(lit)

Thermostat type
Alternator voltage - capacity
Starting Motor voltage - output

23/20

19
Wax pallet type (83 ~ 95 C)

(V - A)

24 - 45

(V - kW)

24 - 6.0

-7-

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

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

The engine cooling water can be used diluting it with antifreezing solution 40% and the additive for rust prevention (DCA4) 3 ~ 5 %.

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.

Since DE12T and POLUS P126TI (generator diesel engine of DE12 series) cylinder liner is
dry type, particularly the cooling water control should be applied thoroughly.

The density of antifreezing solution and additive for rust prevention is able to be confirmed by
the cooling water test kit. (Fleetguard CC2602M)

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.
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.

-8-

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.

Amount of Anti-freeze in winter

Ambient

Cooling water (%)

Anti-freeze (%)

Over -10

85

15

-10

80

20

-15

73

27

-20

67

33

-25

60

40

-30

56

44

-40

50

50

Temperature (C)

2.1.2. Fan belt

Use a fan belt of specified dimensions, and replace if damaged, frayed, or deteriorated.
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)

2.1.3. Engine oil

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

Engine oil should be changed at the specified intervals. (800 hr) Oil in the oil filter should
be changed simultaneously.
- First oil change : 50 hr operating

The oil viscosity grades should be selected SAE NO.15W40 and API CD or CE.

-9-

2.1.4. Oil filter

Check for oil pressure and oil leaks, and

repair or replace the oil filter if necessary.

Change the oil filter cartridge simultaneously at every replacement of engine oil.

Oil filter (Cartridge)

Oil filter head

EQM4010I

2.1.5. Fuel filter

Drain water in cartridge with loosening

the cock under filter manually (6) from

time to time.

The fuel filter should be replaced at

every 1,200 hours.

3
4

5
2

EA2O4009

2.1.6. Air cleaner

In case that elements are deformed,

damaged or if the air cleaner has a
crack, replace it.

By the definite interval, the elements

must be cleaned and replaced.

EFM1002I

- 10 -

2.1.7. Intercooler
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.

Air/air intercooler
with downstream
radiator
(Combined radiator)

Cooling air
Hot charge air
from compressor
Recooled charge air
to intake pipe (max. 50 C)
EA5O4003

- Cleaning of intercooler fins: Every 600 hours.

2.1.8. Valve clearance adjust procedure

After letting the #1 cylinders piston come at the compression top dead center by turning the
crankshaft, adjust the valve clearances.

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.

- 11 -

As for the valve clearance, adjust it when in cold, as follow.

Model

Intake Valve

Exhaust Valve

0.3 mm

0.3 mm

DE12T
P126TI

- By cranking the engine, let #6 cylinders valves overlap.

- In time, adjust the valve clearance corresponding to
- Adjust the valve clearance corresponding to

of lower lists.

of lower lists.

- After reinsuring the valve clearances, retighten if necessary.

No. 1 Cylinder is located at the side where flywheel was installed.

Flywheel

Intake Valve

Exhaust Valve

Cylinder No.

Cooling Fan

EA8O6001

- 12 -

2.1.9. Cylinder compression pressure

Stop the engine after warming up, and

take out nozzle holder assembly.

EA9O5003

Install the special tool (compression

gauge adapter) at the nozzle holder
hole, and connect the compression pressure gauge there.
Standard value

28kg/cm2 over

Limit value

24kg/cm2

Difference
between each cylinder

Within 10 %
EA9O5004

Condition : Water temperature 20C,

Engine rotation 200rpm (10 rotation)

2.1.10. Injection nozzle

Normal

Abnormal

Abnormal

EFM1006I

IInstall a nozzle on the nozzle tester.

If the inspected injection pressure is less than the specified value, adjust using the adjusting shims.
Engine Model

DE 12T

Injection nozzle pressure

220kg/cm2

P126TI
1st : 160kg/cm2
2nd : 220kg/cm2

Check the atomizing state and repiace it if abnormal.

- 13 -

2.1.11. Fuel injection pump

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

Check if the idle operation and speed regulating levers sealing is removed.
The adjustment and testing of fuel injection pump should necessarily be done at the test
bench.

2.1.12. Battery

Inspect for any leakage of electrolytic solution owing to battery crack, and replace the battery in case of poor condition.

Inspect for amount of electrolytic solution, and replenish if insufficient.

Measure the gravity of electrolytic solution, if less than specified value (1.12 ~ 1.28), replenish.

1,100
1,200
1,300

UPPER LEVEL
LOWER LEVEL

EFM1007I

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.

- 14 -

2.1.15. Supercharger
The supercharger 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 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.
Also, In case of washing car and so forth, inspect the wiring state being careful for not to
get.

- 15 -

2.2. Diagnosis and remedy

1. Engine Starting Impossible

Starting motor operation poor

Starting motor revolution

Inspection of battery electorlytic

Ilquid amount & gravity
Normal

Too low

Fuel

Inspect air cleaner

Inspect amount of fuel

Normal

Ajustment
Recharging
Inspection of loose electric
wring & short

Normal

Engine

Retigten
Replace

Polluted
Replace or
clean element

Check compression
pressure

Repair
Replace

Inspection of starting switch

Inspect of
other parts

Repair
Replace

Check valve
clearance

Inspection of starting relay

Normal

Replace
Normal

Adjust

Inspection of magentic switch

Normal

Check cylinder
head gasket

Repair
Replace

Replace

Inspect fuel
injection

No injection

Normal
Continuous
operation after
air removal

Inspect
injection
timing
Normal

Adjust

Inspect injection
nozzle (injection
pressure injection
state etc.)
Normal

Normal
Starting motor
disassembly

None
Replenish

Too low
Normal

Normal

Normal

Engine disassembly
(valve assembly piston
cylinder liner etc.)

Repair
Replace

Injection pump
disassembly

Inspect supply pump operation

Normal
Injection pump
dasassembly

Inspect supply pump valve strainer

Clean
replace

Air mixture in fuel

Normal

Retighten connection
parts. Replace gasket

Inspect fuel filter

Air removal

Element polluted
Overflow valve poor

Continuous air mixing

Replace

- 16 -

Supply pump
disassembly

2. Engine Overheated
Operating state
1. Overload
2. Radiator core clogged
3. Continuous over-run

Fuel unit

Cooling unit
Check coolant

Inspect fuel quality

Normal

Fuel excessive supply

Too low
Poor

Check fan belt

tension wear
or damage etc.

Repair
Replace

Replenish
Normal
Check fresh
water tank cap

Replace

Exteranl

Internal
Engine
disassembly

Normal

Abnormal

Adjust
repair
injection
pump

Repair
Replace

Replace

Normal

Inspect
radiator

Check injection nozzle

Inspect cooling
water leakage

Retighten
Replace

Normal

Check thermostat

Clean and replace

with specilied fuel

Damage

Normal

Check cooling
water pump

Clean cooling
water passage

Normal

Repair
Replace
Repair
Replace

Engine
disassembly

- 17 -

3. Output Insufficient

Engine

Installation improper

Fuel unit

Check for coupling

alignemnt

Others

Check for air mixing

in fuel

Inspect air cleaner

Inspect fuel supply pump

Normal

Normal

Inspect engine control

rod, link, cable, etc.

Clean Replace

Adjust or replace
coupling

Clean Relpace
Inspect air leakage
of air piping line

Inspect fuel filter over folw valve

Adjust

Normal
Normal

Normal

Retighten
Replace

Replace
Check valve clearance

Inspect injection pipe

Adjust

Normal
Normal

Repair Replace

Inspect injection nozzle

injection pressure
atomizing state
Normal

Adjust Replace

Inspect cylinder head

gasket for damage
Replace

Normal

Engine disassembly
(valve assembly)

Check injection timing

Normal

Adjustment

Disassemble engine or
injection pump

Check Turbocharger
Normal

Repair
Replace

Disassemble injection
pump or engine

- 18 -

Inspect air leakage

of Intercooler

4. Oil pressure lowered

Check if oil pressure
gauge indicates wrongly
Check oil amount

Too low

Normal

Use recommended oil

(replenish)

Check cooling
temperature
Too high

Normal

Refer to engine overhea

Inspect oil quality

Normal

Check oil relief

valve

Normal

Retighten
Replace

Water & fuel mixed

in oil
Disassemble engine
or injection pump

Disassemble
engine

- 19 -

Improper

Replace with
recommended oil

5. Fuel Consumption Excessive

Inspect fuel leakage

Causes according to Use Conditions

1. Overload
2. Govemor's Arbitrary Adjustment
3. Full Speed Operation for Long time
4. Sudden Speed Change from Low to
High Speed

Normal
Inspect injection nozzle
(injection pressure
atomizing state etc.)

Oil leakage
Adjust Replace
Retighten Replace

Normal
Check injection timing

Adjust

Normal
Inspect compressed
pressure

Check valve
clearance

Normal
Disassemble
injection pump

Adjust

Normal

Inspect head gasket

Replace

Normal

Disassemble engine
(valve assembly piston
cylinder liner etc.)

- 20 -

Repair Replace
Cylinder liner
Piston ring Piston

6. Oil Consumption Excessive

Cause according to use conditions
1. Excessive oil infusing
2. Continuous operation in low or
extremely cold state

Inspect oil leakage

Inspect air cleaner
Normal

Oil leakage

Check oil quality

External
Retighten
Replace

Replace with
specified oil

Engine disassembly
(piston cylinder liner)

Clean Replace
Internal
Check compressed
pressure

Normal

Disassemble
cylinderhead
(valve stem seal)

7. Engine Knocking
Inspect combustion of fuel & oil
(carbon residue exhaust gas)

Confirm

Unconfirmed
Inspect compressed
pressure

Disassemble
engine
Too low

Normal
Check valve clearance and
cylinderhead gasket for damage

Inspect injection
pump
Normal
Check fuel quality

Adjust

Normal

Replace
Adjust

Disassemble
engine

Use specified fuel

- 21 -

8. Battery Discharge

Battery

Wiring Switch

Check electrolytic
liquid amount

Inspect cut wire

shorts and loose
connections

Generator
Check fan belt
tension & damage

Repair Replace

Normal
Electrolytic
liquid's
standard

Battery room
damage

Battery self
discharge

Battery over
charging

Replenish

Replace

Charging

Inspect generator
Voltage regulator

Normal

Abnormal

Check charged stated

Adjust
Replace

Discharging

Disassemble
generator Voltage
regulator

- 22 -

Condition
1) Starting difficult
(1) Compression pressure

2) Idle operation abnormal

3) Engine output insufficient

(1) Continuous output
insufficient

Causes

Remedies

Valves poor shut, stem distortion

Repair or replace

Valve spring damage

Replace valve spring

Cylinder head gaskets leak

Replace gasket

Wear of piston, piston ring or liner

Adjust

Injection timing incorrect

Adjust

Air mixing at injection pump

Remove air

Valve clearance incorrect

Adjust

Valve tightness poor

Repair

Cylinder head gaskets leak

Replace gasket

Wear, stick, damage of piston ring

Replace piston ring

Injection timing incorrect

Adjust

Fuel injection amount insufficient

Adjust injection pump

Nozzle injection pressure

Adjust or replace

improper or stuck

Supply pumps function lowered

Repair or replace

Fuel pipe system clogged

Repair

Air suction amount insufficient

Clean or replace air

cleaner

(2) Output insufficient

Supercharger poor

Repair or replace

Compression pressure

Disassemble engine

when in acceleration

insufficient

Injection timing incorrect

Adjust

Fuel injection amount insufficient

Adjust injection pump

Injection pump timers function

Repair or replace

insufficient

Nozzle infection pressure, infection

Repair, replace

angle improper

4) Overheating

Supply pumps function lowered

Repair or replace

Air intake amount insufficient

Clean or replace air

Engine oil insufficient or poor

Replenish or replace

Cooling water insufficient

Replenish or replace

Fan belt loosened, worn, damaged

Adjust or replace

Cooling water pumps function lowered

Repair or replace

Water temp. regulators operation poor

Replace

Valve clearance incorrect

Adjust

Exhaust systems resistance

clean or replace

increased

- 23 -

Condition
5) Engine noisy

Cause

Remedies

For noises arise compositely such asrota

ting parts, lapping parts etc., there is nec
essity to search the cause of noises accu
rately.

(1) Crankshaft

As the wear of bearing or crankshaft

Replace bearing &

progress, the oil clearances increase.

grind crankshaft

Lopsided wear of crankshaft

Grind or replace

Oil supply insufficient due to oil

Clean oil passage

passage clogging

Stuck bearing

Replace bearing &

Grind

(2) Con rod and

Con rod bearing

Lopsided wear of con rod bearing

Replace bearing

Lopsided wear of crank pin

Grind crankshaft

Connecting rod distortion

Repair or replace

Stuck bearing

Replace &
grind crankshaft

Oil supply insufficiency as clogging

Clean oil passage

at oil passage progresses

(3) Piston, piston pin &
piston ring

(4) Others

Piston clearance increase as the wear

Replace piston &

of piston and piston ring progresses

piston ring

Wear of piston or piston pin

Replace

Piston stuck

Replace piston

Piston insertion poor

Replace piston

Piston ring damaged

Replace piston

Wear of crankshaft, thrust bearing

Replace thrust

bearing

Camshaft end play increased

Replace thrust plate

Idle gear end play increased

Replace thrust
washer

Timing gear backlash excessive

Repair or replace

Valve clearance excessive

Adjust valve
clearance

6) Fuel Consumption
Exttive

Abnormal wear of tappet, cam

Replace tappet, cam

Supercharger inner part damaged

Repair or replace

Injection timing incorrect

Adjust

Fuel injection amount excessive

Adjust injection
pump

- 24 -

Condition

Cause

Remedies

7) Oil Consumption
Excessive
(1) Oil level elevated

Clearance between cylinder iner &

Replace

piston

Wear of piston ring, ring groove

Replace piston,
piston ring

Piston rings damage, stick, wear

Replace piston ring

Piston ring openings disposition

Correct position

improper

Piston skirt part damaged or

Replace piston

abnormal wear

(2) Oil level lowered

(3) Oil leak

Oil rings oil return hole clogged

Replace piston ring

Oil rings contact poor

Replace piston ring

Looseness of valve stem & guide

Replace in set

Wear of valve stem seal

Replace seal

Cylinder head gaskets leak

Replace gasket

Looseness of connection parts

Replace gasket,
repair

Various parts packing poor

Replace packing

Oil seal poor

Replace oil seal

- 25 -

2.3. Engine inspection

2.3.1. Stopping Engine
Cut off the main circuit breaker of the generator control panel. After checking the engine for
any unusual condition at the idling speed, then press the stop button to stop the engine.

2.3.2. General Engine inspection cycle

: Check & adjust
Inspection

Daily

: Replace

Every

Every

Every Every Every

50hrs

200hrs

600hrs

800hrs 1200hrs

Remark

Check for leakage(hoses, clamp)

Check the water level
Cooling

Change the coolant water

System

Every
2,000hrs

Adjust the V-belt tension

Clean the radiator
Check for leakage
Check the oil level gauge
Lubrication
System

Change the lubricating oil

1st

Replace the oil filter cartridge

1st

Check the leakage for intercooler

(hoses, clamp)
Intake &

Clean and change

Exhaust

the air cleaner element

System

Clean the inter-cooler air fins

clean
Every
2,000hrs

Clean the turbo-charger

Check the leakage fuel line
Clean the fuel strainer
of fuel feed pump
Remove sediment from fuel tank
Fuel
System

Drain the water in separator

Replace the fuel filter element
Check fuel Injection timing

When
necessary

Check the injection nozzles

When
necessary

Check the state of exhaust gas

Check the battery charging
Engine
Adjust

When
necessary

Check the compression pressure

Adjust Intake/Exhaust
valve clearance

1st

- 26 -

When
necessary

2.3.3. Use of original parts for repair and replacement

For engine is being mechanically harmonized with many parts, only when the original parts
that the manufacture recommends to use is used, the engine trouble would be preventively
maintained and capable to keep up the maximum performances.
For the analogous parts not the original parts are poor in qualities and gives ill performances,
it may rather bring early engine failure.

- 27 -

3. Disassembly and reassembly of major components

3.1. Disassembly
3.1.1. General precautions

Maintenance operation should be carried out in a bright and clean place.

Before disassembly, provide parts racks for storage of various tools and disassembled parts.
Arrange the disassembled parts in the disassembly sequence and use care to prevent any
damage to them.

3.1.2. Cooling water

Remove the radiator cap. Open the drain

plug at the radiator lower part to drain the
coolant as the right figure.

CAUTION : When

removing

radiator

filler cap while the engine is

still hot, cover the cap with a
rag, then turn it slowly to
release the internal steam
pressure This will prevent a
person from scalding with
hot steam spouted out from
the filler port.

Drain Valve
EA5O4002

Remove

the drain plug from the cylinder

block and drain out the cooling water into a

container.

EQM3002I

- 28 -

3.1.3. Engine oil

Take out the oil dip dipstick.

Remove the oil drain valve of oil pan and
drain out the engine oil into a prepared
container.

Drain valve
EA8O5001

3.1.4. Alternator belt

Loosen the tension adjusting nut installed

on the alternator bracket, and take off the
alternator belt.

EA8M3001

3.1.5. Cooling fan

Remove the flange fixing bolts, then take

off the flange and cooling fan.

EQM3004I

3.1.6. Alternator

Remove the alternator fixing bolt and disassemble the alternator.

Remove

the tension adjusting bolt and

bracket.

- 29 -

3.1.7. Oil level gauge guide tube

Loosen the flange nut installed on the oil

pan to remove the guide tube.

EQM3005I

3.1.8. Fuel filter

Remove fuel hoses connected to the fuel

injection pump, take off the bracket fixing
bolts, then disassemble the fuel filter.

EA8M3013

3.1.9. Breather

Loosen

the clamp screw to remove the

rubber hose.

3.1.10. Intercooler

Tear

down the various hoses and air

pipes from the inter cooler.

Remove

the intercooler fixing bolts and

tear it down.

EA6M2001

- 30 -

3.1.11. Injection pipe

Unscrew the hollow screws to disassemble the fuel return pipe.

Remove

the nuts installed on the fuel

injection pump and nozzles, then disassemble the injection pipe.

EQM3009I

3.1.12. Intake manifold

Remove

the air hose connected to the

fuel injection pump.

Loosen

the intake manifold fixing bolts,

then disassemble the intake manifold.

EQM3011I

3.1.13. Turbo charger

Release

the clamp screw of the rubber

hose connected to the intake manifold,

and take off the intake pipes both simultaneously.

Unscrew the exhaust pipe bracket fixing

bolts, release the nuts installed on the
turbocharger,

then

disassemble

the

exhaust pipe.

Remove the turbocharger after removing

the oil supply pipe and return pipe and
releasing the fixing nuts.

- 31 -

3.1.14. Exhaust manifold

Release

the exhaust manifold fixing

bolts, disassemble the exhaust manifold,

then remove the heat shield and gasket.

NOTE : Make sure to release the nuts

one after another because the
exhaust

manifold

will

be

removed if you unscrew two

nuts simultaneously.

3.1.15. Thermostat

Remove

the by-pass pipe connected to

the water pump, unscrew the thermostat

fixing bolts, then disassemble the thermostat housing.

Disassemble the thermostat housing and

remove the thermostat.

Disassemble the water pipe by unscrewing the bolts and nuts installed on the
cylinder head.

EAMD014I

3.1.16. Starter

Unscrew the starter fixing bolts, then disassemble the starter.

EAMD017I

- 32 -

3.1.17. Water pump

Remove the water pipe connected to the

expansion tank.

Remove the water pipe and hoses connected to the water pump.

Unscrew the water pump fixing bolts and

remove the water pump.

3.1.18. Injection pump

Remove

the oil supply pipe and return

pipe connected to the fuel injection pump.

Unscrew

the bolts connecting the cou-

pling and drive shaft, loosen the injection

pump attaching bolts, then disassemble
the injection pump.
NOTE : As far as possible, place the
No.1 cylinder in OT position to
disassemble the injection pump.

EAMD021I

Release the pump fixing bracket bolts to

disassemble the bracket from the cylinder block.

NOTE : Do not interchange the shims as

they must be installed in their
original positions at reassembly.

EAMD022I

3.1.19. Oil filter

Using

a filter remover wrench, remove

the oil filter cartridge.

Remove

the pipe connected to the oil

cooler.

Loosen the oil filter fixing bolts and disassemble the oil filter head from the
cylinder block.

- 33 -

3.1.20. Fan drive pulley

Remove

the bolts and disassemble the

fan drive pulley.

3.1.21. Vibration damper

Unscrew

the pulley fixing bolts and dis-

assemble the pulley-vibration damper

assembly.

Unscrew

the vibration damper fixing

bolts and disassemble the damper from

the pulley.

3.1.22. Timing gear case cover

Disassemble the oil seal using an oil seal

removing jig.

Remove the cover fixing bolts and disassemble the cover from the timing gear
case.

EAMD025I

3.1.23. Idle gear

Unscrew

the idle gear fixing bolts and

disassemble the thrust washer and idle

gear.

Disassemble

the idle gear pin using a

rubber hammer to prevent damage to

them.

- 34 -

3.1.24. Fuel injection pump drive assembly

Unscrew

the injection pump drive shaft

bearing housing fixing bolts and remove

the injection pump drive assembly which
the shaft, gear, bearings, and housing
are put together.

EAMD027I

3.1.25. Cylinder head cover

Unscrew

the cover fixing bolts and dis-

assemble the cover.

Keep

the bolts in an assembly state so

that the packings and washers may not

be lost, and keep the cover packing as
assembled with the cover.

EAMD028I

3.1.26. Rocker arm assembly

Unscrew

the rocker arm bracket bolts

and remove the rocker arm assembly.

Take

off the snap rings to remove the

washers and rocker arm, then unscrew

the bracket fixing bolts to take off the
bracket and springs.

Take out the push rods.

EAMD029I

3.1.27. Injection nozzle

Remove

the nozzle fixing nuts and

extract the nozzles.

Remove

the nozzle tube using nozzle

tube removing jig.

Do not perform disassembly operation

unless coolant, gas, etc. leak out.
EAMD030I

- 35 -

3.1.28. Cylinder head

Unscrew

the cylinder head fixing borts

and take off the cylinder head.

Remove the cylinder head gasket.

EAMD031I

3.1.29. Valve and valve stem seal

Compress the valve spring retainer using

a jig and take off the valve cotter pins.

Disassemble

the valve springs and

retainers.

Take off the valves.

Remove and discard the valve stem seal
using a general tool as it should not be

Valve spring
compressor

re-used.
EA0M4007

3.1.30. Oil cooler

Remove the water pipe connected to the

water pump.

Remove

the oil pipe connected to the

cylinder block.

Unscrew the oil cooler cover fixing bolts

and disassemble the oil cooler assembly
from the cylinder block.

Unscrew

the oil cooler fixing bolts and

remove the oil cooler from the oil cooler

cover.

- 36 -

EAMD033I

3.1.31. Oil pan

Stand the engine with the flywheel housing facing the bottom.

Release the oil pan fixing bolts, remove

the stiffeners then disassemble the oil
pan.

EAMD034I

3.1.32. Oil pump and oil pipe

Unscrew

the oil suction pipe bracket

bolts, releasing the pipe fixing bolts, then

disassemble the oil suction pipe assembly.

Disassemble the oil pipe feeding oil from

the oil pump to the cylinder block.

Unscrew

the oil pump fixing borts and

disassemble the oil pump.

EAMD035I

3.1.33. Relief valve

Disassemble the relief valve.

EAMD036I

3.1.34. Piston and connection rod

Disassemble

the pistons by two cylin-

ders while turning the crankshaft.

Unscrew

the connecting rod fixing bolts

and take off the pistons and connecting

rods in the direction of piston.

EAMD037I

- 37 -

 Remove

the piston pin snap rings, take

off the piston pin, then disconnect the

connecting rod from the piston.

Disassemble

the piston rings using ring

pliers.

Use

care not to interchange the disas-

sembled parts and keep them in the

sequence of cylinder No.

3.1.35. Cylinder liner

Disassemble

the cylinder liner using a

liner puller.

EAMD040I

3.1.36. Flywheel

Position

the engine so that the head

installing surface of the cylinder block

faces down.

Unscrew the flywheel fixing bolts and fit

a dowel pin.

Install

flywheel disassembling bolts in

the bolt holes machined on the flywheel,

and disassemble the flywheel.
EAMD041I

- 38 -

3.1.37. Oil seal

Take off the rear oil seal using an oil seal

disassembling jig.

If only the inside guide ring is removed,

use a special tool to take off the outside
seal.

3.1.38. Flywheel housing

Loosen

the housing fixing bolts disas-

semble the flywheel housing.

EAMD043I

3.1.39. Cam shaft and tappet

Remove the cam shaft gear.

Take off the cam shaft gear thrust washer.
Take out the cam shaft using care not to
damage the cam shaft.

Slide out the tappets by hand.

EAMD044I

3.1.40. Crankshaft gear and oil pump idle gear

Loosen

the socket head bolts and take

out the oil pump idle gear.

Use

a puller to remove the crankshaft

gear.

- 39 -

3.1.41. Timing gear case

Unscrew the case fixing bolts and disassemble the timing gear case.

EAMD046I

3.1.42. Crankshaft

Remove the bolts from bearing caps.

Remove the main bearing cap fixing
bolts in the order of assembling.

(Remove

them in the same way of the

cylinder head bolts.)

Maintain

the removed bearing caps in

the order of cylinders.

Temporarily

install the bolts at the both

side of crankshaft, and lift the shaft with

a rope.

NOTE : Do not mingle with the metal

bearings and bearing caps randomly. To prevent mixing, temporarily assemble the metal
bearings to the corresponding
bearing caps in turn.

3.1.43. Oil spray nozzle

Unscrew

the fixing bolt and remove the

oil spray nozzles.

- 40 -

EAMDO47S

3.2. Inspection
3.2.1. Cylinder block
1) Clean the cylinder block thoroughly and make a visual inspection for cracks or damage.
2) Replace if cracked or severely damaged, and correct if slightly damaged.
3) Check oil and water flow lines for restriction or corrosion.
4) Make a hydraulic test to check for any cracks or air leaks.(Hydraulic test) :
Stop up each outlet port of water/oil passages in the cylinder block, apply air pressure of
about 4kg/cm2 against the inlet ports, then immerse the cylinder block in water for about 1
minute to check any leaks. (Water temperature: 70 C)

3.2.2. Cylinder head

1) Inspection

Carefully remove carbon from the lower lace of the cylinder head using nonmetallic material to prevent scratching of the valve seat faces.

Check

the entire cylinder head for very fine cracks or damage invisible to ordinary sight

using a hydraulic tester or a magnetic flaw detector.

2) Distortion at the lower face

Measure the amount of distortion using

a straight edge and a feeler gauge at six

(t)

positions (A ~ F) as shown in the right

figure.

B
A

If the measured value exceeds the standard value, retrace the head with grind-

C
D

ing paper of fine grain size to correct

such defect.

If the measured value exceeds the max-

E
F
EA3M2031

imum allowable limit, replace the cylinder head.

Lower face warpage and height

Warpage

Standard

Limit

0.2 mm or less

0.3 mm

114.95 ~ 115.0 mm

113.9 mm

Thickness : t
(reference)

EA6M2002

- 41 -

3) flatness
Measure flatness of the intake/exhaust
manifolds fitting surfaces on the cylinder
head using a straight edge and a feeler
gauge.
Standard

Limit

0.05 mm

0.2 mm

4) Hydraulic test
Hydraulic test method for the cylinder
head is same as that for cylinder block.

3.2.3. Valve and valve guide

1) Valve
Clean the valves with clean diesel oil,
then inspect them as follows:

Valve stem outer diameter

Measure the valve stem outer diameter
at 3 positions. (top, middle, and bottom)
If the amount of wear is beyond the limit,
replace the valve.
End of stem
Dimension
Description

Standard

Limit

Intake valve stem

10.950 ~ 10.970 mm

10.87 mm

Exhaust valve stem

10.935 ~ 10.955 mm

10.84 mm

Valve seat contacting faces

Check the valve seat contacting faces for
scratches or wear, and correct the faces
with

grinding

paper

as

necessary.

Replace if severely damaged.

- 42 -

EFM2036I

 Valve head thickness

Measure the valve head thickness, and
replace the valve if the measured value
is beyond the limit.
Dimension
Standard
Description

Limit

Intake valve

1.5 mm

1 mm or less

Exhaust valve

1.5 mm

0.9 mm or less

EFM2037I

2) Valve guide

Install the valve into the valve guide and

measure the clearance between them
by valve movement. If the clearance is
excessive, measure the valve and
replace either the valve or the valve
Measuring
position

guide, whichever worn more.

EA0M4052

Valve stem end play

Standard

Limit

Intake valve

0.04 ~ 0.07 mm

0.2 mm

Exhaust valve

0.06 ~ 0.09 mm

0.25 mm

Install

the valve into the cylinder head

valve guide, then check and see if it is

centered with the valve seat using a special tool.

- 43 -

3) Valve seat

Contacting face amount

Measure the contacting face between
the intake valve seat and exhaust valve
seat for valve seat wear, and replace if
the measured value exceeds the specified limit.

Install

the valve into the valve seat on

the cylinder head, and check the amount

of depression of the valve from the lower
portion of the cylinder head using a dial
gauge.

Valve depression

Intake &
Exhaust

Standard

Limit

0 ~ 0.3 mm

0.55 mm

EA0M4046

If the amount of depression is beyond the

specified limit, replace the valve seat.

For removal of the valve seat, apply arc

welding work to two points of valve seat
Valve seat
insert

insert, and pull out the valve seat insert

with inner extractor.
Cylinder head

Welding bead

Undercool a new valve seat with dry ice

for about 2 hours and press the valve
seat insert into position in the cylinder
head using a special tool (bench press).

Apply

valve lapping compound to the

valve head seating face on the valve

seat and lap the valve seat by turning it
until it is seated in position, then wipe out
the lapping compound.

- 44 -

EA3M2032

4) Valve spring

Visual check
Visually check the exterior of the valve
springs for damage, and replace if necessary.

Functional check
- Measure free length and spring tension
with a valve spring tester.

1.0mm or less

- Measure the spring inclination with a

square.
- Compare the measured value with the
standard value to determine whether to

Free length

(Refer to appendix)

replace or repair.

Valve spring
inclination

Standard

Limit

1.0 mm

2.0 mm

EFM2039I

3.2.4. Rocker arm shaft assembly

1) Rocker arm shaft

Rocker arm shaft run-out

Place the rocker arm shaft on two V
blocks and inspect the shaft for bend
using a dial gauge.
If the amount of this run-out is small,
press the shaft with a bench press to
correct the run-out Replace the shaft if
the measured value exceeds the limit.
EDM2037I

Limit

0.2 mm

- 45 -

 Rocker arm shaft diameter

With an outside micrometer, measure
the rocker arm shaft diameter at the
point where the rocker arms have been
installed.
Replace the rocker arm if the amount of
wear is beyond the specified limit.

Standard
23.978 ~

23.959 mm

Limit

EA8M3002

23.75 mm

2) Rocker arm

Visual check
Visually check the face of the rocker arm
in contact with the valve stem end for
scores and step wear. If the wear is
small, correct it with an oil stone or grinding paper of fine grain size. Rocker arm
with a considerable amount of step wear
should be replaced.

Diameter of the rocker arm bushing

Measure the inside diameter of the rocker arm bushing with an inside micrometer or vernier calipers, and compare the
measured values with the rocker arm
shaft diameter. If the clearance exceeds
the limit, replace either bushing or shaft,
whichever worn more.
<Clearance>

EA0M4059

Standard

Limit

0.020 ~ 0.093 mm

0.2 mm

3) Tappet and push rod

Clearance
Measure the clearance of the tappet and
tappet holes of the cylinder block. If the
value is beyond the specified limit,
replace tappets.
Standard

Limit

0.035 ~ 0.077 mm

0.15 mm
- 46 -

 Visual check of tappet

Visually check the face of the tappets in
contact with the cam for pitting, scores or
cracks, and replace if severely damaged.
If the amount of cracks or pitting is small,
correct with an oil stone or grinding

(1) Unevenness

(2) Crack

(3) Normal

paper.

(4) Abnormal

EA0M4070

Outside diameter
With an outside micrometer, measure
the tappet outside diameter If the measured value is beyond the limit, replace
tappets.
Tappet Dia

19.944 ~

Standard
Tappet
Clearance

19.965 mm

Limit
EDM2061I

0.035~0.077mm 0.15mm

Push rod run-out

Limit

0.3 mm or less

Use a feeler gauge to measure the push

rod run-out.
Roll the push rod along a smooth flat surface as shown in the figure.
Feeler gauge
EA0M4073

- 47 -

3.2.5. Cam shaft

1) Cam

Cam lobe height

Standard
Cam lobe height Intake
(C)
Exhaust

50.50~ 50.70 mm

Cam journal diameter(A,B)

59.86~ 59.8 mm

Limit
49.5 mm

50.70~ 50.90 mm
59.52 mm

Use a micrometer to measure the cam

lobe height and journal diameter.

I II

A
C

B
D

B
A

EA0M4062

If the measured number is less than the

specified

limit,

the

camshaft

I II

must

replaced.

Cam surface
Inspect the cam face for scratch or damage.
Slight step wear or damage on the cam
face may be corrected with oil stone or
oiled grinding paper. But, replace if
severely damaged.

2) Cam shaft

Clearance

between camshaft journal

and camshaft bush

- With an outside micrometer, measure
the camshaft journal diameter.
- Measure the inside diameter of the
camshaft bushing on the cylinder block

Camshaft bearing

using a cylinder bore indicator, and

compare the measured value with the
camshaft outside diameter to determine the clearance.

<Clearance>
Standard

Limit

0.050 ~ 0.128 mm

0.2 mm

EA0M4063

Replace the bushing if the measured

value is beyond the specified limit.

- 48 -

 Run-out
Support the camshaft on two V blocks
and check for run-out using a dial indicator. Correct or replace the cam shaft if
the amount of run-out is beyond the
value indicating need for servicing.

Standard

Limit

0.05 mm

0.2 mm
EA0M4066

3) Cam shaft end play

Push

the thrust plate toward the cam

gear.

With a feeler gauge, measure the clearance between the thrust plate and
camshaft journal.

If the end play is excessive, replace the

thrust plate.
Standard

Limit

0.13 ~ 0.27 mm

0.2 mm
EA0M4067

3.2.6. Crank shaft

1) Defect check

Visually check the crankshaft journal and

crank pins for scores or cracks.

Using a magnetic particle test and color

check, inspect the crankshaft for cracks,
and replace the crankshaft which has
cracks.

- 49 -

2) Wear

With an outside micrometer measure the

diameter of the crankshaft journals and
pins in the directions as shown, and
compare the measured values to determine the amount of wear.

If the amount of wear is beyond the limit,

have the crankshaft ground and install
undersize bearings. However, if the
amount of wear is within the limit, you
can correct the wear using an oil stone or
oiled grinding paper of fine grain size.
(Be sure to use grinding paper which has
been immersed in oil.)

Standard

Limit

Journal diameter

95.966 ~ 95.988 mm

94.966 mm

Pin diameter

82.966 ~ 82.988 mm

81.966 mm

EFM2047I

* Undersize bearings available

Standard
0.25 (Inside diameter is 0.25 mm lesser than the standard size.)
0.50 (Inside diameter is 0.50 mm lesser than the standard size.)
0.75 (Inside diameter is 0.75 mm lesser than the standard size.)
1.00 (Inside diameter is 1.00 mm lesser than the standard size.)
Undersize bearings are available in 4 different sizes as indicated above, and the crankshaft
can be reground to the above sizes.

Note : When regrinding the crankshaft

as described below, the fillet sec-

"R"

tion R should be finished correctly. Avoid sharp corners or

"R"

insufficient fillet.

* Standard values of R
"R"

1 Crankshaft Pin R: 4.5

2 Crankshaft journal R: 4

"R"

"R"
EFM2048I

- 50 -

3) Crankshaft run-out

Support the crankshaft on V blocks.

Turn the crankshaft with a dial indicator
placed on the surface plate and take the
amount of crankshaft run-out.
Standard

Limit

0.05 mm

0.1 mm

3.2.7. Crank shaft bearing and connection

rod bearing
1) Visual check
Visually check the crankshaft bearing and
connecting rod bearing for scores, uneven
wear or damage.

2) Oil clearance between crankshaft and

bearing.

Main bearing clearance

Install the main bearing in the cylinder
block, tighten the bearing cap to specified torque, then measure the inside
diameter.
30 kgm

Torque

Standard Dia.

Compare

the

96.06~ 96.108 mm

two

values

obtained

through measurement of main bearing

inside diameter with the outside diameters of crankshaft journals to determine
the oil clearance.

<Main bearing oil clearance>

Standard

Limit

0.072 ~ 0.142 mm

0.25 mm

- 51 -

 Connecting rod bearing clearance

Install the connecting rod bearing in the
connecting rod bearing cap, tighten the
connecting rod cap bolts to the specified
torque, then measure the inside diameter.
28 kgm

Torque

Standard Dia.

83.02~ 83.092 mm

Compare the two values obtained

through measurement of connecting
rod bearing inside diameter with the
outside diameters of crankshaft pins to
determine the oil clearance.
Standard

Limit

0.049 ~ 0.119 mm

0.20 mm
EAMD060I

If

the clearance deviates from the

specified range, have the crankshaft

journals and pins ground and install
undersize bearings.

3) Bearing spread and crush

Inspection
Check to see that the bearing requires a
considerable amount of finger pressure
at reassembly operation.

OA

OB

Spread = O A - O B
EDM2047I

- 52 -

 Crankshaft bearing crush

Install the bearing and cap in the cylinder
block, retighten the bolts to specified
torque, unscrew out one bolt completely,
then measure the clearance between the
bearing cap and cylinder block using a
feeler gauge.
Standard Dia.

0.15 ~ 0.25 mm
EA6M063I

Connecting rod bearing crush

Install the bearing and cap in the connecting rod big end, retighten the bolts to
specified torque, unscrew out one bolt
completely, then measure the clearance
between the bearing cap and connecting
rod big end using a feeler gauge.
Standard

0.086 ~ 0.116 mm
EA6M064I

4) crank shaft end play

Assemble

the crankshaft to the cylin-

der block.

With a dial gauge, measure crankshaft

end play.

Standard

Limit

0.15 ~ 0.325 mm

0.5 mm

- 53 -

3.2.8. Piston
1) Visual check
Visually check the pistons for cracks,
scuff or wear, paying particular attention
to the ring groove.

2) Clearance between the piston and

cylinder liner

With

an outside micrometer, measure

the piston outside diameter at a point

18mm away from the lower end of piston skirt in a direction at a right angle to
the piston pin hole.
Standard

122.854 ~

122.886 mm

Using a cylinder bore gauge, measure

cylinder liner inside diameter at 3
points (cylinder top ring contacting
face, middle, and oil ring contacting
face on BDC) in a direction at an angle
of 45(. Take the mean value with the
largest and smallest values excepted.
Standard
123 ~

The

Limit

123.023 mm

123.223 mm

clearance is computed by sub-

tracting the piston outside diameter

from the cylinder liner inside diameter.
Replace either piston or cylinder liner,
whichever damaged more, if the clearance is beyond the specified limit.

Clearance between piston and liner

Standard

0.114 ~ 0.169 mm

- 54 -

3.2.9. Piston rings

1) Visual check
Replace the piston rings with new ones
if detected worn or broken when the
engine is overhauled.

2) Piston ring gap

Insert the piston ring into the upper portion of the cylinder liner bore so that it is
held at a right angle to the cylinder liner
wall.

Measure the piston ring gap with a feeler gauge.

Standard

Limit

Top ring

0.30 ~ 0.45 mm

1.5 mm

2nd ring

0.35 ~ 0.50 mm

1.5 mm

Oil ring

0.30 ~ 0.50 mm

1.5 mm

Replace piston rings with new ones if

the gap is beyond the limit

3) Piston ring side clearance

Fit the compression ring and oil ring in

the piston ring groove.

With

a feeler gauge, measure side

Feeler gauge

clearance of each ring, and replace

either the ring or piston if the measured
value is beyond the specified limit.
Standard
Top ring

Limit

2nd ring

0.07 ~ 0.102 mm 0.15 mm

Oil ring

0.05 ~ 0.085 mm 0.15 mm

- 55 -

EA4M2007

4) Piston ring tension

With a tension tester, measure piston ring
tension. Replace the piston ring if the
measured value is beyond the limit.
Standard
Top ring

2.27 ~ 3.41 kg

2nd ring

2.0 ~ 3.0 kg

Oil ring

4.03 ~ 5.57 kg

3.2.10. Piston pin

1) Wear
Measure the amount of wear on the piston pin at the points as shown. The measured values are beyond the limit (0.005
mm or greater), replace the pin
Standard
44.995 ~

45 mm

Limit
44.990 mm or less

EA0M4031

2) Clearance
Measure the clearance between the piston pin and connecting rod bushing, and
replace either of them, whichever damaged more, if the measured value is
beyond the limit.
Limit

0.011 mm

EA3M2047

3) Condition check
Check the engaged condition of the piston and piston pin. If it is possible to force
the pin into the piston heated with piston
heater, the piston is normal. When replacing the piston, be sure to replace the piston pin together.

- 56 -

3.2.11. Connecting rod

1) Distorsion
Check the connecting rod for distortion.
As shown in the figure below, install the
connecting rod to the connecting rod
tester, and check for distortion using a
feeler gauge. If the connecting rod is
found distorted, never re-use it but
replace with a new one.

2) Holes alignment (parallelism)

Measure the alignment of the connecting
rod piston pin bushing holes with connecting rod big end holes. At this time
also, use both connecting rod tester and
feeler gauge.
Standard

Limit

0.05 mm

0.1 mm or less

EA0M4034

3) Wear

Assemble

the connecting rod to the

crankshaft and measure connecting

rod big end side clearance using a feeler gauge.

Assemble

the connecting rod to the

piston and measure connecting rod

small end side clearance.

If the measured values are beyond the

limit, replace the connecting rod.
Limit

0.5 mm

- 57 -

3.3. Reassembly
3.3.1. General precautions

Wash clean all the disassembled parts, particularly oil and water ports, using compressed air,
then check that they are free from restrictions.

Arrange the general and special tools in order for engine assembly operation.
To wet each sliding part, prepare the clean engine oil.
Prepare service materials such as sealant, gaskets, etc.
Discard used gaskets, seal rings, and consumable parts, and replace with new ones.
Apply only the specified torque for bolts in the specified tightening order and avoid over-tightening.

Be sure to check that all the engine parts operate smoothly after being reassembled.
Check the bolts for looseness after preliminary reassembly.
After completing the engine reassembly operation, check if there is missing parts or shortage
of parts.

Keep your hands clean during the working.

3.3.2. Cylinder block
Cover the floor of the workshop with wood plate or thick paper to prevent damage to the
cylinder head and place the cylinder block with the head fitting surface facing downward.

3.3.3. Oil spray nozzle

Tighten and assemble the oil spray nozzle
flange with fixing bolts using the spray nozzle jig.

EDM3053I

3.3.4. Tappet and cam shaft

Undercool

a new bush with dry ice for

about 2 hours and press it into position in

the cylinder block using a bench press.
After the pressing operation, measure
the inside diameter of the cam bush to
check if it is not deformed.

- 58 -

 Apply engine oil to the entire face of the

tappets and slide them into the tappet
holes on the cylinder block.

Wet

the cam bush inside diameter and

camshaft with oil, and carefully assemble them while turning the camshaft.

Check

to see that the camshaft rotates

smoothly.

EDM2060I

3.3.5. Crankshaft

Install

the main bearing machined with

Key groove

two holes in the cylinder block so that the

key is aligned with the key groove, then

Oil port and passage

apply oil to the bearing surface.

EA0M4083

Heat the crankshaft gear for at least 10

minutes to 120C, then apply sealant
(Loctite # 641) to the inside wall of the
heated crankshaft gear evenly before
inserting it to the end of crankshaft.
.

EA8M3014

- 59 -

 Semi-tighten

a bolt at both sides of the

crankshaft, apply engine oil to journals

and pins, then assemble the crankshaft
with the cylinder block by tightening the
fixing bolts.

nstall the oiled thrust washers with the oil

groove facing outward.

Install the bearing and thrust washers to

the bearing cap and apply oil to the
bearing and thrust washers.

EAMD077I

Install the bearing cap by matching the

cylinder block No. with the bearing cap
No.
7

EQM3058I

- 60 -

Apply oil to the entire part of the bearing

cap bolts, then tighten in tightening
sequence to specified torque.
Torque

30 kgm

After semi-tightening both bolts evenly,

tighten them diagonally to about 15kg.m
for the first stage and 25 kg.m for the

EQM3059I

second stage respectively, then tighten

them completely to the specified torque
using a torque wrench.

Tighten the bearing cap in the sequence

of 4-3-5-2-6-1-7.

Check to see that the assembled crankshaft turns smoothly.

3.3.6. Flywheel housing

Temporarily install the guide bar on the

cylinder block.

Apply gasket to the cylinder block.

Using the dowel pin and guide bar,
install the flywheel housing and tighten
the fixing bolts in a diagonal sequence
to specified torque.
Torque

12 kgm
EQM3060I

3.3.7. Rear oil seal

Apply lubricating oil to the outside of

theoil seal and flywheel housing inside
diameter and fit them over the crank
shaft, then assemble the oil seal using
an oil seal fitting jig.

- 61 -

3.3.8. Flywheel

Install a guide bar into a bolt hole on the

crank shaft, and lift the flywheel to align
the dowel pin with the pin hole on the flywheel for temporary assembly operation.

Install bolts in the remaining holes, take

out the guide bar, then install a bolt in
the hole where the guide bar had been
inserted.

EAMD081I

Tighten the fixing bolts using a torque

wrench in a diagonal sequence to specified torque.
Torque

18 kgm

5
7

3
EAMD097I

3.3.9. Timing gear case

Mount gasket using dowel pin on the

cylinder block.

Install the timing gear case by aligning

the dowel pin with the dowel pin hole on
the timing gear case.

EAMD082I

- 62 -

3.3.10. Fuel injection pump drive gear

assembly

Mount gasket by aligning the bolt holes

with the pin holes on the bearing housing.

Tighten up the fixing bolts in the direction of fuel injection pump.

EAMD027I

3.3.11. Timing gear

Install the oil pump idle gear onto the

No.7 bearing cap.

Install a thrust washer over the camshaft

and assemble the cam gear by aligning

Idle gear pin

it with camshaft key groove.

Torque

2.2 kgm

EAMD083I

With the oil port on the idle gear pin facing the cylinder block, install the idle

Idle gear pin

gear pin.

EA8M3004

Install the idle gear by coinciding the

Mark "2"

marks impressed on the crank gear,

cam gear, fuel injection pump drive gear,
Fuel injection
pump drive gear

and idle gear.

Install a thrust washer on the idle gear

2 2
2

Cam gear
Idle gear

1 1
1

and tighten to specified torque.

Mark "1"
Torque

6.2 kgm

Mark "0"

Crank
gear
EA8M3005

- 63 -

Check and adjust the amount of backlash between gears using a feeler
gauge.
Backlash

0.15 ~ 0.25 mm

3.3.12. Timing gear case cover

Install dowel pin on the timing gear case.

Mount a gasket by aligning the fixing
bolt holes with those on the gasket.

Align the dowel pin with the cover pin

hole, then install the cover with light tap.

Tighten the fixing bolts beginning with

the oil pan fitting face.

3.3.13. Front oil seal

Apply lubricating oil to the outside of the

oil seal and timing gear case inside
diameter and fit them over the crankshaft, then assemble the oil seal using
an oil seal fitting jig.

Oil seal fitting jig

EAMD086I

3.3.14. Cylinder liner

Stand the cylinder block so that the flywheel faces downward.

Thoroughly clean the liner flange fitting

surface and bore inside with compressed air to prevent the entry of foreign substances.

After the cleaning operation, make the

cylinder liner dried up and push it into
the cylinder block by hand.

Wet the liner inside diameter with engine

oil.

- 64 -

EAMD087I

3.3.15. Piston and connecting rod

Use a piston heater to heat the piston

approximately 100 C (212 F) for 5 minutes.

Align the piston pin hole with the oiled

connecting rod small end and press the
piston pin (by lightly tapping with a rubber hammer) to assemble the connecting rod with the piston.

EAMD088I

Noting the direction of the piston, make

the longer side (machined with key
groove on the bearing) of the connecting
rod big end and the mark of

impressed on the inside of the piston

On the piston head surface, the longer

106

face each other in opposite directions.

side of connecting rod big end is in

opposite direction from the valve seating
surface as well as in the same direction
with the narrow margin of combustion
chamber.

nstall the snap rings and check to see

that it is securely assembled.

Install the piston ring in the piston using

piston ring pliers.

- 65 -

EAMD089I

Identify the mark Y or TOP on the

ring end to prevent the top and bottom of
the piston ring from being interchanged
and make the marked portion face
upward.

Marked with the name of piston ring

manulacturing company
EAMD090I

Adjust the angle among individual piston

O

45

ring gaps to 90( and fit a piston assembling jig onto the piston, Use care not to

2nd ring gap

45

Top ring gap

match the ring gaps with the pin direction.

O

90
Install the bearing by aligning it with the
connecting rod key groove and apply oil

Piston pin

to the bearing and piston.

Piston

Position

the

valve

seating

Oil ring gap

EA8M3006

surface

toward the tappet hole and insert the

piston with hand.
Tappet hole

Use care not to damage the cylinder

liner and piston, and slightly lift and

Valve seating

insert the piston into the cylinder so

that the ring may not be damaged by
the fillet of the liner.

Install the bearing in the connecting rod

cap and apply oil.

Make sure that the manufacture serial

numbers impressed on the connecting
rod cap and connecting rod big end are
identical, and install the connecting rod
cap by aligning it with dowel pin.

Wet the fixing bolts with oil, semi-tightenthem with hand, tighten them to 15
kg.m for 1st stage and 22 kg.m for 2nd
stage respectively, and finally to specified torque.
Torque

28 kgm

- 66 -

EAMD092I

Move the bearing cap with hand, and

release and reassemble it if no movement is detected.

EAMD094I

3.3.16. Relief valve

Assemble the relief valve.

EAMD036I

3.3.17. Oil pump and oil pipe

Install a dowel pin in the No.7 bearing

cap, then assemble the oil pump with
specified torque.
Torque

4.4 kgm

Assemble the oil suction pipe with the

delivery pipe, then install the bracket on
the bearing cap.

- 67 -

EAMD095I

3.3.18. Oil pan

Mount gasket and put the oil pan thereon.

Place stiffeners and tighten bolts.

Align the bolt holes with gasket holes to
prevent damage to the gasket and tighten to specified torque.
Torque

2.2 kgm

EAMD034I

3.3.19. Intake and exhaust valves

Identify the marks of IN and EX

impressed on the valve head before
assembling the valve with the valve
head.

With a valve stem seal fitting jig, assemble the valve stem seal with the valve
guide.

After installing valve springs and spring

retainer, press the retainer with a jig,
then install cotter pin.

Tap the valve stem lightly with a rubber

hammer to check that the valve is
assembled correctly.
Valve spring
compressor

EA0M4007

- 68 -

3.3.20. Nozzle tube

Apply sealant (LOCTITE # 620) to the

nozzle tube and place the O-ring over
the cylinder head fitting face on the nozzle tube, then install the nozzle tube in
the cylinder head.

Install a guider of the nozzle tube insert

assy (Guider + Expander) the cylinder
head, then tighten the nozzle fixing nuts.

Guider

EAMD098I

Apply engine oil to an expander and

install it onto the special tool (guider).

Expander

Tighten the bolts until the expander is

forced out of the cylinder head bottom.

After mounting the nozzle tube, make a

hydraulic test to check for water leaks.
Test pressure

2 kg/cm2

3.3.21. Cylinder head

Install the injection nozzle fixing stud

bolts and water pipe fixing stud bolts.

Clean the head bolt holes on the cylinder block with compressed air to remove
foreign

substances

and

thoroughly

clean the gasket fitting face of the cylinder block.

- 69 -

EAMD099I

Install head gasket, with TOP mark facing upward, on the cylinder block by
aligning the holes with dowels.

TOP

EAMD101I

Check the inside of combustion chamber for foreign substances, and carefully
mount the cylinder head assembly in the
block by aligning the dowel pin with the
dowel pin hole. Be careful not to damage the head gasket. If the dowel pin is
not in alignment, lift the cylinder head
again and then remount it.

Coat the head bolts with engine oil, then

tighten them in proper sequence to the
specified torque.

<Cylinder Head Bolts>

Specification

Torque

Type 1

Type 2

TY
12.9T

TY
10.9T

EAMD102I

M14x1.5x153

M14x1.5x150

24.5 kg.m

6 kg.m +180+150

12

13
1

11

14
7

10
EAMD103I

Coat the push rod with engine oil and

insert it into the push rod hole.

- 70 -

Adjust the valve clearance as following

guide.

<Guide for valve clearance adjustment>

After letting the #1 cylinders piston come at the compression top dead center by turning
the crankshaft, adjust the valve clearances.
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.

As for the valve clearance, adjust it when in cold, as follow.

Model

Intake Valve

Exhaust Valve

0.3 mm

0.3 mm

DE12T
P126TI

- By cranking the engine, let #6 cylinders valves overlap.

- In time, adjust the valve clearance corresponding to
- Adjust the valve clearance corresponding to

of lower lists.

of lower lists.

- After reinsuring the valve clearances, retighten if necessary.

No. 1 Cylinder is located at the side where flywheel was installed.

Flywheel

Intake Valve

Exhaust Valve

Cylinder No.

Cooling Fan

EA8O6001

- 71 -

Adjust valve clearance with a feeler

gauge and tighten the fixing nuts to

Valve clearance adjust

specified torque.
Torque

4.4 kgm

EA8M3007

3.3.22. Rocker arm assembly

Apply lubricating oil to the rocker arm

bush and shaft, and assemble the intermediate bracket with the rocker arm
using fixing bolts.

Torque

4.4 kgm

Semi-install valve clearance adjusting

EAMD100I

bolts onto the rocker arm.

Install the spring, rocker arm, bracket,

rocker arm, spring, washer, and snap
ring in the described sequence.

Install the rocker arm and bracket in the

same direction.

EA8M3008

3.3.23. Injection nozzle

Install the dust seal with its round portion

facing downward.

Mount a seal ring (0.5 mm) on the seal

ring seating surface of the nozzle tube
and assemble nozzle holder assembly
with the stud bolt with the nozzle pipe
installing direction facing outward.

Be sure to follow the specified torque.

EAMD105I

Torque

1.0 kgm

- 72 -

3.3.24. Oil cooler

Install the oil cooler onto the oil cooler

cover.

Carefully apply the gasket to prevent oil

leakage.

Do not damage the gasket and install

the cover onto the cylinder block.

Connect a connection pipe between the

water pump and oil cooler.
EAMD106I

3.3.25. Oil filter

Install the oil filter onto the cylinder

block, and tighten the fixing bolts.

With the hollow screw, assemble the oil

pipe connected between the oil cooler
and cylinder block.

Install a connection pipe between the oil

cooler and oil filter.

Install the oil cooler connecting pipe.

Install packing and assemble the cartridge using a filter wrench.

3.3.26. Injection pump

Install the injection pump bracket in the

cylinder block.

After measuring the amount of run-out

with an alignment setting jig, disassemble the bracket, adjust the shims, then
reassemble it.
Run out

0.2 mm or less

EAMD107I

Mount the top/bottom adjusting shims in

the bracket and then mount the fuel
injection pump.

Tighten the fixing bolts in a diagonal

sequence to specified torque.
Torque

4.4 kgm

- 73 -

Turn the flywheel until No. 1 piston is

placed in the OT position of notch
marks on the flywheel, and then turn

Timing
check hole

again the flywheel clockwise until showing the notch mark of the right figure corresponding to the injection timing is
aligned with the pointer (

) on the fly-

wheel housing.

Fuel injection timing

(B.T.D.C static)

DE12T

P126TI

12

12

Injection timing
notch mark

Flywheel
ring gear

EA8O6002

Turn the timer until the notch mark of the

indicator plate attached to the fuel injection pump is aligned with the notch mark

Notch
mark

of the timer.

EA9O5002

- 74 -

Tighten the Coupling fixing bolts and

nuts to specified torque.
Torque

6.0 kgm

Tighten the drive shaft connecting flange

fixing bolts to specified torque
Torque

7.5 ~ 8.5 kgm

EAMD021I

Install the oil delivery pipe and return

pipe.

3.3.27. Vibration damper end pulley

Install the vibration damper on the

crankshaft pulley.

Install the crankshaft pulley assembly on

the crankshaft, then tighten the bolts
and thrust washers.
Torque

13.4 kgm

3.3.28. Fan drive pulley

Install the fan drive pulley onto the timing gear case cover.

3.3.29. Water pump

Mount a new O-ring.

Install the water pump drive pinion over
the PTO (power take-off) spline.

Connect water pipes and by-pass pipe

to the water pump.

Connect a water pipe to the expansion

tank.

EAMD112I

- 75 -

3.3.30. Power take-off

Assemble the power take-off sub assembly.

EA8M3010

3.3.31. Exhaust manifold

Install the exhaust manifold gasket over

the stud bolts by aligning the gasket with
the exhaust port on the cylinder head so
that the face and back of the gasket can
be positioned correctly.

Semi-assemble the exhaust manifold

and install the heat resisting plate.

First, install the nuts and then place an

additional nut on each of them to prevent

EQM3096I

looseness.

3.3.32. Turbocharger

Fit a new gasket over the stud bolts of

the exhaust manifold before tightening
those turbocharger fixing bolts.

Install the oil supply pipe and return pipe.

Semi-assemble the bracket to the intake

pipe, connect a rubber hose between the
turbocharger and intake pipe using rubber hose, then assemble the bracket
completely.

EA8M3012

- 76 -

3.3.33. Starter

Assemble the starter in position on the

flywheel housing.

EAMD121I

3.3.34. Intake manifold

Fit a gasket on the intake manifold

before assembling the intake manifold.

EQM3011I

3.3.35. Injection pipe

Semi-assemble a nut at both ends of the

fuel high pressure pipe and tighten them
up one by one to specified torque.
Torque

13.4 kgm

Tighten hollow screws to assemble the

fuel return pipe.

Assemble the fuel return hose on the fuel

injection pump.

- 77 -

EAMD120I

3.3.36. Fuel filter

Assemble the fuel filter with the intake

manifold.

Assemble the fuel feed hose according

to the direction of an arrow impressed on
the fuel filter head so that fuel can be fed
in the sequence of FUEL FEED PUMP
FUEL FILTER

FUEL INJECTION

PUMP.
EA8M3013

3.3.37. Cylinder head cover

Assemble the cover packing with the

cover, install the cover on the head, then
tighten the fixing bolts in sequence to
specified torque.
Torque

1.5 kgm

Assemble the breather hose with PCV

valve.

EAMD126I

3.3.38. Alternator

Install the alternator mounting bracket.

Install the alternator with fixing bolts to
the mounting bracket.

- 78 -

3.3.39. Cooling fan

Install the cooling fan and flange, then

tighten the fixing boltd.

EQM3106I

3.3.40. V- belt

Install the V-belt on the crank pulley,

Press here

alternator pulley and fan drive pulley.

15mm

Adjust the V-belt tension using the ten-

Fan
Pulley

Alternator
Pulley

sion adjusting bolt.

V-belt

Crank Pulley

EA8O3005

3.3.41. Oil level gauge

Assemble the oil level gauge and guide

tube on the oil pan.

EQM3005I

- 79 -

3.4. Breaking-in
3.4.1. Operation of a new engine (Break-In)
Because the sliding surfaces of a new engine are not lapped enough, the oil film can be
destroyed easily by overload or overspeed and the engine life-time may be shortened.
Therefore the following things must be obeyed by all means.
Up to the first 2,000km(150 hours)
Engine should be run at fast idling until the temperature of the engine becomes normal
operating condition.
Overload or continuous high speed operation should be avoided.
High speed operation with no load should be prevented.
Abrupt start and stop of the engine should be avoided.
Engine speed must be under 70% of its maximum speed.
Maintenance and inspection must be accomplished thoroughly.

3.4.2. Check points for break-in

During the break-in (the initial running of the engine) period, be particularly observant as follows:
a) Check engine oil level frequently. Maintain oil level in the safe range, between the min.
and max. marks on dipstick.
NOTE : If you have a problem getting a good oil level reading on dipstick, rotate dipstick
180( and re-insert for check.

b) Watch the oil pressure warning lamp. If the lamp blinks, it may be the oil pick-up screen is
not covered with oil. Check oil dipstick. Add oil to the oil pan, if required. Do not overfill. If
level is correct and the status still exists, see your DEALER for possible switch or oil
pump and line malfunction.
NOTE : Oil pressure will rise as RPM increases, and fall as RPM decreases. In addition,
cold oil will generally show higher oil pressure for any specific RPM than hot oil.
Both of these conditions reflect normal engine operation.

c) Watch the engine water temperature gauge and be sure there is proper water circulation.
The water temperature gauge needle will fluctuate if water level in expansion tank is too
low.
At the end of the break-in period, remove break-in oil and replace the oil filter. Fill oil pan
with recommended engine oil. Refer to following table.

<Engine Oil capacity>

Oil pan (only)
DE12T

23 liter

P126TI

23 liter

- 80 -

4. Maintenance of major components

4.1. Cooling system
4.1.1. General information
This engine is water-cooling type. Heat from the combustion chamber and engine oil heat are
cooled down by coolant and radiated to the outside, resulting in the normal operation of the
engine.
Looking into the cooling system, the water pumped up by the water pump circulates around
the oil cooler through the water pipe to absorb the oil heat, and then flows through the water
jacket of the cylinder block and water passage of the cylinder head to absorb the heat of the
combustion chamber.
The water absorbing the oil heat and combustion chamber heat goes on to the thermostat
through the water pipe, and circulates to the water pump if water temperature is lower than
the valve opening temperature on the thermostat, while circulating to the radiator at water
temperature higher than the valve opening temperature. At the radiator, the heat absorbed in
the coolant is radiated to cool down and the coolant recirculates to the water pump.

Water pipe

Thermostart

R
a
d
i
a
t
o
r

Cylinder head

Cylinder block

Water pump

Oil cooler

Air compressor
EQM4001I

Specification
Item
1. Water pump

Specification
Centrifugal type

type
Delivery

About 350 liter/min

Pumping speed

2,100 rpm

Pumping back pressure

760 mmHg

2. Thermostat
Operating temperature
3. Cooling fan and belt
Fan diameter - Number of blades
Fan belt tension

83 ~ 95C
I755 - 7
15mm/ deflection by thumb

- 81 -

4.1.2. Water pump

Loosen the bolt (16) to disassemble the housing cover (15).

Heat the impeller (6) slightly, then remove it using a puller jig.
Remove the mechanical seal.
Unscrew the socket bolt (12) and remove the shaft and bearing assembly from the housing.
With a press, remove the spline shaft and bearing.
Reverse the disassembly sequence for reassembly operation.
Replace the oil seal (7) with a new one at reassembly.
To reassemble the impeller, maintain a constant gap (0.3 ~ 0.6 mm) between the impeller
and pump housing using a feeler gauge.

Thickness 0.3 ~ 0.6

2
1
9
Par latex coating

11
4
6
13

10

12

11
14 13 12

EAMC001I

<Construction of water pump>

1.Water pump housing

8.Ball bearing

13.Spline shaft

4.Shaft

9.Space

14.Gasket

5.Mechanical seal

10.Ball bearing

15.Housing cover

6.Impeller

11.Bearing cover

16.Bolt

7.Oil seal

12.Socket bolt

- 82 -

4.1.3. Thermostat

General descriptions and main data

To radiator

The thermostat maintains a constant temperature of coolant (90 ~ 95 C) and

improves thermal efficiency of the engine
by preventing heat loss.
Namely, when the temperature of coolant
is low, the thermostat valve is closed to
make the coolant bypass to directly enter

From cooling
water pump

the water pump; when the coolant temper-

To bypass
tube

Bypass
valve
EAMC002I

ature rises to open wide the thermostat

valve, the bypass circuit is closed and the
water passage to the radiator is opened so that the coolant is forced to flow into the radiator.
Item

Specifications

Type

Wax-pallet type

Open at

83 C

Open wide at

95 C

Valve lift

8 mm or more

Inspecting
(1) Check the wax pallet and spring for
damage.
(2) Put the thermostat in a container of

Bar
Temp. gauge

water, then heat the water slowly and

check temperature with a thermometer.
If the valve lift is 0.1 mm (starting to

Wooden plate

open) at temperature of 83 C and 8 mm

or more (opening wide) at temperature
of 95 C, the thermostat is normal.

EFM2055I

Replacing thermostat and precautions for handling

(1) Precautions for handling
The wax pallet type thermostat does not react as quickly as bellows type one to a variation of temperature of coolant. Such relatively slow reaction is mainly due to the large
heat capacity of the wax pellet type thermostat. Therefore, to avoid a sharp rise of
coolant temperature, it is essential to idle the engine sufficiently before running it. In
cold weather, do not run the engine at overload or overspeed it immediately after starting off.
(2) When draining out or replenishing coolant, do it slowly so that air is bled sufficiently
from the entire cooling system.
(3) Replacing thermostat
If the thermostat is detected defective, retrace with a new one.

- 83 -

4.1.4. Diagnostics and troubleshooting

Complaints
1. Engine overheating

Possible causes

Lack of coolant
Radiator cap pressure

Corrections

Replenish coolant
Replace cap

valve spring weakened

Fan belt loosened or

Adjust or replace fan belt

broken

Fan belt fouled with oil

Thermostat inoperative
Water pump defective
Restrictions in water
passages due to deposit

Replace fan belt

Replace thermostat
Repair or replace
Clean radiator and water
passages

of scales

Injection timing incorrect

Adjust injection timing cor

rectly

Restriction in radiator

Clean exterior of radiator

core

Gases leaking into water Replace cylinder head

jacket due to broken cyli

gasket

nder head gasket

2. Engine overcooling

Thermostat inoperative
Ambient temperature

Replace thermostat
Install radiator curtain

too low
3. Lack of coolant

Radiator leaky
Radiator hoses loosely
connected or damaged

Correct or replace
Retighten clamps or
replace hoses

Radiator cap valve spring Replace cap

weakened

Water pump leaky

Heater hoses loosely

Repair or replace
Tighten or replace hoses

connected or broken

Cylinder head gasket

leaky

Replace cylinder head

gasket

Cylinder head or cylinder Replace cylinder head

block cracked
4. Cooling system
noisy

Water pump bearing

block

Replace bearing

defective

Fan loosely fitted or bent Retighten or replace fan

Fan out of balance
Replace fan
Fan belt defective
Replace fan belt

- 84 -

4.2. Lubricating system

4.2.1. General descriptions and main data

General descriptions
All the engine oil pumped up from the oil pan by the gear type oil pump is filtrated through
the oil cooler and oil filter, and this filtrated oil is forced through the main oil gallery in the
cylinder block from where it is distributed to lubricate the various sliding parts, and fuel
injection pump in order to ensure normal engine performance.

Specifications
Item

Specifications

Lubricating system

Item

Specifications

Forced pressure Oil filter type

Full flow

circulation
Oil pump type

Gear type

Relief valve opening pressure

Bypass for filter element

101.5 kgcm

Bypass for oil cooler

Valve opening pressure 1.8 2.3 kgcm2

Bypass for entire oil filter

Opening pressure

5+1 kgcm

Valve opening pressure 4.0 ~ 4.8 kgcm2

Adjusting valve for spray nozzle

Opening pressure

1.5 ~ 1.8 kgcm2

Diagram of lubricating system

Rocker arm

WAter pump
bearing
Fuel injection
pump
Turbocharger

Conn. rod bearing

Main bearing
Oil spray nozzle
1.3bar
Main oil gallery
Relief valve
4.4bar

Oil cooler

Oil filter

Valve

Valve

5bar

2bar

Oil pump

Valve
10bar

EQM4005I

- 85 -

4.2.2. Oil pump

Disassembly
(1) Disassembly of oil pump drive gear
a .Unscrew the screw and disassemble the oil relief valve.
b. Unfold the washer for the oil pump
drive gear fixing nut and remove
the nut.
c. Disassemble the drive gear.
EQM4006I

(2) Remove the oil pump cover fixing nuts

and disassemble the oil pump cover.
The oil pump cover is fixed with the
two dowel pins.

(3) Disassemble the drive gear and driven gear.

EQM4007I

Inspection and correction

(1) With steel rule and feeler gauge, measure the axial end play of the oil pump
gear. Replace if the measured value is
beyond the limit.
End play

0.025 ~ 0.089 mm

Steel plate
Feeler gauge
EQM4008I

(2) With a feeler gauge, measure the

amount of backlash between the oil
pump drive gear and driven gear.
Replace if the measured value is
beyond the limit.
Backlash

0.50 ~ 0.64 mm

EQM4009I

- 86 -

(3) Measuring clearance between drive shaft and bushing

a. Measure the outside diameters of the drive shaft and driven shaft, and replace if the
measured values are less than the limit.
Standard

16.95 ~

16.968 mm

b. Measure the inside diameter of the pump body bushing to determine the clearance
between the bushing and shaft, and compare the measured value with the standard
value to determine whether to replace or not.
Clearance

0.032 ~ 0.077 mm

Reassembly

(1) For reassembly, reverse the disassembly sequence.

4.2.3. Oil filter

The oil filter mounted in this engine is of cartridge type, so it is necessary to replace it with a
new one at the specified intervals.

Oil filter (Cartridge)

Oil filter head

EQM4010I

- 87 -

4.2.4. Diagnostics and troubleshooting

Complaints
1. Oil consumption
excessive

Possible causes

Corrections

Poor oil

Use suggested oil

Oil seal or packing leaky

Replace

Pistons or piston rings worn Replace pistons and/or pis

ton rings

Cylinder liner worn

Replace cylinder liner

Piston rings sticking

Replace pistons and/or pis

ton rings

Valve guide oil seals or valve Replace

guides, or valve stem worn
2. Oil pressure too low

Poor oil

Use suggested oil

Relief valve sticking

Replace

Restrictions in oil pump

Clean strainer

strainer

Oil pump gear worn

Replace

Oil pump feed pipe cracked Replace

Oil pump defective

Correct or replace

Oil pressure gauge defective Correct or replace

3. Oil deteriorates
quickly

Various bearings worn

Replace

Restriction in oil filter

Replace filter element

Gases leaking

Replace piston rings and

cylinder liner

Wrong oil used

- 88 -

Use suggested oil

4.3. Fuel injection pump

4.3.1. General information of fuel system
The fuel system consists of the fuel tank, injection pump, injection nozzle, fuel filter, and fuel
lines such as pipes and hoses necessary to connect those components.

4
7

8
12
10
9

11

EA8O3004

1. Fuel filter

7. Delivery pipe

1a. Fuel water drain plug

8. Fuel pipe (manual pump

2. Air bleeding screw (for fuel filter)

9. Fuel tank

3. Injection nozzle

10. Fuel return pipe

4. Overflow tube

11. Suction pipe

5. Fuel pipe (filter

injection pump)

12. Feed pump

6. Overflow valve

13. Injection pump

- 89 -

filter)

4.3.2. Injection pump

The components relating to the injection pump should be serviced at regular intervals as the
plunger and delivery valve may be worn after a given length of time for use and cause the
deterioration of the engine.
Make sure that servicing should be performed at the professional maintenance shop as
authorized by Bosch or Zexel Company.
For adjustment of fuel injection volume, refer to the Specifications of fuel injection pump
described on the following pages.

1) DE12T
(1) Main data and specifications
Part No.

: 65.11101-7222(106672-9920)

Model

: NP-PE6P120/720RS3000(106061-7250)

Governor

: NP-EP/RSV200-1200PD36C311(105407-4720)

Timer

: without timer

Plunger

Delivery valve

: 120 mm3/st( 8 x 2.4mm)

Fuel feed pump

: NP-FP/K-P(105207-1400)

Pre-stroke

: 4.7 mm

12, right hand helix 30 lead

(2) Nozzle holder assembly

: 65.10101-7300(105160-4351)

(3) Nozzle

: 65.10102-6046(105029-1330)

(4) Injection pipe

: 65.10301-7004B

(5) Injection order

: 1-5-3-6-2-4

(6) Injection timing

: BTDC 12C

(7) Calibration data

Adjusting Rack position Pump speed

Injection volume

Variation Basic Fixing

point

(mm)

(rpm)

(mm3/1,000st)

rate (%)

10.8

900

1292

11

875

(135)3

Approx. 6.4

250

14.51.5

15

100

193.510

Content

point

Ref.

point

Engine

Specification

Application
Adjusting

Nozzle holder assembly

conditions Nozzle
Nozzle holder
Opening pressure
Injection pipe

105780-8140

65.10101-7300

105780-0000

65.10102-6046

105780-2080

175 kgcm

220 kgcm2

8x

3 - 600 mm

Fuel delivery pressure

1.6 kgcm

Fuel temperature

35 ~ 45 C

- 90 -

6x

2.2 - 650 mm
35 ~ 45 C

(8) Governor adjustment

Rack limit

over 14

RACK POSITION (mm)

11.0

10.8

Idle spring
0
Set : 6.5 -0.5
mm

6.5
6.4

C
0
45 -10

_
250 400+20

_
900+5

PUMP SPEED (rpm)

EA8M4001

- 91 -

2) P126TI
(1) Main data and specifications
Part No.

: 65.11101 -7310 (106674-4130 ZEXEL)

Model

: NP-PE6P120/700RS3S (106067-6020)

Governor

: GAC electric (65.11501-7002A)

Plunger & barrel

Delivery valve

: 90mm2/st ( 7 x 2.35mm)

Fuel feed pump

: NP-FP/KD-PS (105237-5470)

Pre-stroke

: 3.9 0.05 mm

12, right hand double helix 30 lead

(2) Nozzle holder assembly

: 65.10101-7054 (10501-8520)

(3) Nozzle

: 65.10102-6048 (105019-2450)

(4) Injection pipe

: 65.10301-6042, 65.10301-6043

(5) Injection order

: 1-5-3-6-2-4

(6) Injection timing

: BTDC 12

(A) Test condition

for injection pump

Nozzle & Holder Assy 105780-8130

Injection pipe(ID ,OD ,L)
Test oil

Opening pressure : 175 kgcm2

3.0 x

Temperature :405C

ISO4113
65.10101-7054

(B) Engine standard

Nozzle (5 x

Nozzle & holder Assy

Injection pipe(ID, OD ,L)

0.37)

1st pressure : 160 kgcm2

65.10102-6048

parts

8.0 - 600 mm

2nd pressure : 220 kgcm2

65.10301-6042

2.2 x

6 - 600mm

65.10301-6043

Rack diagram and setting valve at each point

Check
point

Rack

Pump

position

speed

(mm)

(rpm)

Standby power
B

Injection Qty on RIG

(mm3 / 1,000 st)
(A) Test condition (B) Engine
for inj. pump

900

Press.
(mmHg)

standard parts
2403

- 92 -

4.3.3. Governor system (P126TI)

Governor system for fuel injection pump consists of Integral Actuator and Speed Control
Unit.
(1) Integral Actuator

<Side View>

<Top View>

- 93 -

Fig. No.

Description

Qty

Remark

stop lever (emergency)

pump gasket

washer

allen screw

7 ~ 9 N.m

ball link

stop nut

3.5 ~ 4.0 N.m *

operating lever

oil seal

counter nut

10

stop screw

11

connector screw

12

mounting bar

13

flat washer

14

lock washer

15

nut

16

flat washer

17

lock washer

18

nut

19

threaded bolt (part of bearing kit)

20

actuator spring

21

gasket, lower cover

22

lower cover

23

washer

24

allen screw

25

receptacle

26

sealing screw

27

gasket, upper cover

28

flat washer

29

screw, ball link

30

connecting rod

31

nut

32

stop plate

33

top cover

34

manual stop device complete

linkage complete

4.5 ~ 6.0 N.m

17 ~ 21 N.m

7 ~ 9 N.m

2.0 ~ 3.0 N.m

3.5 ~ 4.5 N.m

comprise pos. 5,6,28,29,30,31,32

35

fixing screw

12.5 ~ 13.0 N.m

36

stop nut

12.5 ~ 13.0 N.m

- 94 -

(2) Speed control unit for governor system

The ESD5550 Series speed control unit is an all electronic device designed to control
engine speed with fast and precise response to transient load changes. This closed loop
control, when connected to a proportional electric actuator and supplied with a magnetic
speed sensor signal, will control a wide variety of engines in an isochronous or droop
mode. It is designed for high reliability and built ruggedly to withstand the engine environment.
Simplicity of installation and adjustment was foremost in the design. Non-interacting performance controls allow near optimum response to be easily obtained.
The primary features of the ESD5550 Series speed control unit are the engine STARTING
FUEL and SPEED RAMPING adjustments. The use of these features will minimize engine
exhaust smoke experienced prior to attaining engine operating speed.
Other features include adjustable droop and idle operation, inputs for accessories used in
multi-engine or special applications, protection against reverse battery voltage, transient
voltages, accidental short circuit of the actuator and fail safe design in the event of loss of
speed sensor signal or battery supply.
Engine model

P126TI

GAC governor model

ACE 175A

Speed control unit model

ESD5550

- 95 -

(A) Specification
PERFORMANCE
Isochronous Operation/steady State Stability
Speed Range/Governor
Speed Drift with Temperature
Idle Adjust CW
Idle Adjust CCW
Droop Range
Droop Adj. Max. (K-L Jumpered)
Droop Adj. Min. (K-L Jumpered)
Speed Trim Range
Remote Variable Speed Range
Terminal Sensitivity
J
L
N
P
Speed switch adjustment range
ENVIRONMENTAL
Ambient Operating Temperature Range
Relative Humidity
All Surface Finishes
INPUT POWER
Supply

0.25% or better
1 K ~ 7.5 KHz continuous
1% Maximum
60% of set speed
Less than 1,200 Hz.
1 ~ 5 % regulation*
400 Hz 75 Hz per 1.0 A change
15 Hz 6 Hz. per 1.0 A change
200 HZ
500 ~ 7.5 Hz or any part thereof
100 Hz 15 Hz/Volt @ 5.0 K Impedance
735 Hz 60 Hz/Volt @ 65 K Impedance
148 Hz 10 Hz/Vo1t @ 1 Meg. Impedance
10 VDC Supply @ 20 ma Max.
1,000 ~ 10,000 Hz
- 40 F to 180F (- 40 C to + 85 C)
up to 95 %
Fungus Proof and Corrosion Resistant
12 or 24 VDC Battery Systems
(Transient and Reverse Voltage Protected)**
Negative Ground (Case Isolated)
50 ma continuous plus actuator current
Min.2.5 Amps/ Max. 10 Amps continuous ***

Polarity
Power Consumption
Actuator Current Range
@ 77 F (25 C) -(Inductive Load)
Speed Sensor Signal
Speed switch relay contacts (N.O. and N.C.)
RELIABILITY
Vibration
Testing
PHYSICAL
Dimensions
Weight
Mounting

0.5 ~ 120 Volts RMS

10 Amps
1G @ 20 ~ 100 Hz
100% Functionally Tested
See Outline
1.8 lbs (820 grams)
Any Position, Vertical Preferred

Note :
* Droop is based on a speed sensor frequency of 4,000 Hz and an actuator current
change of 1 amp from no load to full load. Applications with higher speed sensor signals
will experience less percentage of droop. Applications with more actuator current
change will experience higher percentages of droop. See droop description for specific
details on operation of droop ranges.
** Protected against reverse voltage by a series diode. A 15 Amp. fuse must be Installed in
the positive battery lead,
*** Protected against short circuit to actuator (shuts off current to actuator), unit automatically turns back on when shorts is removed.

- 96 -

(B) Diagram

6.00 (152)
5.25 (133)

O 0.27 (7)

C2
ON
SOFT COUPLING
OFF

C1 OFF
LEAD CIRCUIT
ON

OVERSPEED
OVERNORS
MERICA

GA

1 2 3

RESET TEST
OVERSPEED

ORP

SPEED CONTROL UNIT

SPEED

MODEL : ESD5550
S/N

GAIN
STABILITY

6.00 (152)

6.05 (165)

MADE IN AGAWAM, MA U.S.A

STARTING
FUEL

SPEED
RAMPING

CAUTION

ACTUATOR

E3

DEAD TIME
COMPENSATION
JUMPER

DROOP

ENGINE SPEED CONTROL

COMPONENT WHEN INSTALLING
OR SERVICING REFER TO
PRODUCT PUBLICATION

PICK-UP

E2
E1

_
+
BATTERY

IDLE
AUX

10V
OUTPUT

A B C D E F G H J K L M N P

OPTIONAL ACTUATOR
CABLE SHELDING TO
MEET CE DIRECIVE

ACCESSORY POWER
SUPPLY
ACCESSORY INPUT

ADD JUMPER FOR 12V

BATTERY OR ACTUATOR
CURRENTS ABOVE 5A
GROUND REFERENCE

ACTUATOR
CW

MAGNETIC
PICK-UP
_

BATTERY

1.03 (26)

CLOSE FORDROOP
SPED TRIM
CONTROL - 5K

S1

CLOSE FOR IDLE

FUSE
15A MAX

SEE SPECIFIC ACTUATOR PUBLICATION FOR PROPER

WIRING OF ACTUATOR BASED ON BATTERY VOLTAGE

EA6M4004

- 97 -

Note :
* If wire leads are longer than 3 meters (10 ft), a shielded cable should be used. Ground
shield at

ONE END ONLY.

* The speed control unit is rugged enough to be placed in a control cabinet or engine
mounted enclosure with other dedicated control equipment. If water, mist, or condensation may come in contact with the controller, it should be mounted vertically. This will
allow the fluid to drain away from the speed control unit.
* EXTREMely heat should be avoided.

Caution :
An overspeed shutdown device, independent of the governor system, should be provided
to prevent loss of engine control which may cause personal injury or equipment damage.
Do not rely exclusively on the governor system electric actuator to prevent overspeed. A
secondary shutoff device, such as a fuel solenoid must be used.

(C) Wiring
Basic electrical connections are illustrated above. Actuator and battery connections to
Terminals A, B, E, and F should be #16 AWG (1.3 mm2) or larger. Long cables require an
increased wire size to minimize voltage drops.

The battery positive (+) input, Terminal F, should be fused for 15 amps as illustrated.

Magnetic speed sensor connections to Terminals C and D MUST BE TWISTED AND/OR

SHIELDED for their entire length. The speed sensor cable shield should only be connected to terminal D. The shield should be insulated to insure no other part of the shield
comes in contact with engine ground, otherwise stray speed signals may be introduced to
the speed control unit. With the engine stopped, adjust the gap between the magnetic
speed sensor and the ring gear teeth. The gap should not be any smaller than 0.020 in,
(0.45 mm). Usually, backing out the speed sensor 3/4 turn after touching the ring gear
tooth will achieve a satisfactory air gap. The magnetic speed sensor voltage should be at
least 1 VAC RMS during cranking.

- 98 -

(D) System Trouble shooting

SYSTEM INOPERATIVE
If the engine governing system does not function, the fault may be determined by performing the voltage tests described in Steps 1, 2, 3, and 4. (+) and (-) refer to meter
polarity. Should normal values be indicated as a result of following the trouble shooting
steps, the fault may be with the actuator or the wiring to the actuator See the actuator
publication for testing details.

Step

Terminals

Normal Reading

Probable Cause Of Abnorma Reading

F(+) & E(-)

Battery supply voltage

1. DC battery power not connected. Check

(12 or 24 VDC)

for blown fuse

2. Low battery voltage.
3. Wiring error.

C&D

1.0 VAC RMS min.,

1. Gap between speed sensor and gear teeth

while cranking

too great. Check gap.

2. Improper or defective wiring to the speed
sensor. Resistance between terminals C
and D should be 30 to 1,200 ohms.
3. Defective speed sensor.

P(+) & G(-)

10 VDC,

1. Short on terminal P (This will cause a

Internal Supply

defective unit.)
2. Defective Speed Control.

F(+) & A(-)

1.0~ 2.0 VDC

1. SPEED adjustment set too low

while cranking

2. Short/open in actuator wiring.

3. Defective speed control.
4. Defective actuator.

- 99 -

 UNSATISFACTORY PERFORMANCE
If the governing system functions poorly, perform the following tests.
Symptom
Engine overspeeds

Test

Probable Fault

1. Do not crank. Apply DC power to the

governor system

1. Actuator goes to full fuel. Then, disconnect speed sensor at Terminals C

& D.
If actuator still at full fuel speed control
unit defective. If actuator at minimum
fuel position - erroneous speed signal.
Check speed sensor data.

2. Manually hold the engine at the

desired running speed. Measure the
DC voltage between Terminals A(-) &
F(+) on the speed control unit.

1. If the voltage reading is 1.0 to 2.0 VDC.

a) SPEED

adjustment

set

above

desired speed.
b) Defective speed control unit.
2. If the voltage reading is above 2.0
VDC, a) Actuator or linkage binding.
3. If the voltage reading is below 1.0
VDC, a) Defective speed control unit.
4. Gain set too low.

Actuator does
not energize

1. Measure the voltage at the battery

while cranking.

1. If the voltage is less than 7V for a 12V

system, or14V for a 24V system,
replace the battery if it is weak or

fully.

undersized.
2. Momentarily connect Terminals A and

1. Actuator or battery wiring in error.

F The actuator should move to the full

2. Actuator or linkage binding.

fuel position.

3. Defective actuator.
4. Fuse opens. Check for short in actuator or actuator wiring harness.

Engine remains
below desired
governed speed.

1. Measure

the

actuator

output.

1. If voltage measurement is within

Terminals A & B, while running under

approximately 2 volts of the battery

governor control.

supply voltage, then fuel control

restricted from reaching full fuel position. Possibly due to interference from
the mechanical governor, carburetor
spring or linkage alignment.
2. Speed setting too low.

- 100 -

4.3.4. Fuel feed pump

1) General descriptions and construction

Priming pump

Check valve
Check valve

Outlet
side

Inlet
side

Tappet
Piston

Cam shaft
EQM4019I

The P-type injection pump is mounted with K-ADS or KP type feed pump. These pumps
have the same basic construction and operation, and the general descriptions of the KP
type pump are given below:
The figures show its construction (right figure) and operation (below figure). The piston in
the fuel feed pump is driven by the push rod and tappet via the camshaft of injection pump
and performs reciprocating operation to control the suction and delivery of fuel. When the
cam reaches the Bottom Dead Center as shown in the figure, the fuel is drawn in through
the check valve on the inlet side.
The fuel pressurized as the cam rotates on flows through the check valve on the outlet side
as shown in (B). If the feeding pressure increases abnormally, the spring is compressed,
resulting in interrupting further delivery of fuel as shown in (C).

- 101 -

(A)
Inlet side

(B)
Outlet side

(C)
Interruption

EQM4020I

This feed pump is mounted with a priming pump designed to permit manual feeding of fuel from the
fuel tank with the injection pump mounted in the engine. During the manual feeding operation, air
must be bled from the fuel lines.
When using the priming pump, fix it securely to prevent the possible entry of moisture or other foreign substances in the inside of feed pump.

In addition, a strainer is fitted into joint bolt on the inlet side of the fuel feed pump to filtrate any foreign substances possibly mixed in fuel.

- 102 -

2) disassembly

Clamp the feed pump with a vise and disassemble the plugs (30, 32), strainer (31) and
gaskets (35, 36).

Take off the priming pump (25), plug (16), both gaskets (18), spring (15), and check
valve (14).

Take off the prig (7), gasket (8), spring (6), and piston (5) on the piston side.
Pull out the snap ring (20) holding the tappet (10).
Disassemble the snap ring, then take off the tappet (10) and push rod (1).
3) Inspection

If the check valve is damaged or scored on its seat face, replace it with a new one.
Inspect the piston and tappet for damage.
Replace the push rod if excessively worn, and replace together with the pump housing if
required. The inspection for wear should be performed in the same procedure as for
suction pressure test described below.

4) Reassembly
Reassembly operation is performed in reverse order of disassembly. All the gaskets must
be replaced with new ones at reassembly.

- 103 -

5) Testing
(1) Suction capacity test
Connect one end of a hose to the inlet
side of the feed pump and immerse the

Outlet hose

other end of it into the fuel tank as illusFeed pump

trated.
Hold the feed pump in position about 1
m above the level of fuel in the fuel
tank.

Inlet hose

Operate the tappet at the rate of 100

rpm and check to see if fuel is drawn in
and delivered for 40 seconds or so.

Fuel tank
EQM4022I

(2) Delivery test

Make a test with the feed pump mounted
on a pump tester as illustrated. Operate
the pump at the rate of 1,000 rpm and
check to see if the pump delivery is more
than 405 cc/15 seconds.

EAMC016I

(3) Sealing test

Plug up the delivery port on the feed
pump and apply compressed air of 2

Compressed
air 2kg / cm2

Mass cylinder

kg/cm2 into the inlet side.

Submerge the feed pump in a container of
diesel fuel and check for air leak.

Feed pump
EQM4023I

- 104 -

4.3.5. Injection nozzle

1) General descriptions
Pressurized fuel delivered from the fuel injection pump is sprayed into the combustion
chamber past the injection nozzle at proper spray pressure and spray angle, then burnt
completely to achieve effective engine performance.

(1) At valve closed

(2) At valve opened

EQM4024I

2) 1-spring type
(1) Disassembly

1. Cap nut
2. Adjusting screw
3. Spring
4. Push rod
5. Connector
6. Retaining nut
7. Needing valve
8. Nozzle
9. Nozzle holder

- 105 -

(2) Reassembly

After

removing carbon deposit, sub-

merge the nozzle in diesel oil and clean

it.

Replace all the gaskets with new ones.

Assemble the parts and tighten them to
specified torque.

(3) Adjustment

Remove

the cap nut and assemble a

nozzle to a nozzle tester.

With

the adjusting screw loosened,

operate the nozzle 2 ~ 3 times to bleed

it.

Operate

the nozzle tester lever at the

specified rate.

Adjust the injection pressure to the standard

pressure

using

the

adjusting

EA0M3003

screw.

After

adjusting the injection pressure,

tighten the cap nut to specified torque.

Re-check

the injection pressure and

see if the spray pattern is normal.

(4) Testing
With the nozzle assembled to a nozzle
tester and pressure of 20 ~ 21 MPa (200
~ 210 bar) applied, check the nozzle for
fuel leakage.

EAMC022I

- 106 -

3) 2-spring type
(1) Disassembly

31
30

7
1
6
4
10
11
12
15

3
13
14
16

17

EQM4029I

1. Nozzle holder body

13. Lift pin

2. Push rod

14. Pin

3. Primary spring

15. Spacer

4. Adjusting screw

16. Pin

6. Gasket

17. Retaining nut

7. Cap nut

30. Gasket

10. Adjusting shim

31. Eve bolt

11. Scondary spring

A. Nozzle

12. Spring Seat

- 107 -

(2) Inspection and adjustment

Adjusting the primary opening pressure a.
Install

the

plate

of

plate

assembly

(157944-9520) onto a vise.

NOTE : Use the plate assembly

(157944-9520) in fixing a nozzle
holder having a flange. A nozzle
holder without flange should be

EQM4030I

directly installed onto a vise.

b. With the nut, install the two pins on the plate.

c. Install the nozzle holder body (1) onto

the plate with the cap nut side facing
downward.

EQM4031I

d. Assemble adjusting shim (10), secondary

spring (11), and spring seat (12) on the
nozzle holder body in the order as
described.

12
11
10

Note: The secondary spring is the same

one as the primary spring.

EQM4032I

e. Assemble the pin (14), lift piece (13), and

spacer (15) with the nozzle holder body.

15
14
13

EQM4033I

- 108 -

f. Install the pin (16) and nozzle (A) onto the

spacer.

A
16

EQM4034I

g. After installing the gasket (157892-1500)

on the nozzle, use the cap nut (1578924000 : SW22mm) to fix the nozzle onto the
nozzle holder.

Note : While

tightening

the

cap

nut,

keep checking to see if the lock pin

comes all the way into the nozzle.

Note : Tighten

the

retaining

nut

until

it resists hand tightening, then further tighten it using a torque

wrench.

h. Be sure to follow the specified torque rating when tightening the adjusting retaining
nut.

Torque

6.0 ~ 8.0 kgm

EQM4036I

i. With the cap nut facing upward, install the

nozzle holder on the plate.

- 109 -

j. Assemble the push rod (2), primary spring

(3), and adjusting screw (4) on the nozzle
holder in the order described.

k. Install the gasket and cap nut onto the

adjusting screw.

l. Assemble the nozzle and nozzle holder

60

assembly to the nozzle tester (105785-

40
80
20

1010).

100

EQM4039I

m. Adjust the primary opening pressure to

the specified pressure using the adjusting
screw (4).

EQM4040I

n. With a monkey wrench, fix the nozzle holder securely and tighten the cap nut (SW
19mm) to specified torque.

Torque

3.0 ~ 4.0 kgm

EQM4041I

- 110 -

 Inspecting the needle valve for full lift

a. Install gasket (026508-1140) and plug
(157892-1600 : SW12mm) onto the
adjusting retaining nut (157892-1400).

EQM4042I

b. Install the nozzle holder on the plate

with the cap nut facing upward.

c. Install the holder into the cap nut.

d. Install a nut (157892-1000 : SW 17mm)

on the holder.

e. Assemble the pin (157892-4200 or

157892-4300)

to

the

dial

gauge

(157954-3800).

Part No.

L (mm)

157892-4200

160

157892-4300

110

Note : L means the length of the pin

except the threaded portion.
EQM4045I

- 111 -

f. Install the dial gauge on the holder assembly so that the pin is brought into contact
with the upper end of the push rod, then fix
the pin with the nut.

Note 1 : Fix the dial gauge so that a

stroke of 2 mm or so can be measured.
Note 2 : Overtightening

the

nut

may

cause a sticking of the dial gauge

seat.

g. Assemble the nozzle and nozzle holder

assembly to the nozzle tester and zero the
dial gauge.

h. Operate the nozzle tester, bleed the retaining nut, and check for fuel leakage.

I. Operate the nozzle tester and increase the

tester pressure up to 350 ~ 450kgfcm2 in

order that the needle valve can be fully lifted. Then, record the full lift value L.

Note : This testing is to be made in order

to check the nozzle seat portion for
unusual wear or whether the nozzle
assembly is a standard item.

0
EQM4048I

- 112 -

 Inspection of pre-lift
a. If the nozzle tester handle is released
200

with the needle valve engaged in a full lift

300

condition, the tester pressure drops,

100

400

being accompanied by decrease in the

needle valve lift value (indicated value on
500

the dial gauge).

kgf / cm

EQM4049I

Amount of lift

0
Tester pressure

EQM4050I

b. Take the indicated value on the dial

gauge at the point of time when the secondary spring completes its operation
and the needle valve puts an end to
descent (the position of needle valve lift
value as shown in the above and right
figures) and check that the value is within the specified limit.
EQM4051I

Measuring point for pre-lift

L

at a point of primary opening pressure +

approx. 1 0 kgfcm2.

Note : Locate

the

opening

point

of

primary

pressure

approx.

10kgfcm while dropping the pres2

sure.

- 113 -

Amount of lift

Take the indicated value on the dial gauge

0
Primary opening pressure
Tester pressure
EQM4052I
EQM4050I

c. If the measured pre-lift value deviates

14
15

13
16

from the specified limit, replace the pin

(14, 16), lift piece (13), spacer (15), and
nozzle assembly (A) with a new nozzle

service kit.

EQM4053I

Inspection of secondary opening pressure

a. After confirming the pre-lift, operate the

pressure up to 350 ~ 450 kgf/cm2 to fully

lift the needle valve.

Amount of lift

nozzle tester and increase the internal

+0.05

b. Release the nozzle tester handle to

decrease the tester pressure, then take
a note of the movements of the dial

0
Primary opening
pressure

Secondary
opening pressure

350~450
kgf/cm2
EQM4054I

gauge.

c. Take the indicated value on the pressure

gauge at the point of time when the nee60

dle of the dial gauge indicates the speci-

40
80

20

fied needle valve lift value. (In general,

0

100

pre-lift + 0.05mm. Refer to following

figure.)

EQM4055I

0
90

200

10

300

80
20

100

400

70
30
0

60

500

40
50

EQM4056I

- 114 -

 Adjusting secondary opening pressure

a. In the event that the measured value
deviates from the specified limit, readjust
the primary opening pressure if the
amount of deviation is small. (to the standard range of the primary opening pressure)
- If the secondary opening pressure is
lower than the standard value: Adjust the
primary opening pressure up to the top

EQM4040I

limit of the standard vague, and then

measure the secondary opening pressure.
- If the secondary opening pressure is
higher than the standard value: In a
reverse manner, readjust the primary
opening pressure down to the bottom
limit of the standard value.

b. If the secondary opening pressure still

deviates from the specified limit in spite

10

of the readjusting the primary opening

pressure, take off the nozzle fixing portion from the nozzle holder and remove
the adjusting shim (10).

c. If the secondary opening pressure is

higher than the standard value, fit a thin-

EQM4058I

ner adjusting shim than the existing one.

d. After replacing the existing adjusting
shim, measure the secondary opening pressure and continue the adjustment until a value
satisfying the standard value.

- 115 -

Adjusting shim for secondary opening pressure

(Out diameter =

9.5 , Inner diameter =

4.5)

Part No.

Thickness(mm)

Part No.

Thickness(mm)

1505380-4900

0.40

1505380-5300

0.56

1505380-5000

0.50

1505380-5400

0.58

1505380-5100

0.52

1505380-5500

0.60

1505380-5200

0.54

1505380-5600

0.70

Retaining nut
a. Take out the dial gauge, nut, holder and
gasket from the cap nut.
b. Remove the adjusting retaining nut and
gasket, and install the original retaining
nut. (SW 19mm)

7
Torque

6.0 ~ 8.0 kgm

EQM4036I

Inspection at completion
a. Assemble the nozzle holder to a nozzle
60

tester and check the primary opening

40
80
20

pressure, spray patterns, oil tightness of

100

seat portion, and oil leakage from each

part.

EQM4039I

b. When replacing the nozzle, replace it

with a new nozzle service kit integrated
with a nozzle, lift piece, and spacer as a

13
15

complete set.

Note : If only a nozzle is replaced, the

amount of pre-lift will deviate from

the specified value.
EQM4060I

- 116 -

4.3.6. Diagnostics and troubleshooting

Complaints

Possible causes

Corrections

1. Engine wont start

(1) Fuel pipes clogged or air into pipe line

Correct

1) Fuel not being pumped

(2) Feed pump valve defective

Replace

(3) Feed pump piston or push rod sticking

Disassemble, correct

(1) Fuel filter element restricted

Clean

(2) Air in fuel filter or injection pump

Bleed

(3) Plunger and/or delivery valve sticking

Disassemble, correct

out from feed pump

2) Fuel not being injected
from injection pump

or defective
3) Fuel injection timing
incorrect

(1) Injection pump not properly installed

Check, correct

on pump bracket
(2) Injection pump tappet incorrectly

Check, correct

adjusted

4) Injection nozzles
inoperative

(3) Cams on cam shaft worn excessively

Replace

(1) Needle valves sticking

Correct or replace

(2) Fuel leaking past clearance between

Correct or replace

nozzle and needle valve

2. Engine starts but

stalls immediately

(3) Injection pressure incorrect

Adjust

(1) Pipe from feed pump to injection pump

Clean

clogged or filter clogged

(2) Air in fuel

Bleed

(3) Feed pump delivery insufficient

Disassemble, correct

(4) Fuel delivery insufficient due to clogging

Replace breather

of fuel tank air breather

3. Engine lacks power

(1) Plunger worn excessively

Replace

(2) Injection timing incorrect

Adjust

(3) Delivery valves defective

Replace

(4) Nozzle leaks excessively

Correct or replace

(5) Nozzle not working normally

Disassemble, correct

(1) Injection timing too fast

Adjust

(2) Nozzle injection pressure too high

Adjust

(3) Nozzles not working normally

Disassemble, correct

(1) Injection timing incorrect

Adjust

seriously producing

(2) Nozzle injection pressure too low

Adjust

excessive exhaust

(3) Nozzle spring broken

Replace

smoke

(4) Nozzles not working normally

Replace

(5) Plungers worn excessively

Adjust

(6) Delivery valves seat defective

Replace

(7) Supply of fuel excessively

Check feed pump

4. Engine knocking

5. Engine knocks

- 117 -

Complaints
6. Engine output
unstable

Possible causes
(1) Supply of fuel insufficient

Check feed pump

(2) Air in fuel

Bleed

(3) Water in fuel

Replace fuel

(4) Operation of plungers unsmooth

Disassemble, correct

(5) Movement of control rack sluggish

Disassemble, correct

(6) Nozzles defective

Disassemble, correct

(7) Injection starting pressure of each barrel

Adjust

incorrect

7. Engine does not reach

maximum speed
8. Engine idling unstable

Corrections

Disassemble, correct

(8) Automatic timer defective

Disassemble, correct

(1) Nozzles not working normally

Disassemble, correct

(2) Governor defective

Disassemble, correct

(1) Movement of control rod sluggish

Disassemble, correct

(2) Operation of plungers unsmooth

Disassemble, correct

(3) Control pinions not engaged with control

rod correctly

- 118 -

4.4. Turbocharger
4.4.1. Main data and specifications
1) Main data and specifications
Specification

DE12T

P126TI

Turbocharger Model

T45

TV51

At maximum output

Air pressure at compressor outlet

Approx. 1.257 kg/cm2

Approx.1.9 kg/cm2

Air suction volume

Approx. 19.0m3/min

Approx. 26.0m3/min

Approx. 95,00 rpm

Approx. 91,000rpm

110,000rpm

105,414rpm

750C

750C

External oil supply

External oil supply

14kg

14kg

Speed of turbine revolution

Maximum allowable speed
Max. allowable temperature of exhaust gas at turbine inlet
Lubricating system
Weight

2) Operating principle

Turbine wheel and

shaft assembly

Oil inlet

Turbine housing
Exhaust pipe

Compressor
housing

Exhaust gas discharge

Oil outle

Fresh
air inlet
Compressed
air folw
Compressor
wheel
Intake pipe

EM0A8001
The turbocharger is a system designed to make use of the engine exhaust gas energy to charge
high-density air into the cylinders, thereby to increase the engine output.

- 119 -

3) Construction

1.

Turbine housing

15.

Retainer ring

25.

Bolt

2.

Plug

16.

Bearing

26.

O-ring

5.

Crank

17.

Thrust collar

27.

Compressor wheel

7.

V-band

18.

Screw

28.

Nut

8.

Wheel

19.

Thrust bearing

29.

Bolt

9.

Piston ring

20.

Thrust space

30.

Clamp

10.

Wheel shroud

21.

Piston ring

31.

Compressor housing

11.

Center housing

22.

Seal ring

32.

Elbow

12.

Retainer ring

23.

Seal ring

38.

Retainer

13.

Bearing

24.

Rear plate

45.

Bolt

14.

Retainer ring

- 120 -

4.4.2. General descriptions

The engine output is determined by the fuel delivery volume and engine efficiency.
To burn the supplied fuel completely to change into effective power for the engine, the volume
of air enough to burn the fuel completely should be supplied into the cylinders.
Therefore, the engine output is determined substantially by the cylinder capacity, and a
greater volume of compressed air is charged into cylinders of given capacity, the greater
engine output can be obtained as a greater volume of air charged into the cylinders burns so
much more fuel.
As explained, the compressing of air to supply into the cylinders is called Supercharging and
the making use of the energy of exhaust gas discharged from the combustion chamber to
charge the compressed air into the cylinders is called Turbocharging.

4.4.3. Functions
1) Turbine
Exhaust gas discharged from the combustion chamber distributes its own energy to the turbine blades while passing the inside of the turbine housing, with the result that the turbine
shaft can get rotating force. This is the operating principle of turbine, which is mounted
with seal rings and heat protector to prevent exhaust gas from affecting the bearings
adversely.

2) Compressor
The compressor, which is connected to the turbine over the one and same shaft to form a
rotating body, takes in and compresses ambient air with rotating force transmitted from the
turbine shaft. Then, the compressed air is delivered to the intake stake. This is the operating principle of the compressor.

3) Bearings
(1) Thrust bearing
The turbine wheel creates thrust force. Therefore, exercise care so that the shaft is not
deviated from its the original position due to this thrust.

(2) Journal bearing

This journal bearing of floating type forms a dual oil film on both the inside and outside of
the bearing so that the bearing can rotate independently. As the dual oil film plays a role as
a damper, the sliding speed of the bearing surface becomes lower than the rotating speed
of the shaft, resulting in assurance of stability in its movement.

4) Sealing-Compressor shaft
The compressor is of a dual construction type composed of seal plate and seal ring to prevent the leak of compressed air or lubricating oil.

- 121 -

4.4.4. Precautions for operation

1) Precautions for operation of engine
The following precautions should be observed when starting, operating, or stopping the
n

engine:
Operations
When starting
the engine

Precautions
1) Check oil level
2) Crank the engine with starter to
check the increase in oil pressure(until the needle of pressure
gauge starts to move or pressure
indicator lamp is actuated) before
starting the engine.
3) When having replaced oil, oil filter
element, or lubricating parts, or
when having stopped the engine
for extended period of time, or in a
cold place, loosen the oil pipe connections and operate the starter
motor until oil is discharged. After
completing the operation, be sure
to retighten the oil pipe connections
portion before starting the engine.

Immediately
after starting

Immediately
after starting

During
operation

When stopping
the engine

1) Run the engine at idle for 5 minutes after starting off.

2) Check each part for leakage of

oil, gas, and air, and take proper
measure.

Reasons

2) Abrupt starting of the engine

causes the engine to rotate with
oil not being distributed not only
to each part but also to the turbocharger, resulting in abnormal
wear or seizure on the bearing
due to insufficient supply of oil.
3) In the case of the engine stopped
for extended time or in a cold
place, oil fluidity within the pipes
can be deteriorated.

1) Applying load abruptly If load is

abruptly applied with the engine
and turbocharger rotating
unsmoothly, such parts that a sufficient amount of oil has not
reached can be seized up.
2) Leakage of oil, gas, and air (especially, oil leak) causes drop in oil
pressure and loss of oil. resulting
in seizure of the bearing.

Check the followings:

1) Oil pressure
At idle: 0.8kg/cm2 or more
At full load: 3.0~4.8kg/cm2
2) If unusual sound or vibration is
heard or felt, reduce engine revolutions slowly and locate the
cause.

1) Excessively low oil pressure causes unusual wear or seizure of the

bearing. Too high pressure causes oil leakage.
2) The engine is operated continuously with unusual sound or vibration not corrected, it can be damaged beyond repair.

1) Run the engine at idle for 5 minutes before stopping.

1) If the engine is put to a stop after

being operated at high load, heat
from the red-hot turbine blades is
transmitted to the bearing portion
and burns oil to cause seizure of
the bearing metal and rotating
shaft.

- 122 -

4.4.5. Walk-around check and servicing

As the condition of turbocharger depends greatly on how well the engine is serviced, it is very
important to maintain the engine in accordance with the specified maintenance procedure.

1) Intake system
Pay particular attention to the air cleaner when servicing the intake system.
In the case of wet-type air cleaner, if the level of oil surface is lower than specified, cleaning effect is poor; if too high, the cleaner draws in oil to foul the case.
Especially, if the rotor is fouled, the sophisticatedly-tuned balance is broken to create vibration and to cause seizure and unusual wear to the bearing.
Therefore, it is very important to use a good quality air cleaner all the time.
In the case of dry-type air cleaner, it is essential to clean it to reduce intake resistance as
much as possible.

2) Exhaust system
Pay particular attention to prevent gas leaks and seizure when servicing the exhaust system because leakage of exhaust gas from discharge pipes, turbocharger fixing portions, etc.
lowers charging effect.
As such components as turbine chamber that becomes red-hot during operation use heat
resisting steel nuts, do not interchange these nuts with ordinary steel nuts. In addition, apply
anti-seizure coating to fixing nuts on the portions as designated.

3) Fuel system
If the full load stopper regulating the maximum injection volume and the maximum speed
stopper regulating the maximum speed in the fuel injection pump are adjusted without using
a pump tester, the turbocharger rotates at excessively rapid speed and may suffer damage.
Besides of it, if spray pattern from the fuel injection nozzles is bad or the injection timing is
incorrect, temperature of exhaust gas rises up to affect the turbocharger adversely. To avoid
such trouble, be sure to make a nozzle test.

4) Lubricating system
Pay particular attention to oil quality and oil filter change intervals when servicing the lubricating system. Deteriorated engine oil affects adversely not only the engine but torso the
turbocharger. Suggested engine oils for the turbocharger-mounted engine are as follows:

SAE 15W30
API grade CD or CE

- 123 -

4.4.6. Periodical checking and servicing

Make it a rule to check the turbocharger assembly for condition and contamination periodically.

1) Guide for checking the rotor for rotating condition

The inspection of the rotor assembly for rotating condition should be performed by the
degree of unusual sound. If a sound detecting bar is used, install its tip on the turbocharger housing and increase the engine revolutions slowly. If a high-pitch sound is heard continuously, it means that the rotor assembly is not normal. In this case, as the metal bearing
and rotor are likely to be in abnormal conditions, the turbocharger should be replaced or
repaired.

2) Guide for checking rotor end play

Disassemble the turbocharger from the engine, then check the rotor axial play and radial
play.
When disassembling the turbocharger, be sure to plug the oil inlet and outlet ports with taps,
etc.

(1) Rotor axial play

Magnet vise

Turbine wheel room

Move the turbine

shaft to axial
direction
Dial gauge
Wear limit : 0.117~0.20mm
Limit of wear : 0.24mm EA8M4003

- 124 -

(2) Rotor radial play

Dial gauge
Magnetic vise

Oil outlet

Radial play
Limit of wear : 0.075~0.11mm
Limit of wear : 0.12mm

Move the turbine shaft

in both directions
simultaneously

Oil inlet

EA8M4004

(3) If the measured axial and radial plays are beyond the limit of wear, replace or repair the
turbocharger.

3) Guide for disassembling/cleaning and checking the turbocharger

First, disassemble the turbocharger from the engine and clean/check it with the oil inlet and
outlet plugged with tape and so on.

4) Precautions for reassembling the tarbocharger onto the engine

For reassembly of the turbocharger or handling it after reassembly operation, be sure to
observe the following precautions:
Especially, exercise extreme care to prevent foreign matters from entering the inside of the
turbocharger.

(1) Lubricating system

Before reassembling the turbocharger onto the engine, inject new oil in the oil inlet port
and lubricate the journal and thrust bearings by rotating them with hand .

Clean not only the pipes installed between the engine and oil inlet port but also the oil
outlet pipe and check them for damage or foreign matters.

Assemble each joint on oil pipes securely to prevent oil leaks.

(2) Intake system

Check the inside of the intake system for foreign matters.

Assemble each joint on the intake duct and air cleaner securely to prevent air leaks.

- 125 -

(3) Exhaust system

Check the inside of the exhaust system for foreign matters.

Be sure to use heat resisting steel bolts and nuts. Do not interchange them with ordinary steel bolts and nuts when performing reassembly operation. Apply anti-seizure
coating to the bolts and nuts.

Assemble each joint on the exhaust pipes securely to prevent gas leaks
4.4.7. Diagnostics and troubleshooting
Complaints

Possible causes

Corrections

1. Excessive black 1) Air cleaner element clogged

smoke
2) Restrictions in air duct
3) Leakage at intake manifold
4) Turbocharger seized up and not rotating
5) Turbine blades and compressor blades
coming in contact with each other or
damaged
6) Exhaust piping deformed or clogged

Replace or clean
Check and correct
Check and correct
Disassemble/repair or replace
Disassemble/repair or replace

2. Excessive white 1) Oil leak into turbine and compressor

smoke
2) Worn or damaged seal ring due to
excessive wear of bearing

Disassemble/repair or replace
Disassemble/repair or replace

3. Low engine
output

1)
2)
3)
4)

Gas leak at each part of exhaust system

Air cleaner element restricted
Turbocharger fouled or damaged
Leakage at discharge port on
compressor side

Check and correct

Replace or clean
Disassemble/repair or replace
Check and correct

4. Unusual sound
or vibration

1)
2)
3)
4)

Rotor assembly coming in contact

Unbalanced rotation of rotor
Seized up
Each joint loosened

Disassemble/repair or replace
Disassemble/repair or replace
Disassemble/repair or replace
Check and correct

- 126 -

Check and correct

5. Special tool list

No.

Description

Part No.

Nozzle tube Insert assy

DPN-5337

Valve stern oil seal installer

EF.123-082

Injection pump setting assy

EF.123-015

Oil seal insert assy(FR)

EF.123-127

Oil seal insert assy(RR)

EF.123-053

Oil seal puller assy(FR)

EF.123-052

Illustration

EA8M5001

- 127 -

No.

Description

Part No.

Oil seal puller assy(RR)

EF.123-048

Cylinder pressure tester

EU.2-0531

Illustration

adapter

Cylinder liner puller assy

EU.123-087

10

Valve stem seal punch

EF.123-066

11

Valve clearance adjust assy

EU.2-0131

12

Valve spring press

EF.123-065

EA8M5001

- 128 -

No.

Description

Part No.

13

Crankshaft gear punch

EU.2-0647

14

Feeler gauge

60.99901-0027

15

Snap ring plier

T7610001E

16

Piston ring plier

T7621010E

- 129 -

Illustration

Appendix

Tightening torque for major parts

Major Parts

Screw

Strength

(diameter x pitch)

(Grade)

M14 x 1.5

12.9T

Cylinder head bolt

Tightening torque
6 kgm+180+150
Angle

Connecting rod bearing cap bolt

M14 x 1.5

12.9T

28.0 kgm

Crankshaft main bearing cap bolt

M16 x 1.5

12.9T

30.0 kgm

Balance weight fixing bolt

M14 x 1.5

10.9T

9.0 kgm

Flywheel fixing bolt

M14 x 1.5

10.9T

18.0 kgm

Crankshaft gear fixing bolt

M12 x 1.5

10.9T

13.4 kgm

Tightening torque for injection pump system

Parts

Tightening Torque

Injection pump delivery valve holder

2.0 ~ 3.0 kgm

Nozzle holder fixing cap nut

7.0 kgm

Nozzle fixing cap nut

6.0 ~ 8.0 kgm

High pressure injection pipe fixing cap nut

Max. 3.0 ~ 5.0 kgm

- 130 -

Remarks

Standard bolt tightening torque table

Refer to the following table for bolts other than described above.

Degree of strength
Diameter
x

3.6

4.6

4.8

5.6

5.8

6.6

6.8

6.9

8.8

10.9

12.9

(4A)

(4D)

(4S)

(5D)

(5S)

(6D)

(6S)

(6G)

(8G)

(10K)

(12K)

54

64

90

108

pitch
(mm)

Limit value for elasticity (kg/mm2)

20

24

32

30

40

36

48

Tightening torque (kgm)

M5

0.15

0.16

0.25

0.22

0.31

0.28

0.43

0.48

0.50

0.75

0.90

M6

0.28

0.30

0.45

0.40

0.55

0.47

0.77

0.85

0.90

1.25

0.5

M7

0.43

0.46

0.70

0.63

0.83

0.78

1.20

1.30

1.40

1.95

2.35

M8

0.70

0.75

1.10

1.00

1.40

1.25

1.90

2.10

2.20

3.10

3.80

M8x1

0.73

0.80

1.20

1.10

1.50

1.34

2.10

2.30

2.40

3.35

4.10

M10

1.35

1.40

2.20

1.90

2.70

2.35

3.70

4.20

4.40

6.20

7.40

M10x1

1.50

1.60

2.50

2.10

3.10

2.80

4.30

4.90

5.00

7.00

8.40

M12

2.40

2.50

3.70

3.30

4.70

4.20

6.30

7.20

7.50

10.50

12.50

M12x1.5

2.55

2.70

4.00

3.50

5.00

4.60

6.80

7.70

8.00

11.20

13.40

M14

3.70

3.90

6.00

5.20

7.50

7.00 10.00

11.50 12.00

17.00

20.00

M14x1.5

4.10

4.30

6.60

5.70

8.30

7.50 11.10

12.50 13.00

18.50

22.00

M16

5.60

6.00

9.00

8.00 11.50

10.50 17.90

18.50 18.00

26.00

31.00

M6x1.5

6.20

6.50

9.70

8.60 12.50

11.30 17.00

19.50 20.00

28.00

33.00

M18

7.80

8.30

12.50

11.00 16.00

14.50 21.00

24.20 25.00

36.00

43.00

M18x1.5

9.10

9.50

14.50

12.50 18.50

16.70 24.50

27.50 28.00

41.00

49.00

M20

11.50 12.00

18.00

16.00 22.00

19.00 31.50

35.00 36.00

51.00

60.00

M20x1.5

12.80 13.50

20.50

18.00 25.00

22.50 35.00

39.50 41.00

58.00

68.00

M22

15.50 16.00

24.50

21.00 30.00

26.00 42.00

46.00 49.00

67.00

75.00

M22x1.5

17.00 18.50

28.00

24.00 34.00

29.00 47.00

52.00 56.00

75.00

85.00

M24

20.50 21.50

33.00

27.00 40.00

34.00 55.00

58.00 63.00

82.00

92.00

M24x1.5

23.00 25.00

37.00

31.00 45.00

38.00 61.00

67.00 74.00

93.00 103.00

Others:
1. The above torque rating have been determined to 70% or so of the limit value for bolt elasticity.
2. Tension is calculated by multiplying tensile strength by cross section of thread.
3. Special screws should be tightened to 85% or so of the standard value.
For example, a screw coated with MoS2 should be tightened to 60% or so of the standard
value.

- 131 -

- 132 -

Valve seat depression

parts

ring

Piston

Direction of ring gap

clearance

Piston ring groove

Piston ring gap

Oil ring

2nd ring

0.05~0.085

0.07~0.102

0.30~0.50

Oil ring
Top ring

0.35~0.50

0.15

0.15

1.5

1.5

1.5

96g

15g
0.30~0.45

113.9

0.55

0.55

0~0.12

4.040~4.060

3.060~3.080

3.5

0.114~0.169

2nd ring

Top ring

Permissible weight difference of each piston

Oil ring

2nd ring

Tor ring

moving

grooves

Width of piston ring

Piston projection from cylinder block upper surface

Piston

Clearance between piston and liner

122.854~ 122.886

Piston diameter (18mm from the lower side)

114.95~115

0~0.3

0~0.3

Exhaust

Intake

0.05

Hydraulic test for 1 minute (kg/cm2)

head &
valve Height

Cylinder

Hydraulic test for 1 minute (kg/cm2)

Correction

Install ring by 120

Replace ring or piston

is beyond specified value

Replace piston if groove width

Replace if leaky

Replace cyl. head

Correct with a surface grinder

123.223 Replace liner

-

123~ 123.023

Inside diameter of Cylinder. liner for wear

Limit for
use

0.03~0.08

Standard value
for assembly

Check

Cylinder Projected portion of liner

block &
The upper surface of cylinder block for distortion
liner

Part

Major

Engine
body

Group

Maintenance specification table

standard clearance

Limit for use if for

diameter : 123

Standard gauge inside

Measure unworn portion beneath

the rim of upper side

Water temp : 70C

In case of new valve and seat

Per distortion length for 200mm

Measure unworn portion beneath

the rim of upper side

Remarks

- 133 -

Major
moving
parts

Group

60

Balance of crank shaft

0.22~0.319

End play of con. rod crush

28

Tightening torque of con-rod bearing cap bolt (kgm)

0.3

0.043~0.167

0.3
0.15

0.13~0.27

Axial play of camshaft

0.20

0.025~0.091

0.050~0.128

Clearance between cam shaft and bush

59.52

18g

0.12

0.5

0.20

Replace thrust collar

Replace thrust plate

Apply oil to bolt

Replace conn. rod

Replace bearing

Replace oil seal if oil leaking

Apply oil to bolt

60 or less Check dynamic balance

Permissible weight difference of each conn. rodrod

59.860~ 59.880

Replace thrust bearing

Replace bearing

0.1 or less Adjust by a press if bent

0.5

0.25

0.03

0.03

0.025

81.966 Replace crank shaft

Outside diameter of cam shaft

Correct with a grinder

Correction

94.966 Replace crank shaft

0.1

Limit for
use

0.086~0.116

Conn. rod bearing crush height

Timing Clearance between idle gear shaft and inserting hole

gear End play of idle gear shaft

shaft

Cam

rod

0.050~0.080

0.049~0.119

0.15~0.25

Clearance between conn. bearing & crank pin

Oil seal for wear

Journal bearing crush

30

0.05

Run-out of crank shaft

Tightening torque of journal bearing cap bolt(kg.m)

0.15~0.325

End play of crank shaft

0.01

Permissible taper of journal & pin

0.072~0.142

0.01

Permissible radial run-out of journal & pin

Clearance between crank shaft & bearing

0.008

82.966~ 82.988

Outside diameter of pin

Out of round of journal & pin

95.966~ 95.988

0.05

Standard value
for assembly

Outside diameter of journal

Axial run-out of journal and pin

Check

Conn. Clearance between small end bush & piston pin

shaft

Crank

Part

60

After completing installation of bearing,

loosen one stud bolt and measure

Replace with new one, use shim

No foreign matters on bearing

cap installing surface
Measure by tightening metal cap
and then loosening one stud bolt

Measure at 400 rpm

No.4 bearing(holding Nos. 1 & 7)

Measure in the position of crown

83 g6

96 g6

In horizontal and vertical directions

Remarks

- 134 -

system

Valve

Group

Check

1.5

Exhaust

Exhaust

2.0

61.8

72

2.0

36.1

61.75

2.0

61.8

72

0.25

0.2

0.9 or more

1 or more

0.18

0.15

10.84

10.87

Limit for
use

0.3

0.3

1.0

Straightness(against free length)

Intake

61.8~68.3

75.5

1.0

36.1~39.9

Spring tension(set length:37mm) kg

Contacting face of valve stem & rocker arm

(at cold)

Valve clearance

Outer

Free length

Spring

Spring tension(set length: 34mm) kg

Straightness(against free length)

Inner

65

1.0

Straightness(against free length)

Free length

61.8~68.3

75.5

22

Spring tension(set length : 37mm) kg

Free length

Exhaust

Spring

Intake

Exhaust

22

0.01~0.39

Clearance between valve guide & cyl. head installing hole

Intake

0.06~0.09

0.04~0.07

1.5

Intake

Intake

0.045~0.080

Exhaust

Exhaust

stem & valve head

Perm. radial run-out between valve

Thickness of valve

0.030~0.065

Intake

10.935~ 10.955

Outside diameter of exhaust valve stem

Clearance between valve

stem and valve guide

10.950~ 10.970

0.10~0.20

0.10~0.20

Standard value
for assembly

Outside diameter of intake valve stem

Between idle gear & cam shaft gear

Valve Clearance between valve

guide & valve spring seat

gear

Timing Between crank gear & idle gear

Part

Correct or replace if severely

pitted on tip of arm and stem

Adjust

Replace valve spring

Replace valve spring

Replace

Replace

Replace

Replace & valve guide

Replace valve & valve guide

Replace gear

Correction

Apply oil to valve guide and press in

Replace valve guide together

when replacing valve

Remarks

- 135 -

System

Lubricating

Oil filter Oil filter element for damage

Control valve for spray nozzle (kg/cm2)

8.5~11.5

5~6

1.5~1.8

0.8

0.8

120

4.0~4.8

1.8~2.3

By-pass valve for filter element (kg/cm2)

0.15~0.25

0.15~0.25

4.3~4.7

Between oil pump drive gear and intermediate gear

Between crank gear & oil pump drive gear

27.939~ 27.960

Oil pressure control valve (kg/cm2)

Backlash

Outside diameter of drive gear bushing

16.950~ 16.968

0.040~0.082

Clearance between drive gear bushing & cover hole

Outside diameter of gear shaft

0.032~0.068

0.055~0.105

Clearance between gear shaft & oil pump over hole

Axial play of oil pump gear

Permissible oil temperature in short time C

105

0.6

0.8~1.4
-

3.5

0.15

Correction
Replace bush or shaft

Clean or replace

Replace valve

Adjust backlash

Replace bushing

Replace gear

Replace bushing or cover

Replace gear or cover

Use suggested oil

Correct oil leakage and clearance between each part

Replace if excessively worn or deformed

Replace tappet

Replace tappet

Replace

23.75 Replace

0.2

Limit for
use

4.5 or less

19.944~ 19.965

0.035~0.077

Max. permissible oil temperature C

Valve By-pass valve for full oil filter (kg/cm2)

opening
By-pass valve for oil cooler (kg/cm2)
pressure
Relief valve for oil pump (kg/cm2)

pump

Oil

Oil
temp

Oil pressure(nominal speed) kg/cm2

Oil
Pressure Oil pressure(idling) kg/cm2

Contacting face of tappet & cam

Tappet Outside diameter of tappet

Clearance between tappet & cyl. block

23.978~ 23.959

Rocker arm shaft for wear

System

0.020~0.093

Clearance between rocker arm shaft & rocker arm bush

0.3

Standard value
for assembly

Check

Permissible taper of push rod

Part

Valve

Group

28e7

17e7

Temperature above this

not allowable

Remarks

- 136 -

difference of each cylinder

Cylinder compression
Inspection
Cylinder Pressure of cylinder(kg/cm2)
at
completion
pressure Compression pressure

Running-in the engine

Clearance between injection pump coupling and coupling (mm)

against average

10% or less

24~28

0.2~0.4

4.3

Height of projected nozzle on the cyl. head (mm)

220

more

24 or

1.6

Injection pressure of injection nozzle (kg/cm2)

95 or lower

83

System Opening pressure of overflow valve (kg/cm2)

Fuel

Piping Fuel pipe, injection pipe & Nozzle holder for

and the damage, cracks, looseness, bad packing
other
Fuel filter element for damage

Full opening temp. C

(under atmospheric pressure) C

Thermostat opening temp.

103

103

Thermostat

95

90~95

Cooling Operating temperature(permissible temp.) C

water
temp Permissible temperature in a short time C

0.3~0.6

Approx. 270

Limit for
use

Clearance between pump impeller & pump body

Back pressure:1kg/cm2

system pump

Engine speed 1,800rpm

0.2

Negative pressure valve for opening pressure (kg/cm2)

1.0

Test for leakage(air pressure) kg/cm2

0.5

Radiator & water pump for corrosion, damage & improper connecting

Pressure valve for opening pressure kg/cm 2

Standard value
for assembly

Check

Water temp 24C

Radiator

Part

Cooling Water Delivery volume l/min

Group

1st : 160, 2nd : 220

allowable

Remarks

Correct

Overhaul the engine

at 200rpm or more (20C)

Refer to supplement running-in Retighten head bolt after running in

Replace cyl. head and nozzle

Replace valve

Adjust by shim

Clean or replace

Correct or replace

Stroke : minimum 8mm

Replace if defective

Temperature above this not

Replace if contacted impeller and pump body

Submerge in water and replace if air bubbles found

Correct or replace

Correction

INCIO

DAEWOO HEAVY INDUSTRIES &

MACHINERY LTD. AROUND THE WORLD

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Head Office

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Tel : 82-32-760-1114 Fax : 82-32-762-1546

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Tel : 1-216-595-1212 Fax : 1-216-595-1214

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8th floor Daewoo Heavy Industries & Machinery Bidg, 14-34,
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Tel : 82-2-2167-3114 Fax : 82-2-785-2677

Daewoo Rep. C/O Boeing Co.

ASIA & OCEANIA

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P.O.Box 3707 M/S 39-AH, Seattle, WA 98124-2207, U.S.A

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Tel : 61-2-9633-4544 Fax : 61-2-9633-5266

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CF47QU, U.K. / Tel : 44-1443-84-2273 Fax : 44-1443-84-1933

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Tel : 86-991-463-2217 Fax : 86-991-461-8641

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FECHAR