950106-00121

Operation &
Maintenance Manual
GENERATOR DIESEL ENGINE

DE12T
P126TI
P126TI-1
P126TI-II

POWER UNIT DIESEL ENGINE

PU126TI
 FOREWORD

This maintenance manual is designed to serve as a reference for DOOSAN Infracore (here after DOOSAN’s)
customers and distributors who wish to gain basic product knowledge on DOOSAN's generator and power unit
diesel engines (DE12T, P126TI, P126TI-1, P126TI-II and PU126TI)
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 & power unit 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 manufacturer’s

Directional Indication Lubricate with oil

Inspection Lubricate with grease

Measurement

During engine maintenance, please observe following instructions to prevent environmental damage;
z Take old oil to an old oil disposal point only.
z Ensure without fail that oil and diesel fuel will not get into the sea or rivers and canals or the ground.
z Treat undiluted anti-corrosion agents, antifreeze agents, filter element and cartridges as special waste.
z The regulations of the relevant local authorities are to be observed for the disposal of spent coolants
and special waste.

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

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

Doosan Infracore Co., Ltd.

Nov. 2009
 CONTENTS

<Operation>

1. Safety Regulations
1.1. General Notes ................................................................................................................................. 1
1.2. Regulations Designed to Prevent Accidents ................................................................................. 1
1.3. Regulations Designed to Prevent Damage to Engine and Premature Wear ............................ 3
1.4. Regulations Designed to Prevent Pollution .................................................................................. 3
1.5. Notes on Safety in Handling Used Engine Oil ............................................................................ 3

2. General Information
2.1. Engine Assembly ............................................................................................................................ 5
2.2. Engine Specification ...................................................................................................................... 10

3. Technical Information
3.1. Engine Model and Serial Number ............................................................................................... 12
3.2. Engine Type .................................................................................................................................. 13
3.3. Engine Timing ............................................................................................................................... 13
3.4. Valves ............................................................................................................................................ 14
3.5. Lubrication System ........................................................................................................................ 14
3.6. Air Cleaner .................................................................................................................................... 15
3.7. Fuel System .................................................................................................................................. 16
3.8. Cooling System ............................................................................................................................. 18
3.9. V-belt Tension Check and Adjust ............................................................................................... 20
3.10. Turbocharger ............................................................................................................................... 21
3.11. Electrical Equipment ................................................................................................................... 22

4. Commissioning and Operation

4.1. Preparation .................................................................................................................................... 24
4.2. Breaking-in ..................................................................................................................................... 24
4.3. Inspections after Starting .............................................................................................................. 26
4.4. Operation in Winter Time ............................................................................................................. 26
4.5. Tuning the Engine ........................................................................................................................ 27

5. Maintenance and Care

5.1. Periodical Inspection and Maintenance ....................................................................................... 28
5.2. Lubrication System ........................................................................................................................ 28
5.3. Cooling System ............................................................................................................................. 31
5.4. Air Intake System ......................................................................................................................... 34
5.5. Fuel System .................................................................................................................................. 36
5.6. Injection Nozzle Maintenance ...................................................................................................... 39
5.7. Turbocharger ................................................................................................................................. 40
6. Checking and Setting
6.1. Adjustment of Valve Clearance ................................................................................................... 41
6.2. Adjustment of Injection Timing .................................................................................................... 43
6.3. Cylinder Compression Pressure ................................................................................................... 44
6.4. V-belts ............................................................................................................................................ 45

7. Operation Tip
7.1. Periodic Inspection Cycle ............................................................................................................. 47
7.2. Trouble Shooting ........................................................................................................................... 48
7.3. Causes and Remedies ................................................................................................................. 55

<Maintenance>

8. General Information
8.1. General Repair Instructions .......................................................................................................... 57
8.2. Engine Characteristics .................................................................................................................. 58

9. Disassembly and Reassembly of Major Components

9.1. Disassembly ................................................................................................................................... 59
9.2. Inspection ....................................................................................................................................... 72
9.3. Reassembly ................................................................................................................................... 91
9.4. Breaking-in ................................................................................................................................... 113

10. Maintenance of Major Components

10.1. Cooling System ......................................................................................................................... 114
10.2. Lubricating System .................................................................................................................... 118
10.3. Fuel Injection Pump .................................................................................................................. 122
10.4. Turbocharger ............................................................................................................................. 159

11. Special Tool List ........................................................................................................................... 167

z Appendix
z Part & After service center
z Applications for Doosan Engine
1. Safety Regulations

1.1. General Notes

Handling diesel engines and the necessary resources is no problem when the personnel commissioned
with operation and maintenance are trained accordingly and use their common sense.

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.

1.2. Regulations Designed to Prevent Accidents

1.2.1. 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 DOOSAN 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 DOOSAN

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.

- 1 - Safety Regulations
1.2.2. 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 ìCoolingî.
● 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 manufacturerís instructions when handling batteries.

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

1.2.3. 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.

Safety Regulations - 2 -
1.3. 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 DOOSAN.

2) If faults occur, find the cause immediately and have it eliminate in order to prevent more serious of
damage.
3) Use only genuine DOOSAN spare parts. DOOSAN 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 DOOSAN-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.

1.4. Regulations Designed to Prevent Pollution

1.4.1. 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.

1.4.2. 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.

1.5. 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.

- 3 - Safety Regulations
 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.

Safety Regulations - 4 -
2. General Information

2.1. Engine Assembly

2.1.1. Engine sectional view (longitudinal)

2 3 4 5 6 7 8 9

10 11 12 13 14 15 16 17 18
EI6OM007

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

- 5 - General Information
2.1.2. Engine sectional view (Cross)

7 8 9 10

2
11

3
12

EI6OM008

1. Intake manifold 5. Cylinder block 9. Cylinder head cover

2. Fuel filter 6. Oil filter 10. Turbocharger
3. Oil cooler 7. Injection nozzle assembly 11. Exhaust manifold
4. Injection pump 8. Rocker arm 12. Piston ring

General Information - 6 -
2.1.3. Engine assembly views
1) DE12T

1 2 3 12 4 27 13 18

22

23 8 6 9 11 10

16 17 15 7 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

- 7 - General Information
 2) P126TI / P126TI-1 / P126TI-II / PU126TI

3 4

2 5

11
10
9
8 16
15 17
7
14

13
12

21

20
18
19
EI6OM009

1. Flywheel housing 8. Oil filter 15. Fuel filter

2. Air pipe to intercooler 9. Oil cooler 16. Intake manifold
3. Turbocharger 10. Injection pump 17. Breather filter
4. Oil filter cap 11. Oil level gauge 18. Oil pan
5. Cylinder head cover 12. Alternator 19. Mounting bracket
6. Cooling fan flange 13. Thermostat 20. Exhaust manifold
7. Flywheel 14. Air pipe to Intercooler 21. Starter

General Information - 8 -
3) PU126TI (for Fire Pump)

3
4
2
1

10
9
8
5 7
6
21
13
12
11

20

19
18
14 17
15
16

EI6OM010

1. Intercooler 8. Oil cooler 15. Water pump

2. Breather filter 9. Injection pump 16. Oil pan
3. Oil filter cap 10. Oil level gauge 17. Cylinder head cover
4. Thermostat 11. Alternator 18. Exhaust manifold
5. Flywheel 12. Fuel filter 19. Starter
6. Flywheel housing 13. Intake manifold 20. Mounting bracket
7. Oil filter 14. Crankshaft pulley 21. Turbocharger

- 9 - General Information
2.2. Engine Specification

Engine Model
DE12T P126TI P126TI-1 P126TI-II PU126TI
Items
Water-cooled, 4
Water-cooled, 4 cycle in-line type
Engine type cycle in-line
Turbo charged & intercooled
type Turbo charged
Combustion chamber type Direct injection type
Cylinder liner type Replaceable dry liner
Timing gear system Gear driven type
No. of piston ring Compression ring 2, oil ring 1
No. of cylinder-bore x stroke
4 - 123 x 155
(mm)
Total piston displacement
11,051
(cc)
Compression ratio 17.1 : 1
Engine dimension
1,365.5 x 870 x 1,046 1,383 x 870 x 1,207
(length x width x height) (mm)
Engine weight (kg) 930 910
Rotating direction
Counter clockwise
(from flywheel)
Fuel injection order 1 - 5 - 3 - 6 - 2 - 4
Fuel injection timing
12° 16° 12° 16° 14°
(B.T.D.C static)
Injection pump type Zexel in-line “P” type
Mechanical gover-
Governor type Electric governor type(Ghana Control)
nor type (RSV)
Multi-hole type
Injection nozzle type Multi-hole type (5 hole)
(5 hole)
Fuel injection pressure
220 1st : 1 60, 2nd : 220
(kg/cm2)
Compression pressure
28 (at 200 rpm)
(kg/cm2)
50Hz 60Hz 50Hz 60Hz 60Hz 60Hz 50Hz 70Hz
condition
(1,500rpm) (1,800rpm) (1,500rpm) (1,800rpm) (1,800rpm) (1,800rpm) (1,500rpm) (2,100rpm)
Power 205PS 245PS 328PS 378PS 356PS 418PS 360PS
Prime
(ISO 3046) (151kW) (180kW) (241kW) (278kW) (262kW) (307kW) (265kW) 400S
226PS 270PS 370PS 405PS 392PS 465PS 400PS (294kW)
Stand by
(166kW) (199kW) (272kW) (298kW) (288kW) (342kW) (294kW)
Intake and exhaust valve
0.3
clearance (at cold) (mm)
Open at 18° (B.T.D.C)
Intake valve
Close at 34° (A.B.D.C)
Open at 46° (B.B.D.C)
Exhaust valve
Close at 14° (A.T.D.C)

General Information - 10 -
 Engine Model
DE12T P126TI P126TI-1 P126TI-II PU126TI
Items
Lubrication method Full forced pressure feed type
Oil pump type Gear type driven by crankshaft
Oil filter type Full-flow, Cartridge type
Lubricating oil capacity
23 / 20
(max./min.) (lit)
Oil cooler type Water cooled
Water pump Gear driven impeller type
Cooling Method Pressurized circulation
Cooling water capacity
19
(engine only) (lit)
Wax pallet type
Thermostat type Wax pallet type (85°C)
(95°C)
Alternator voltage - capacity
24 - 45
(V - A)
Starting Motor voltage-output
24 - 6.0
(V-kW)

- 11 - General Information
3. Technical Information

3.1. Engine Model and Serial Number

● The engine model and serial number
are located on the engine as illustrated. Engine Number
● These numbers are required when
requesting warranty and ordering parts.

EI6OM011

EI6OM012

● Engine serial No. (example 1 : DE12T)

EBHOA900001

Serial No.
Production Year(2009)
Engine Model Suffix (EBHOA)

● Engine serial No. (example 2 : P126TI series)

EDIOA900001

Serial No.
Production Year(2009)
Engine Model Suffix (EDIOA~EDIOE)

● Engine serial No. (example 3 : PU126TI)

EDIPA900001

Serial No.
Production Year(2009)
Engine Model Suffix (EDIPA~EDIPB)

Technical Information - 12 -
3.2. Engine Type
The Engines DE12T/ P126TI / P126TI-1 / P126TI-II / PU126TI are in-line vertical water-cooled 6-cylinder
four-stroke diesel engines with direct injection. DE12T is turbo-charged engine, and P126TI / P126TI-1 /
P126TI-II / PU126TI models are turbo-charged 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 indi-
vidual 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.

3.3. Engine Timing

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

Injection pump gear Camshaft gear Water pump gear

(Z = 72) (Z = 72) (Z = 29)

Idle gear
(Z = 52)

Crankshaft gear
(Z = 36)
Oil pump idle gear
(Z = 31)

Oil pump drive gear

(Z = 32)

EA8O3002

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

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.

Rock arm

Cam shaft
W/P
BRG.
Piston

I/P
Con-rod bearing
Main bearing

Oil jet valve T/C

1.3 bar
Main gallery

Filter Oil pump

Cooler
Relief valve
4.4 bar Valve : 10 bar
Valve : 5 bar Valve : 3 bar

ED5OM001

Technical Information - 14 -
3.5.1. Oil cooler
An oil cooler is provided between the oil fil-
ter and the cylinder block. This cooler is a
flat tube type with turbulence inserts and
operated by the coolant.

3.5.2. Oil filter

Check for oil pressure and oil leaks, and
repair or replace the oil filter if necessary.
Change the oil filter cartridge simulta-
Oil filter (Cartridge)
neously at every replacement of engine
oil.
Oil filter head

EQM4010I

3.6. Air Cleaner

In case that elements are deformed, dam-
aged 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 400 hours.

- 15 - Technical Information
3.7. 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 injec-
tion 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.

3.7.1. Fuel filter

This fuel filter has two functions not only
oil filtering but also water separating. 1
Before entering the suction chamber of
3
the injection pump, the fuel is cleaned in
5
a strainer of fuel feed pump and a fuel fil- 4

ter. 2
Drain water in cartridge with loosening the
cock under filter manually (6) from time to
6
time.
EA2O4009
The fuel filter should be replaced at every
400 hours.

3.7.2. Fuel requirements

DOOSAN 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 possi-
ble. When temperatures are below -7 °C (20 °F), 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 kero-
sene has been added, the engine should be run for several minutes to mix the fuel.

3.7.3. How to select fuel oil

Fuel quality is an important factor in obtaining satisfactory engine performance, long engine life,
and acceptable exhaust emission levels. DOOSAN engines are designed to operate on most die-
sel 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 perfor-
mance. 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.

Technical Information - 16 -
 Fuel oil selection chart

General Fuel ASTM No. 1 No. 2

DIN 51601
Classification Test ASTM 1-D ASTM 2-D
Gravity,°API #) D 287 40 ~ 44 33 ~ 37 0.815 ~ 0.855
Flash Point
D 93 100 (38) 125 (52) 131 (55)
Min. °F (°C)
Viscosity, Kinematic
D 445 1.3 ~ 2.4 1.9 ~ 4.1 1.8 ~ 10
CST 100 °F (40 °C )
Cloud Point °F #) D 2500 See Note 1) See Note 1) See Note 1)
Sulfur Content
D 129 0.5 0.5 0.15
wt%, Max.
Carbon Residue
D 524 0.15 0.35 0.1
on 10%, wt%, Max.
Accelerated Stability
Total Insolubles D 2274 1.5 1.5
mg/100 ml, Max. #)
Ash, wt%, Max. D 482 0.01 0.01
Cetane Number, Min. #) D 613 45 45 > 45
Distillation D 86
Temperature, °F(°C)
IMP, Typican #) 350(177) 375(191)
10% Typical #) 385(196) 430(221)
50% Typical #) 45(218) 510(256) 680(360)
90% +) 500 (260) Max. 625(329) Max.
End Point #) 550(288) Max. 675(357) Max.

Water & Sediment

D 1796 0.05 0.05 0.05
%, Max.

#) Not specified In ASTM D 975

+) Differs from ASTM D 975

NOTE :
1. The cloud point should be 6°C(10°F) below the lowest expected fuel temperature to
prevent clogging of fuel fitters by crystals.

- 17 - Technical Information
3.8. 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 radi-
ator, and then clean them with cleaning solution.
● Be sure to mix soft water with antifreeze solution.

Water pipe

Thermostat

Cylinder head

Reserve tank

Water pump Cylinder block

EJM4001I

Technical Information - 18 -
3.8.1. Coolant pressure cap
Check the pressure valve opening pres-
sure using a expansion tank cap tester.
Replace the filler cap assembly if the
Rediater Cap
measured valve does not reach the speci-
fied limit. (pressure valve opening pres-
sure : 0.5 kg/cm2)
Rediater
NOTE :
Because it is dangerous to open
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

3.8.2. 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 , P126TI / P126TI-1 and P126TI-II / PU126TI 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.

- 19 - Technical Information
 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.

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 addi-
tive 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 (%)
Temperature (°C)
Over -10 85 15
-10 80 20
-15 73 27
-20 67 33
-25 60 40
-30 56 44
-40 50 50

3.9. V-belt Tension Check and Adjust

By the finger-pressure the belt is pressed
Press here
by 10mm ~ 15mm between the fan pulley
and the alternator pulley in normal condi- 15mm
tion. For the adjustment of the tension, Alternator Fan
Pulley Pulley
loosen the adjusting bolts which support
the alternator, adjust the tension and
tighten the bolts again. V-belt

Crank Pulley EA8O3005

Technical Information - 20 -
3.10. Turbocharger
The exhaust gases of the engine are passed through the turbine rotor of the turbocharger. Air com-
pressor 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.

1 D 2
3

A B

4
E

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

- 21 - Technical Information
3.11. Electrical Equipment

3.11.1. 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.

P-TAB : KET GP 890545

TACHOMETER CHARGE INDICATOR
M6 x 1.0 THREAD ALDO SYSTEM FREQUENCY = RPM
10
BATTERY TERMINAL

"L" Terminal
"R" Terminal

CONNECTOR HOUSING
KET MG 620042
TERMINAL
KET ST 740254

EA8O3006

The alternator is maintenance-free, never-

To Battery +
theless, it must be protected against dust
Regulator
and, above all, against moisture and
water.

RL = 150~250 OHM
Operate the alternator according to
the instructions given in the
chapter.

EA8O3007

Technical Information - 22 -
3.11.2. Starter motor
The sliding-gear starter motor is flanged to the rear of the flywheel housing on the left-hand side.
When the starting key switch is turned on, the starter motor pinion flies out and engages the ring
gear of the flywheel. Then the main contact is closed, current flows, and the engine is started.
After the engine starts, the pinion automatically returns to its initial position when the starting key
switch is released. Once the engine starts, the starting key switch should be released immedi-
ately. Otherwise, the starter motor may be damaged or burned out.
In case of repairing the engine dip the pinion of the starter and ring gear into the fuel and
remove the corrosion with brush. After that apply the grease on them to protect the corrosion.
Whenever you clean the starter, always pay attention not to occur the electric short due to enter-
ing the water.

TERMINAL "B" TERMINAL S/W 24V x 6.0kW

M10 x P1.5 M5 x P0.8

EA8O3008

Always protect starter motor against moisture.

WARNING :
S/W B W
Always disconnect the battery
earth cable before starting work on Motor
S/W B S
the electrical system. Connect up
the earth cable last, as there is S/W M
otherwise a risk of short-circuits. KS

2.5A(20oC 24V)
EA8O3009

- 23 - Technical Information
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 DOOSAN 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 50 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.

Commissioning and operation - 24 -

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 / P126TI-1 /
23 liter
P126TI-II / PU126TI

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.

- 25 - Commissioning and operation

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 71 ~ 85°C 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 life-time.

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 pre-
vent the engine from excessive cooling. If the temperature of coolant does not reach to normal
condition (71 ~ 85 °C) 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”.

Commissioning and operation - 26 -

4.5. Tuning the Engine
The purpose of an engine tune-up is to restore power and performance thatís 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 itís 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 proce-
dure 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.

- 27 - Commissioning and operation

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 intervals.
(Refer to " 7.1. Periodic Inspection Cycle")

5.2. Lubrication System

5.2.1. Exchanging of lubrication oil

Engine oil and the oil filter are important fac-
tors 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 break-in 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 contami-
EA4O4001
nation 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.

Maintenance and Care - 28 -

5.2.3. Oil exchange procedure
While the oil is still hot, exchange oil as fol-
lows:
● 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 valve
EA8O5001

● Reassemble the drain valve with the oil

pan and the drain plug with oil filter

head after draining out the engine oil.

EA2O4001

● Refill with new engine oil at the oil filler

neck on the head cover and the lubri-
cating oil in accordance with the oil
Oil filler cap
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 Cylinder head cover

level. EA7O5003
● For a few minutes, operate the engine

at 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 addi-
tional oil if necessary.

- 29 - Maintenance and Care

● Recommend of lubricating oil

Initial factory filling is high quality break-in oil (API Service CH-4 grade). During the break-in period
(50 hours), check the oil level frequently. Somewhat higher oil consumption is normal until piston
rings are seated. The oil level should be maintained in the safe range between Min. and Max.
mark on the dipstick. To obtain the best engine performance and engine life, Engine oil is specified
by API Service, lettered designations and SAE viscosity numbers. If the specified engine oil is
not available, use a reputable brand of engine oil labeled for API Service CH-4 and SAE viscosity
15W40 or 10W40. Refer to oil identification symbol on the container.

Engine oil viscosity - ambient temperature

SAE 20, 20W SAE 40, 50

Single SAE 10W SAE 30

grade

Ambient -30 C -15 C -0 C 15 C 25 C 30 C

temp (-20 F) (-0 F) (-32 F) (60 F) (80 F) (90 F)

Multi
grade SAE 10W - 30

SAE 15W - 40

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

SAE 5W - 20
EA4M1008

Maintenance and Care - 30 -

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 :
Don’t 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 fil-
ter wrench.

NOTE :
It is strongly advisable to use
DOOSAN 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 which-
ever comes first. If the coolant is being
fouled greatly, it will lead an engine overheat
or coolant blow off from the expansion tank.

- 31 - Maintenance and Care

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

c) Loosen the coolant drain plug. Loosen

the coolant drain plug of the cylinder
block.

EI6OM001

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.

5.3.2. Cleaning of the cooling system inside circuit (by authorized specialist personnel)
When the cooling system circuits 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, gray or black signs 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)

Maintenance and Care - 32 -

 d) Warm up engine under load. After a temperature of 60?C 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.

5.3.3. Intercooler
The intercooler is air to air type and has a large cooling fan capacity. The intercooler life and per-
formance 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.

- 33 - Maintenance and Care

5.4. Air Intake System

1 2 3 4 5 6 7
1. Connection port, fouling indicator
2. Cleaner housing
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 ìtopî 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.

NOTE : EA6O5013
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.

Maintenance and Care - 34 -

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
out of the filter pleats.
EA6O5014

● By washing

Before washing, the element should be

precleaned by means of compressed air,
as described above.
Then allow the element to soak in luke-
warm 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 and allow drying at room tempera-
EA6O5015
ture. 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 oneís 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 car-
tridge with a flashlight.
Damaged cartridges should not be reused
EA6O5016
under any circumstances. In cases of
doubt, discard the cartridge and install a
new one.

- 35 - Maintenance and Care

5.5. Fuel System

5.5.1. Fuel filter

● After every 200 hour of operation, drain the
water and sediment from the fuel-water 1
separator.
3
● Shut off the engine. Use your hand to
5
open the drain valve ⑥. 4

● Turn the valve counter clockwise approx- 2

imately 2 ~ 3 turns until draining occurs.

Drain the filter sump of water until close
6
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 ② by turning it

counter-clockwise with filter wrench.

(Discard the used filter.)
● Remove the fuel filter thread adapter seal

ring ④.
● Use a clean lint free cloth to clean the

gasket surface of the fuel filter head ③.

● Install the new thread adapter seal ring EA7O5008

④ 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.

NOTE :
Mechanical over tightening of the
filter can distort the thread or
damage the filter element seal.

Maintenance and Care - 36 -

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 dayís 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. DOOSAN
recommends installation of a fuel water separator on generator units.

● 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 injec-
tion 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.

● Fuel supply pump

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

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 ìslimeî 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.

NOTE :
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.

- 37 - Maintenance and Care

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
and rinse it in the fuel oil.
Strainer(Inner)

EA7O5009

5.5.6. Bleeding the fuel system

Whenever fuel filter is changed or the engine
is stopped by cause of the fuel lack, the air
of fuel line must be removed as follows.
Bleed the fuel by manually operating the
priming pump with fuel filter outlet joint
bolt and injection pump bleeder screw
Priming pump
loosened.
● Press the feed pump cap repetitively
until the fuel without bubbles overflows EA9O4005
from the bleeding plug screw.
● After the whole air is pulled out, close the

plug screws of the filter and the pump.

● Confirm the resistance of fuel delivery by

repetition pressing of the feed pump cap,

Pressure and turn the priming 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 dam-

aged 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.

Maintenance and Care - 38 -

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
EA0M3003
by means of shims at the compression spring.

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 P126TI / P126TI-1 / P126TI-II / PU126TI

1st : 160kg/cm2
Opening pressure 220kg/cm2
2nd : 220kg/cm2

NOTE :
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.

● 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.

- 39 - Maintenance and Care

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 nec-
essary 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 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 Turbine wheel chamber
Magnetic vise
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 dam- Move the turbine
shaft to axial
age is caused to the rotor and bearings. direction
Dial gauge
<Measuring rotor axial clearance>
(mm) Wear limit : 0.20mm
EA4M2017
Axial clearance 0.2

<Measuring radial clearance>

(mm)
Radial clearance 0.65

Dial gauge
Magnetic vise

Move the turbine shaft

Radial play
in both directions
Limit of wear : 0.57mm
simultaneously

Oil inlet
EA4M2018

Maintenance and Care - 40 -

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 hour’s 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.

6.1.2. Adjusting order of the valve clearance

● Cylinder No. 1 begins from the rear side where the flywheel is mounted but cylinder No. 6
begins from the front side of the engine on the contrary.

Flywheel Intake Valve Exhaust Valve Cylinder No. Crank pulley

1 2 3 4 5 6

ED5OM005

Step 1 :
● After letting the cylinder No.6 in the overlap TDC position by turning the crankshaft, adjust the valves

corresponding to " " of following figure. At this time cylinder No. 1 should be at the ignition TDC
position(O.T).

Step 2 :
● After adjusting upper valves turn the crank pulley 360° to adjust the other valve clearance until

the cylinder No. 1 comes to overlap TDC position.

At this time cylinder No. 6 should be at the ignition TDC position(O.T).

● Adjust the valves corresponding to " " in upper figure.

After reconfirming the valve clearances, retighten it if necessary.

- 41 - Checking and Setting

 ● Loosen the lock nuts of the rocker arm adjusting screws and push the specified feeler gauge

and adjust the valve clearance with adjusting screw respectively.

(mm)
Model Intake Valve Exhaust Valve
DE12T / P126TI / P126TI-1 /
0.3 0.3
P126TI-II / PU126TI

6.1.3. Method of adjusting the valve clearance

1) Loosen the lock-nuts ① using a ring spanner.
2) Insert a thickness gauge of 0.3mm between
4
valve stem ② and rocker arm ③.

3) Turn the adjusting bolts ④ using a screw

driver until the gauge can be pulled out
with some restriction. 1
4) After the adjustment fix the adjusting bolt 3
not to rotate and tighten the lock-nut at the
2
same time. EA0O4014

5) Measure the clearance one more time and

if necessary adjust again.

Checking and Setting - 42 -

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
Timing
on the flywheel, and then turn again the 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.

DE12T / P126TI /
PU126TI
P126TI-1 P126TI-II
Fuel injec-
tion timing
12° 16° 14°
(B.T.D.C
static) Injection timing Flywheel
notch mark ring gear

EA8O6002

● Turn the timer until the notch mark of

the indicator plate attached to the fuel

Notch
injection pump is aligned with the notch mark
mark of the timer.

EA9O5002

- 43 - Checking and Setting

 ● Tighten the coupling fixing bolts and
nuts to specified torque.

Torque 6.0 kg⋅m

EAMD021I

● Tighten the drive shaft connecting flange

fixing bolts to specified torque.

Torque 7.5 ~ 8.5 kg⋅m

● Install the oil delivery pipe and return

pipe.

6.3. 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 com-
pression pressure gauge to the adapter.

3) Cut off fuel circulation, rotate the starter,

then measure compression pressure of
each cylinder.

Standard value 25 ~ 28 kg/cm2

Limit 24 kg/cm2 or less
EA9O5004
Difference between
Within ± 10%
each cylinder

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

Checking and Setting - 44 -

6.4. 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
The tension is correct if the V-belts can
Press here
be pressed in by about the thickness of
15mm
the V-belt. (no more midway between
Alternator Fan
the belt pulleys) Pulley
Pulley
A more precise check of the V-belt tension
is possible only by using a V-belt tension
V-belt
tester.

Crank Pulley EA8O3005

(4) Measuring tension

1) Lower indicator arm (1) into the scale.
● Apply tester to belt at a point mid-
way between two pulleys so that
edge of contact surface (2) is flush
1
with the V- belt.
● 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
has disengaged a false reading will be EA6O6011

obtained!
2)Reading of tension
● Read of the tensioning force of
the belt at the point where the
top surface of the indicator arm 3
(1) intersects with the scale.
● Before taking readings make
ensure that the indicator arm
remains in its position.

2
EA6O6012

- 45 - Checking and Setting

 Tensioning forces on the tester
new installation
Type Drive belt width When servicing after
After 10 min. long running time
Installation
running time
A 11.8 mm 55 kg 50 kg 45 kg

* V-belt of raw edge cogged type

When servicing after

Type new installation
long running time
3V 45 kgf 41 kg

3V 2 - 0000 3V 4 - 0000

Belt length Belt length

No. of belt rib No. of belt rib
Belt type Belt type
EF8OM084

(5) Tensioning and changing V-belt

● Remove fixing bolts. (1)

● Remove lock nut. (2)

● Adjust nut (3) until V-belts have cor- (2)

rect tensions. (3)
● Retighten lock nut and fixing bolts. (1)

EA8O6004

Checking and Setting - 46 -

7. Operation Tip

7.1. Periodic Inspection Cycle

{ : Check & adjust z : Replace

Every Every Every Every Every

Inspection Daily Remark
50hrs 200hrs 400hrs 800hrs 1,200hrs

Check for leakage(hoses, clamp) {

Check the water level {
Cooling Change the coolant water z
System
Every
Adjust the V-belt tension {
2,000hrs
Clean the radiator {
Check for leakage {

Lubrica- Check the oil level gauge {

tion z
Change the lubricating oil
1st
z
System

Replace the oil filter cartridge z z

1st
Check the leakage for intercooler
{
(hoses, clamp)
Intake & Clean and change { z
Exhaust the air cleaner element clean
System Clean the inter-cooler air fins {
Every
Clean the turbo-charger
2,000hrs
Check the leakage fuel line {
Clean the fuel strainer
{
of fuel feed pump
Remove sediment from fuel
{
tank
Fuel
Drain the water in separator {
System
Drain the water in separator z
When
Check fuel Injection timing {
necessary
When
Check the injection nozzles {
necessary
Check the state of exhaust gas {
Check the battery charging {
Engine When
Check the compression pressure {
Adjust necessary
Adjust Intake/Exhaust { When
valve clearance 1st necessary

- 47 - Operation Tip
7.2. Trouble Shooting

7.2.1. Engine Starting Impossible

1. Engine Starting Impossible

Starting motor operation poor Starting motor revolution

Inspection of battery electorlytic Engine Fuel

Ilquid amount & gravity
Inspect air cleaner Inspect amount of fuel
Normal Too low

Ajustment・ Normal Polluted Normal None

Recharging
Replace or Replenish
Inspection of loose electric clean element Inspect fuel
wring & short injection No injection
Check compression
pressure
Retigten・ Normal
Normal
Replace Too low
Continuous
Normal operation after
Inspection of starting switch Repair・
air removal
Replace
Inspect
Repair・ Inspect of
Normal injection
Replace other parts
timing
Inspection of starting relay Check valve Adjust
clearance Normal
Normal Replace
Inspect injection
Normal Adjust
nozzle (injection
Inspection of magentic switch
Check cylinder pressure injection
Replace state etc.)
Repair head gasket
Normal
Replace Repair・
Normal Normal
Replace
Starting motor
disassembly Engine disassembly Injection pump
(valve assembly piston disassembly
cylinder liner etc.)

Inspect supply pump operation

Normal Inspect supply pump valve strainer Air mixture in fuel

Injection pump Clean・ Retighten connection

Normal
dasassembly replace parts. Replace gasket

Inspect fuel filter Air removal

Element polluted Continuous air mixing

Overflow valve poor
Supply pump
Replace disassembly

Operation Tip - 48 -
7.2.2. Engine Overheated

2. Engine Overheated

Operating state

1. Overload
2. Radiator core clogged
Cooling unit Fuel unit 3. Continuous over-run

Check coolant
Inspect fuel quality Fuel excessive supply

Normal Too low

Poor

Check fan belt Clean and replace

Repair Check injection nozzle
tension wear with specilied fuel
Replace
or damage etc.

Replenish Inspect cooling

Normal water leakage

Check fresh
Replace
water tank cap Exteranl Internal

Normal Retighten Engine

Normal Abnormal
Replace disassembly

Check thermostat Replace

Adjust
repair Repair
Normal injection Replace
pump
Inspect heat Repair
Damage
exchanger Replace

Check cooling Repair

Normal
water pump Replace

Clean cooling
Normal
water passage

Engine
disassembly

- 49 - Operation Tip
7.2.3. Output Insufficient

3. Output Insufficient

Engine Installation improper

Fuel unit Check for coupling

Others
alignemnt
Check for air mixing
Inspect air cleaner Adjust or replace
in fuel
coupling
Inspect fuel supply pump Normal Clean Relpace

Inspect air leakage

Normal Clean Replace Inspect engine control
of air piping line
rod, link, cable, etc.

Inspect fuel filter over folw valve

Retighten
Normal Adjust Normal
Replace
Normal Replace
Check valve clearance
Inspect air leakage
Inspect injection pipe
Adjust of Intercooler
Normal
Normal Repair Replace
Inspect cylinder head
Inspect injection nozzle gasket for damage
injection pressure
atomizing state Normal Replace

Normal Adjust Replace Engine disassembly

(valve assembly)
Check injection timing

Normal Adjustment

Disassemble engine or Check Turbocharger

injection pump

Normal Repair
Replace

Disassemble injection
pump or engine

Operation Tip - 50 -
7.2.4. Oil pressure lowered

4. Oil pressure lowered

Check if oil pressure

gauge indicates wrongly

Check oil amount

Too low
Normal

Use recommended oil

Check cooling
(replenish)
temperature
Too high
Normal

Refer to engine overhea

Inspect oil quality

Normal

Check oil relief Water & fuel mixed Improper

valve in oil

Replace with
Retighten Disassemble engine
Normal recommended oil
Replace or injection pump

Disassemble
engine

- 51 - Operation Tip
7.2.5. Fuel Consumption

5. Fuel Consumption Excessive

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
Inspect fuel leakage High Speed

Normal

Oil leakage
Inspect injection nozzle
(injection pressure Adjust Replace
atomizing state etc.) Retighten Replace

Normal

Check injection timing Adjust

Normal

Repair Replace
Inspect compressed Check valve
Cylinder liner
pressure clearance
Piston ring Piston

Normal

Disassemble
Adjust
injection pump

Normal

Inspect head gasket Replace

Normal

Disassemble engine
(valve assembly piston
cylinder liner etc.)

Operation Tip - 52 -
7.2.6. Oil Consumption Excessive

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

Clean Replace
Normal Oil leakage

Check oil quality External Internal

Retighten Check compressed

Replace with
Replace pressure
specified oil

Engine disassembly Normal

(piston cylinder liner)

Disassemble
cylinderhead
(valve stem seal)

7.2.7. Engine Knocking

7. Engine Knocking

Inspect combustion of fuel & oil

(carbon residue exhaust gas)

Unconfirmed Confirm

Inspect compressed Disassemble

pressure engine

Too low
Normal

Check valve clearance and

Inspect injection cylinderhead gasket for damage
pump

Normal Adjust Normal Replace

Adjust
Check fuel quality
Disassemble
engine
Use specified fuel

- 53 - Operation Tip
7.2.8. Battery Discharge

7. Engine Knocking

Inspect combustion of fuel & oil

(carbon residue exhaust gas)

Unconfirmed Confirm

Inspect compressed Disassemble

pressure engine

Too low
Normal

Check valve clearance and

Inspect injection cylinderhead gasket for damage
pump

Normal Adjust Normal Replace

Adjust
Check fuel quality
Disassemble
engine
Use specified fuel

Operation Tip - 54 -
7.3. Causes and Remedies

Condition Causes Remedies

1) Starting difficult ● Valveís poor shut, stem distortion Repair or replace
(1) Compression pressure ● Valve spring damage Replace valve spring
● Cylinder head gasket’s leak Replace gasket
● Wear of piston, piston ring or liner Adjust
2) Idle operation abnormal ● Injection timing incorrect Adjust
● Air mixing at injection pump Remove air
3) Engine output insufficient ● Valve clearance incorrect Adjust
(1) Continuous output insufficient ● Valve tightness poor Repair
● Cylinder head gasket’s 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 improper or stuck Adjust or replace
● Supply pump’s function lowered Repair or replace
● Fuel pipe system clogged Repair
● Air suction amount insufficient Clean or replace air cleaner
● Supercharger poor Repair or replace
(2) Output insufficient when in ● Compression pressure insufficient Disassemble engine
acceleration ● Injection timing incorrect Adjust
● Fuel injection amount insufficient Adjust injection pump
● Injection pump timer’s function insufficient Repair or replace
● Nozzle infection pressure, infection angle Repair, replace
improper
● Supply pump’s function lowered Repair or replace
● Air intake amount insufficient cleaner Clean or replace air
4) Overheating ● Engine oil insufficient or poor Replenish or replace
● Cooking water insufficient Replenish or replace
● Fan belt loosened, worn, damaged Adjust or replace
● Cooling water pump’s function lowered Repair or replace
● Water temp. regulator’s operation poor Replace
● Valve clearance incorrect Adjust
● Exhaust system’s resistance increased Clean or replace
5) Engine noisy For noises arise compositely such asrota ting
parts, lapping parts etc., there is nec essity to
search the cause of noises accurately.
(1) Crankshaft ● As the wear of bearing or crankshaft Replace bearing & grind
progress, the oil clearances increase. crankshaft
● Lopsided wear of crankshaft Grind or replace
● Oil supply insufficient due to oil passage Clean oil passage
clogging
● Stuck bearing Replace bearing & Grind

- 55 - Operation Tip
 Condition Causes Remedies
(2) Con rod and Con rod ● Lopsided wear of con rod bearing Replace bearing
bearing ● Lopsided wear of crank pin Grind crankshaft
● Connecting rod distortion Repair or replace
● Stuck bearing Replace & grind crank-
● Oil supply insufficiency as clogging at oil shaft
passage progresses Clean oil passage
(3) Piston, piston pin & piston ● Piston clearance increase as the wear of Replace piston & piston
ring piston and piston ring progresses ring
● Wear of piston or piston pin Replace
● Piston stuck Replace piston
● Piston insertion poor Replace piston
● Piston ring damaged Replace piston
(4) Others ● Wear of crankshaft, thrust bearing bearing Replace thrust
● Camshaft end play increased Replace thrust plate
● Idle gear end play increased Replace thrust washer
● Timing gear backlash excessive Repair or replace
● Vale clearance excessive Adjust valve clearance
● Abnormal wear of tappet, cam Replace tappet, cam
● Supercharger inner part damaged Repair or replace
● Injection timing incorrect Adjust
6) Fuel Consumption Exttive
● Fuel injection amount excessive Adjust injection pump
7) Oil Consumption Excessive
(1) Oil level elevated ● Clearance between cylinder iner & piston Replace

● Wear of piston ring, ring groove Replace piston, piston ring

● Piston ring’s damage, stick, wear Replace piston ring
● Piston ring opening’s disposition improper Correct position
● Piston skirt part damaged or abnormal wear Replace piston
● Oil ring’s oil return hole clogged Replace piston ring
● Oil ring’s contact poor Replace piston ring
(2) Oil level lowered ● Looseness of valve stem & guide Replace in set
● Wear of valve stem seal Replace seal
● Cylinder head gasket’s leak Replace gasket
(3) Oil leak ● Looseness of connection parts Replace gasket, repair
● Various part’s packing poor Replace packing
● Oil seal poor Replace oil seal

Operation Tip - 56 -
8. General Information

8.1. General Repair Instructions

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

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

3) Engine oil and anti-freeze solution must be handled with reasonable care as they cause paint damage.
4) The use of proper tools and special tools where specified is important to efficient and reliable service
operation.

5) Use genuine DOOSAN 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.

- 57 - General Information
8.2. Engine Characteristics

8.2.1. 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 P126TI series, DE12T and PU126TI
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 con-
sumption.

EA8M1001

8.2.2. Oil Gallery Cooling Type Piston

(P126TI / PU126TI)
Oil gallery cooling is used for the piston of
P126TI series and PU126TI engine. When
thermal loading is high, piston cooling by
means of an oil gallery in the crown is normally
necessary to prevent crown cracking and ring
sticking. The design of the gallery, the design
and location of the oil spray nozzle and the
quantity of oil flowing in the gallery are critical
in order to achieve the desired temperature
reduction.
The cross section shape of the gallery
should be designed to achieve sufficient oil
movement to maximize cooling efficiency.

General Information - 58 -
9. Disassembly and Reassembly of Major Components

9.1. Disassembly

9.1.1. 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 disassem-

bled parts.
● Arrange the disassembled parts in the
disassembly sequence and use care to
prevent any damage to them.

9.1.2. 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.

EI7OM003

- 59 - Disassembly and Reassembly of Major Components

9.1.3. Engine oil
● Take out the oil dipstick.

● Remove the oil drain valve of oil pan and

drain out the engine oil into a prepared

container.

Drain valve
EA8O5001

9.1.4. Alternator belt

● Loosen the tension adjusting nut installed

on the alternator bracket, and take off

the alternator belt.

EA8M3001

9.1.5. Cooling fan

● Remove the flange fixing bolts, then take
off the flange and cooling fan.

EQM3004I

9.1.6. Alternator
● Remove the alternator fixing bolt and

disassemble the alternator.

● Remove the tension adjusting bolt and

bracket.

Disassembly and Reassembly of Major Components - 60 -

9.1.7. Guide tube of oil level gauge
● Loosen the flange nut installed on the
oil pan to remove the guide tube.

EQM3005I

9.1.8. Fuel filter

● Remove fuel hoses connected to the fuel

injection pump, take off the bracket fixing

bolts, then disassemble the fuel filter.

EI6OM016

9.1.9. Breather
● Loosen the clamp screw to remove the
rubber hose.

9.1.10. Intercooler
● Tear down the various hoses and air

pipes from the inter cooler.

● Remove the intercooler fixing bolts
and tear it down.

EA6M2001

- 61 - Disassembly and Reassembly of Major Components

9.1.11. Injection pipe
● Unscrew the hollow screws to disassem-
ble the fuel return pipe.
● Remove the nuts installed on the fuel
injection pump and nozzles, then dis-
assemble the injection pipe.

EQM3009I

9.1.12. Intake manifold

● Remove the air hose connected to the

fuel injection pump.

● Loosen the intake manifold fixing bolts,

then disassemble the intake manifold.

EQM3011I

9.1.13. Turbo charger

● Release the clamp screw of the rub-
ber hose connected to the intake
manifold, and take off the intake pipes
both simultaneously.
● Unscrew the exhaust pip5e bracket
fixing bolts, release the nuts installed
on the turbocharger, then disassemble
the exhaust pipe.
● Remove the turbocharger after remov-

ing the oil supply pipe and return pipe

and releasing the fixing nuts.

Disassembly and Reassembly of Major Components - 62 -

9.1.14. Exhaust manifold
● Release the exhaust manifold fixing
bolts, disassemble the exhaust mani-
fold, 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.

9.1.15. Thermostat
● Remove the by-pass pipe connected to

the water pump, unscrew the thermostat

fixing bolts, then disassemble the ther-
mostat 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

9.1.16. Starter
● Unscrew the starter fixing bolts, then

disassemble the starter.

ED5OM009

9.1.17. 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.

- 63 - Disassembly and Reassembly of Major Components

9.1.18. 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, disassemble the

injection pump mounting bolts, then
detach theinjection pump.

NOTE :
After letting No.1 cylinder to the 'OT' EAMD021I
position by turning the crankshaft,
disassemble the injection pump.

● Release the pump fixing bracket bolts

to disassemble the bracket from the
cylinder block.

NOTE :
Do not mix the disassembled shims.
These should be reassembled to the
original position.

EAMD022I

9.1.19. 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.

9.1.20. Fan drive pulley

● Remove the bolts and disassemble
the fan drive pulley.

Disassembly and Reassembly of Major Components - 64 -

9.1.21. Vibration damper
● Unscrew the pulley fixing bolts and
disassemble the pulley-vibration
damper assembly.
● Unscrew the vibration damper fixing
bolts and disassemble the damper
from the pulley.

9.1.22. Timing gear case cover

● Disassemble the oil seal using an oil

seal removing jig.

● Remove the cover fixing bolts and dis-

assemble the cover from the timing

gear case.

EAMD025I

9.1.23. 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.

9.1.24. 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, bear-
ings, and housing are put together.

EAMD027I

- 65 - Disassembly and Reassembly of Major Components

9.1.25. Cylinder head cover
● Unscrew the cover fixing bolts and
disassemble the cover.
● Keep the bolts in an assembly state
so that the packings and washers may
not be lost, and keep the cover pack-
ing as assembled with the cover.

EI7OM005

9.1.26. 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

9.1.27. Injection nozzle

● Take off the injection pipes between
the injection pump and injection noz-
zles.

● Remove the nozzle tube using nozzle

tube removing jig.

Do not disassemble injection nozzle

unless coolant or gas come out.
EAMD030I

9.1.28. Cylinder head

● Unscrew the cylinder head fixing bolts
and take off the cylinder head.
● Remove the cylinder head gasket.

EAMD031I

Disassembly and Reassembly of Major Components - 66 -

9.1.29. Valve and valve stem seal
● Compress the valve spring retainer
using a jig and take off the valve cot-
ter pins.
● Disassemble the valve springs and
retainers.
● Take off the valves.
Valve spring
● Remove using a general tool and dis- compressor
card the valve stem seals in order not
to be re-used. EA0M4007

9.1.30. 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 EAMD033I
cooler cover.

9.1.31. Oil pan

● Stand the engine with the flywheel
housing facing the bottom.
● Release the oil pan fixing bolts,
remove the stiffeners then disassem-
ble the oil pan.

EAMD034I

9.1.32. 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 bolts and

disassemble the oil pump.

EAMD035I

- 67 - Disassembly and Reassembly of Major Components

9.1.33. Relief valve
● Disassemble the relief valve.

EAMD036I

9.1.34. 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 pis-
ton.

EAMD037I

● Remove the piston pin snap rings,

take off the piston pin, then discon-
nect the connecting rod from the pis-
ton.

● 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.

Disassembly and Reassembly of Major Components - 68 -

9.1.35. Cylinder liner
● Disassemble the cylinder liner using a
liner puller.

EAMD040I

9.1.36. 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 fly-
wheel, and disassemble the flywheel.

EAMD041I

9.1.37. 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.

9.1.38. Flywheel housing

● Loosen the housing fixing bolts disas-

semble the flywheel housing.

EAMD043I

- 69 - Disassembly and Reassembly of Major Components

9.1.39. 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

9.1.40. 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.

9.1.41. Timing gear case

● Unscrew the case fixing bolts and dis-
assemble the timing gear case.

EAMD046I

Disassembly and Reassembly of Major Components - 70 -

9.1.42. 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.

9.1.43. Oil spray nozzle

● Unscrew the fixing bolt and remove

the oil spray nozzles.

- 71 - Disassembly and Reassembly of Major Components

9.2. Inspection

9.2.1. 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) :
5) 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)

9.2.2. Cylinder head

1) Inspection
● Carefully remove carbon from the lower face 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
(t)
using a straight edge and a feeler
gauge at six positions (A ~ F) as
B
shown in the right figure. A
● If the measured value exceeds the C
D
standard value, retrace the head
with grinding paper of fine grain size
E
to correct such defect.
F
● If the measured value exceeds the EA3M2031
maximum allowable limit, replace the
cylinder head.

<Lower face warpage and height>

(mm)
Standard Limit
Warpage 0.2 or less 0.3
Thickness : t 114.95 ~
113.9
(reference) 115.0

EA6M2002

Disassembly and Reassembly of Major Components - 72 -

 3) flatness
Measure flatness of the intake/exhaust
manifolds fitting surfaces on the cylin-
der head using a straight edge and a
feeler gauge.
(mm)
Standard Limit
0.05 0.2

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

9.2.3. 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 diame-

ter at 3 positions. (top, middle, and
bottom) If the amount of wear is
beyond the limit, replace the valve.
(mm) End of stem

Dimension
Standard Limit
Description
EFM2036I
Intake valve Ø 10.950 ~
Ø 10.87
stem Ø 10.970
Exhaust valve Ø 10.935 ~
Ø 10.84
stem Ø 10.955

● Valve seat contacting faces

Check the valve seat contacting

faces for scratches or wear, and cor-
rect the faces with grinding paper as
necessary. Replace if severely dam-
aged.

- 73 - Disassembly and Reassembly of Major Components

 ● Valve head thickness

Measure the valve head thickness,

and replace the valve if the mea-
sured value is beyond the limit.
(mm)
Dimension
Standard Limit
Description
Intake valve 1.5 1 or less
Exhaust valve 1.5 0.9 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 guide, whichever worn Measuring
position
more.

EA0M4052

<Valve stem end play>

(mm)
Standard Limit
Intake valve 0.04 ~ 0.07 0.2
Exhaust valve 0.06 ~ 0.09 0.25

● 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.

Disassembly and Reassembly of Major Components - 74 -

3) Valve seat
● Contacting face amount

Measure the contacting face

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

<Valve contact width> Contact width

(mm)
Standard Limit
0 ~ 0.03 0.55 EA0M4047

● 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.

EDM2032P

<Valve Depression>
(mm)
Standard Limit
Intake &
0 ~ 0.3 0.55
Exhaust

If the amount of depression is beyond

Depression
the specified limit, replace the valve
seat.
EA0M4046

● For removal of the valve seat, apply

arc welding work to two points of
valve seat insert, and pull out the Valve seat

valve seat insert with inner extractor.

Cylinder head

Welding bead EA3M2032

- 75 - Disassembly and Reassembly of Major Components

 ● For assembling of a new valve seat, by putting it among the dry ices of an ice box previ-

ously for about 2 hours for the cold shrinkage, and press it in the cylinder head by a special
tool. (bench press)
● Apply the valve lapping compound on the valve head seating face and lap the valve seat by
turning it until it is seated in its position, then wipe out the lapping compound.

NOTE :
Clean the valve and cylinder head with light oil or equivalent after the valve seat
finishing is completed, and make sure that there are no grinding materials
remained.

4) Valve spring
● Visual check

Visually check the exterior of the

valve springs for damage, and
replace if necessary.

● Valve spring free length

Use a vernier caliper to measure the

valve spring free length.
If the measured value is less than
the specified limit, the valve spring
must be replaced.
(mm)
Spring free Length Standard
Intake valve 75.5
EJM2049I
Exhaust Inner 65
valve Outer 75.5

● Valve spring inclination

Use a surface plate and a square to

measure the valve spring inclination.
Inclination
If the measured value exceeds the
specified limit, the valve spring must
be replaced.
Free length

(mm)
Standard Limit
Valve spring
1.0 2.0 Square
Inclination
EJM2050I

Disassembly and Reassembly of Major Components - 76 -

 ● Valve spring tension

Use a spring tester to measure the

valve spring tension if the measured
value is less than the specified limit,
the valve spring must be replaced.

Spring
Set Length Limit
force
Valve Spring Spring tester
Intake Tension at 61.8 ~
61.8 kg
valve 37mm Set 68.3 kg
Length EA0M4056

Exhaus 36.1 ~
Inner 34mm 36.1 kg
t valve 39.9 kg

9.2.4. 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.
(mm)
EDM2037I
Limit 0.2

● Rocker arm shaft diameter

With an outside micrometer, mea-
sure 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 speci-
fied limit.
(mm)
Standard Limit
EA8M3002
Ø 23.978 ~ Ø 23.959 Ø 23.75

- 77 - Disassembly and Reassembly of Major Components

 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 bush-

ing
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, which-
ever worn more.

<Clearance> EA0M4059
(mm)
Standard Limit
0.020 ~ 0.093 0.2

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.
(mm)
Standard Limit
0.035 ~ 0.077 0.15

Disassembly and Reassembly of Major Components - 78 -

● Visual check of tappet

Visually check the face of the tap-

pets in contact with the cam for pit-
ting, scores or cracks, and replace if
severely damaged. If the amount of
cracks or pitting is small, correct (1) Unevenness (2) Crank (3) Normal

with an oil stone or grinding paper.

Abnormal
EA0M4070

● Outside diameter

With an outside micrometer, mea-

sure the tappet outside diameter If
the measured value is beyond the
limit, replace tappets.
(mm)
Tappet Dia Ø 19.944 ~ Ø 19.965

(mm)
Standard Limit
Tappet 0.035 ~ EDM2061I
0.15
Clearance 0.077

● Push rod run-out

(mm)
Limit 0.3 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

- 79 - Disassembly and Reassembly of Major Components

9.2.5. Cam shaft
1) Cam
● Cam lobe height

(mm)
Standard Limit
Cam journal Ø 59.86 ~
Ø 59.52
diameter(A,B) Ø 59.88

Use a micrometer to measure the

I II I II
A
cam journal diameter.
C B B

If the measured number is less than D A

EA0M4062
the specified limit, the camshaft must
replaced.

● Cam surface

Use a micrometer to measure the

cam journal diameter.
If the measured number is less than
the specified limit, the camshaft must
replaced.

2) Cam shaft
● Clearance between camshaft jour-

nal and camshaft bush

- With an outside micrometer, mea-
sure the camshaft journal diameter.
- Measure the inside diameter of the
camshaft bushing on the cylinder Camshaft bearing
block using a cylinder bore indica-
tor, and compare the measured
value with the camshaft outside
diameter to determine the clear-
ance.

<Clearance>
(mm) EA0M4063
Standard Limit
0.050 ~ 0.128 0.2

Replace the bushing if the measured

value is beyond the specified limit.

Disassembly and Reassembly of Major Components - 80 -

 ● 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.
(mm)
Standard Limit
0.05 0.2
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.
(mm)
Standard Limit
0.13 ~ 0.27 0.3

EA0M4067

- 81 - Disassembly and Reassembly of Major Components

9.2.6. 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 crank-
shaft which has cracks.

2) Wear
● With an outside micrometer measure

the diameter of the crankshaft jour-

nals 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,
EAMD057I
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.)
(mm)
Standard Limit A

Journal diame- Ø 95.966 ~

Ø 94.966
ter Ø 95.988 B B

Ø 82.966 ~
Pin diameter Ø 81.966 B B
Ø 82.988

A
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.

Disassembly and Reassembly of Major Components - 82 -

 NOTE :
When regrinding the crankshaft as "R"

described below, the fillet section

ëRí should be finished correctly.
"R"
Avoid sharp corners or insufficient
fillet.
"R" "R" "R"

* Standard values of "R”

0 Normal Poor Poor EFM2048I
① Crankshaft Pin "R" : 4.5 -0.2

0
② Crankshaft journal "R" : 4 -0.2

3) Crankshaft run-out
● Support the crankshaft on V blocks.

● Turn the crankshaft with a dial indi-

cator placed on the surface plate

and take the amount of crankshaft
run-out.
(mm)
Standard Limit
0.05 0.1

- 83 - Disassembly and Reassembly of Major Components

9.2.7. Crank shaft bearing
& 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

& bearing.

● Main bearing clearance (Method 1)

Install the main bearing in the cylinder

block, tighten the bearing cap to
specified torque, then measure the
inside diameter.

Torque 30 kg⋅m

(mm)
Standard Dia. Ø 96.06 ~ Ø 96.108

Compare the two values obtained

through measurement of main bearing
inside diameter with the outside diame-
ters of crankshaft journals to determine
the oil clearance.

<Main bearing oil clearance>

(mm)
Standard Limit
0.072 ~ 0.142 0.25

● 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 mea-
sure the inside diameter.

Torque 28 kg⋅m

(mm)
Standard Dia. Ø 83.02 ~ Ø 83.092

Disassembly and Reassembly of Major Components - 84 -

 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.
(mm)
Standard Limit
0.049 ~ 0.119 0.20

EAMD060I
● If the clearance deviates from the

specified range, have the crankshaft

journals and pins ground and install
undersize bearings.

● Connecting rod bearing clearance

(Method 2 : with plastic gauge)
Assemble the crankshaft on the cylinder block and put the plastic gauge on journal and pin
of crankshaft and then after assembling bearing cap, tighten the bolts at the specific torque.
Again after disassembling the bearing cap by removing the bolts, take out the flatted plastic
gauge and measure the width of plastic gauge by means of plastic gauge measuring scale.
This is the oil clearance.

3) Bearing spread and crush

● Inspection

Check to see that the bearing

requires a considerable amount of fin-
ger pressure at reassembly operation.

OA OB

Spread = O A - O B

EDM2047I

- 85 - Disassembly and Reassembly of Major Components

 ● 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.
(mm) EA6M063I
Standard Dia. 0.15 ~ 0.25

● 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 mea-
sure the clearance between the
bearing cap and connecting rod big
end using a feeler gauge.
(mm) EA6M064I
Standard 0.086 ~ 0.116

4) crank shaft end play

● Assemble the crankshaft to the cylin-

der block.
● With a dial gauge, measure crank-

shaft end play.

(mm)
Standard Limit
0.15 ~ 0.325 0.5

Disassembly and Reassembly of Major Components - 86 -

9.2.8. Piston
1) Visual check
Visually check the pistons for cracks,
scuff or wear, paying particular atten-
tion to the ring groove.

2) Clearance between the piston &

cylinder liner
● With an outside micrometer, measure

the piston outside diameter at a point

Position of measuring
18mm away from the lower end of outside diameter
piston skirt in a direction at a right
angle to the piston pin hole.
(mm)
Standard Dia. Ø 122.433 ~ Ø 127.863
18mm

EI6OM002

● 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.
(mm)
Standard Limit
Ø 123 ~ Ø 123.023 Ø 123.223

● The clearance is computed by subtract-

ing the piston outside diameter from
the cylinder liner inside diameter.
Replace either piston or cylinder liner,
whichever damaged more, if the clear-
ance is beyond the specified limit.

<Clearance between piston and liner>

(mm)
Standard 0.114 ~ 0.169

- 87 - Disassembly and Reassembly of Major Components

9.2.9. 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.
(mm)
Standard Limit
Top ring 0.30 ~ 0.45 1.5 Feeler gauge
2nd ring 0.35 ~ 0.50 1.5
Oil ring 0.30 ~ 0.50 1.5

Replace piston rings with new ones if

EA0M4033
the gap is beyond the limit

3) Piston ring side clearance

● Fit the compression ring and oil ring
in the piston ring groove.
Feeler gauge
● With a feeler gauge, measure side
clearance of each ring, and replace
either the ring or piston if the mea-
sured value is beyond the specified
limit.
(mm)
Standard Limit
EA4M2007
Top ring 0.105 ~ 0.155
2nd ring 0.07 ~ 0.102 0.15
Oil ring 0.05 ~ 0.085 0.15

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

Disassembly and Reassembly of Major Components - 88 -

 Oil ring 4.03 ~ 5.57 kg

9.2.10. 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
(mm)
Standard Limit
Ø 44.995 ~ Ø 45 Ø 44.990 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.
(mm)
Standard Limit
0.003 ~ 0.009 0.011

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.

- 89 - Disassembly and Reassembly of Major Components

9.2.11. 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 connect-
ing rod piston pin bushing holes with
connecting rod big end holes. At this
time also, use both connecting rod
tester and feeler gauge.
(mm)
Standard Limit
0.05 0.1 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.

(mm)
Limit 0.5

Disassembly and Reassembly of Major Components - 90 -

9.3. Reassembly

9.3.1. 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.

9.3.2. 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.

9.3.3. Oil spray nozzle

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

EDM3053I

9.3.4. 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.

- 91 - Disassembly and Reassembly of Major Components

 ● Apply engine oil to the entire face of
the tappets and slide them into the tap-
pet holes on the cylinder block.

● Wet the cam bush inside diameter and

camshaft with oil, and carefully assem-

ble them while turning the camshaft.
● Check to see that the camshaft rotates

smoothly.

EDM2060I

9.3.5. Crankshaft
● Install the main bearing machined with
two holes in the cylinder block so that Key groove
Oil port and passage
the key is aligned with the key groove,
then apply oil to the bearing surface.

EA0M4083

● Heat the crankshaft gear for at least 10

minutes to 120°C, then apply sealant

(Loctite # 641) to the inside wall of the
heated crankshaft gear evenly before
inserting it to the end of crankshaft.

EA8M3014

Disassembly and Reassembly of Major Components - 92 -

● 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.

EAMD075S

● Install 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 6 5 4 3 2 1

EQM3058I

- 93 - Disassembly and Reassembly of Major Components

 ● Apply oil to the entire part of the bear-
ing cap bolts, then tighten in tightening
sequence to specified torque.

Torque 30 kg⋅m

● After semi-tightening both bolts evenly,

tighten them diagonally specified torque

using a torque wrench as follows.
EQM3059I

<Tightening order>
(1) First stage : Coat engine oil over the bolts.
(2) Second stage : Temporary assemble the bolts about 1 ~ 2 threads
(3) Third stage : With impact wrench, tighten up to about 15 kg.m
(4) Fourth stage : With torque wrench, tighten up to about 25 kg.m
(5) Fifth stage : By means of torque wrench, tighten finally in the specified torque. (30 kg⋅m).

● Tighten the bearing cap in the

sequence of 4-3-5-2-6-1-7.
● Check to see that the assembled
crankshaft turns smoothly.

Disassembly and Reassembly of Major Components - 94 -

9.3.6. 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 kg⋅m
EQM3060I

9.3.7. 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.

Oil seal fitting jig

EA8M3003

9.3.8. 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 kg⋅m

4 8

6 1

2 5

7 3

EAMD097I

- 95 - Disassembly and Reassembly of Major Components

9.3.9. 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

9.3.10. Fuel injection pump drive gear

assembly
● Mount gasket by aligning the bolt holes
with the pin holes on the bearing hous-
ing.
● Tighten up the fixing bolts in the
direction of fuel injection pump.

EAMD027I

Disassembly and Reassembly of Major Components - 96 -

9.3.11. Timing gear
● Install the oil pump idle gear onto the
No.7 bearing cap.

● Install a thrust washer over the cam- Idle gear pin

shaft and assemble the cam gear by
aligning it with camshaft key groove.

Torque 3.1 kg⋅m

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

marks impressed on the crank gear, Mark "2"
cam gear, fuel injection pump drive
Fuel injection Cam gear
gear, and idle gear.
pump drive gear 1 1
2 2
2 1
● Install a thrust washer on the idle Idle gear
gear and tighten to specified torque.
Mark "1"
Torque 7.4 kg⋅m Crank
Mark "0"
gear
EA8M3005

● Check and adjust the amount of backlash

between gears using a feeler gauge.
(mm)
Measuring
position Backlash Limit
(between)
Cam gear &
0.16 ~ 0.28 0.35
idle gear
Crank gear &
0.16 ~ 0.28 0.35
idle gear
Injection pump
0.16 ~ 0.28 0.35
& idle gear

- 97 - Disassembly and Reassembly of Major Components

9.3.12. 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.

9.3.13. 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

9.3.14. Cylinder liner

● Stand the cylinder block so that the
flywheel faces downward.

● Thoroughly clean the liner flange fitting

surface and bore inside with com-

pressed air to prevent the entry of for-
eign substances.
● After the cleaning operation, make the
cylinder liner dried up and push it into
the cylinder block by hand. EAMD087I

● Wet the liner inside diameter with

engine oil.

Disassembly and Reassembly of Major Components - 98 -

9.3.15. Piston and connecting rod
● Use a piston heater to heat the piston
Piston heater
approximately 100 °C (212 °F) for 5
minutes.

EA3M2058

● 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 “DI” impressed on the inside of the
piston face each other in opposite
106

directions. On the piston head surface,

the longer side of connecting rod big
end is in opposite direction from the
EAMD089I
valve seating surface as well as in the
same direction with the narrow margin
of combustion chamber.

● Install the snap rings and check to

see that it is securely assembled.

● Install the piston ring in the piston using

piston ring pliers.

- 99 - Disassembly and Reassembly of Major Components

 ● Identify the mark "Y" or "TOP" on the
ring end to prevent the top and bot-
tom of the piston ring is interchanged
each other and make the marked top
face upward.

NOTE :
Be sure to make the piston ring Marked with the name of piston ring
end marked face("Y" or "TOP") manulacturing company
EAMD090I
upward.

● Adjust the angle among individual pis-

O O

ton ring gaps to 90° and fit a piston 45 45

2nd ring gap Top ring gap
assembling jig onto the piston, Use
care not to match the ring gaps with
the pin direction. O
90
● Install the bearing by aligning it with
the connecting rod key groove and Piston pin
apply oil to the bearing and piston. Oil ring gap
Piston
EA8M3006

● Position the valve seating surface

toward the tappet hole and insert the
piston with hand.
Use care not to damage the cylinder Tappet hole

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 EAMD092I

rod cap and apply oil.

● Make sure that the manufacture serial

numbers impressed on the connect-

ing rod cap and connecting rod big
end are identical, and install the con-
necting rod cap by aligning it with
dowel pin. Serial No.

EA0M4092

Disassembly and Reassembly of Major Components - 100 -

 ● Wet the fixing bolts with oil, semi-tighten them with hand, tighten them to specified torque

using a torque wrench as follows.

<Tightening order>
(1) First stage : Coat engine oil over bolts
(2) Second stage : Temporary screw the bolt about 1 ~ 2 threads
(3) Third stage : With torque wrench, tighten at about 15 kg⋅m
(4) Fourth stage : With torque wrench, tighten up to about 22 kg⋅m
(5) Fifth stage : Finally, tighten in the specified torque 28kg.m with torque wrench.

Torque 28 kg⋅m

● Move the bearing cap with hand, and

release and reassemble it if no move-

ment is detected.

EAMD094I

9.3.16. Relief valve

● Assemble the relief valve.

EAMD036I

9.3.17. 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 kg⋅m

● Assemble the oil suction pipe with the

delivery pipe, then install the bracket on

the bearing cap.
EAMD095I

- 101 - Disassembly and Reassembly of Major Components

9.3.18. 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 kg⋅m

EAMD034I

9.3.19. 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 rub-

ber hammer to check that the valve is

assembled correctly.
Valve spring
compressor

EA0M4007

Disassembly and Reassembly of Major Components - 102 -

9.3.20. 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 assíy (Guider + Expander) the
cylinder head, then tighten the nozzle Guider

fixing nuts.

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 bot-

tom.

● After mounting the nozzle tube, make a

hydraulic test to check for water leaks.

Test pressure 2 kg/cm2

EAMD099I

9.3.21. Cylinder head

● Install the injection nozzle fixing stud
bolts and water pipe fixing stud bolts.
● Clean the head bolt holes on the cyl-
inder block with compressed air to
remove foreign substances and thor-
oughly clean the gasket fitting face of
the cylinder block. TOP

● Install head gasket, with 'TOP' mark

facing upward, on the cylinder block EAMD101I
by aligning the holes with dowels.

Semi steel
Asbestos core type
Cylinder type
Head Rubber
gasket Rubber color : Black color :
Red

Use bolt TY TY
12.9T 10.9T

- 103 - Disassembly and Reassembly of Major Components

 ● Check the inside of combustion chamber for foreign substances, and carefully mount the cyl-

inder head assembly in the block by aligning the dowel pin with the dowel pin hole. Be care-
ful 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>

Type1 Type2 Type3 (12.9T) Type4 (12.9T) Type5 (10.9T)

TY TY TY
DL08
12.9T 10.9T
Type
M14 x 1.5 x M14 x 1.5 x M14 x 1.5 x M14 x 1.5 x M14 x 1.5 x
153 150 153 150 150
1st : 6 kg⋅m 1st : 6 kg⋅m 1st : 7kg⋅m 1st : 6 kg⋅m
Tighten
24.5 kg.m 2nd : 180° 2nd : 90°+ 90° 2nd : 90°+ 90° 2nd : 90°+ 90°
torque
Finished : 150° Finished : 30° Finished : 90°

However, before tightening bolts, align the side face of 2 cylinder heads with parallel. They
should be adjusted in a straight line exactly.

<Tightening order of bolts by steps>

(1) First stage : Coat the bolts with engine
oil.
(2) Second stage : Tighten 1 ~ 2 threads
with hands.
(3) Third stage : Tighten at about 6 kg⋅m
with a wrench.
(4) Fourth stage : Tighten at rotating angle
method 90° with a wrench. EAMD102I
(5) Fifth stage : Tighten at rotating angle
method 90° with a wrench.
(6) Sixth stage : Finally, tighten at rotating
angle method 90° with a
8 2 3 9
torque wrench .
12 13
Especially, all bolts are tightened simulta- 1 4
neously in each step according to above
process as possible.
11 14

7 6 5 10
EAMD103I

Disassembly and Reassembly of Major Components - 104 -

NOTE :
Cylinder head bolts should be replaced by new one after using two or three times
because of being loosed as a result of its length too extended. (Limit length 150mm)

● Coat the push rod with engine oil and insert it into the push rod hole.

● Adjust the valve clearance as following guide.

<Guide for valve clearance adjust-

ment>
● After letting the #1 cylinderís 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.

(mm)
Model Intake valve Exhaust valve
DE12T
0.3 0.3
P126TI series / PU126TI

- By cranking the engine, let #6 cylinder’s valves overlap.

- In time, adjust the valve clearance corresponding to “ ” of lower lists.

- Adjust the valve clearance corresponding to “ ” 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. Crank pulley

1 2 3 4 5 6

ED5OM005

- 105 - Disassembly and Reassembly of Major Components

 ● Adjust valve clearance with a feeler
gauge and tighten the fixing nuts to Valve clearance adjust
specified torque.

Torque 4.4 kg⋅m

EA8M3007

9.3.22. Rocker arm assembly

● Apply lubricating oil to the rocker arm

bush and shaft, and assemble the inter-

mediate bracket with the rocker arm
using fixing bolts.

M10(x2) : 4.4 kg⋅m

Torque
M8 : 2.2 kg⋅m

● 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

9.3.23. Injection nozzle

● Install the dust seal with its round por-

tion 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 kg⋅m

Disassembly and Reassembly of Major Components - 106 -

9.3.24. 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

9.3.25. 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 car-

tridge using a filter wrench.

9.3.26. Injection pump

● Install the injection pump bracket in
the cylinder block.

● After measuring the amount of run-out

with an alignment setting jig, disas-

semble the bracket, adjust the shims,

then reassemble it.

Run out 0.2 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 kg⋅m

- 107 - Disassembly and Reassembly of Major Components

 ● Turn the flywheel until No. 1 piston is
placed in the “OT" position of notch Timing
Check hole
marks on the flywheel, and then turn
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 flywheel housing.

DE12T / P126TI /
PU126TI
P126TI-1 P126TI-II
Fuel
injection
timing 12° 16° 14° Injection timing Flywheel
(B.T.D.C notch mark ring gear
static)

EA8O6002

● Turn the timer until the notch mark of

the indicator plate attached to the fuel

Notch
injection pump is aligned with the mark
notch mark of the timer.

EA9O5002

● Tighten the Coupling fixing bolts and

nuts to specified torque.

Torque 6.0 kg⋅m

● Tighten the drive shaft connecting flange

fixing bolts to specified torque

Torque 7.5 ~ 8.5 kg⋅m

EAMD021I
● Install the oil delivery pipe and return pipe.

Disassembly and Reassembly of Major Components - 108 -

9.3.27. 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 kg⋅m

EAMD011I

9.3.28. Fan drive pulley

● Install the fan drive pulley onto the

timing gear case cover.

9.3.29. 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 expan-
sion tank.

EAMD112I

9.3.30. Power take-off

● Assemble the power take-off sub assem-

bly.

EA8M3010

- 109 - Disassembly and Reassembly of Major Components

9.3.31. 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 EQM3096I
prevent looseness.

9.3.32. Turbocharger
● Fit a new gasket over the stud bolts

of the exhaust manifold before tighten-

ing 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 assem-
ble the bracket completely.

EA8M3012

9.3.33. Starter
● Assemble the starter in position on the

flywheel housing.

ED5OM009

Disassembly and Reassembly of Major Components - 110 -

9.3.34. Intake manifold
● Fit a gasket on the intake manifold
before assembling the intake manifold.

EQM3011I

9.3.35. Injection pipe & fuel return pipe

● Assemble the injection pipe according

to specified torque as blow

Nut size Torque

Spanner Dia.
3.0 kg⋅m
17mm
Spanner Dia.
4.0 kg⋅m
19mm

EAMD011I

● Semi-assemble the nuts at both end of

the fuel injection pipe and tighten them
up one by one to specified torque.

Torque 1 ~ 1.5 kg⋅m

● Tighten the hollow screws to assemble

the fuel return pipe.
● Assemble the fuel return hose on the
EI6OM015
fuel injection pump.

9.3.36. 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.
EI6OM016

- 111 - Disassembly and Reassembly of Major Components

9.3.37. 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 2.5 kg⋅m

● Assemble the breather hose with PCV

valve.
EI7OM011

9.3.38. Alternator
● Install the alternator mounting bracket.

● Install the alternator with fixing bolts to

the mounting bracket.

9.3.39. Cooling fan

● Install the cooling fan and flange, then
tighten the fixing boltd.

EQM3106I

9.3.40. 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
Alternator Fan
tension adjusting bolt. Pulley Pulley

V-belt

Crank Pulley EA8O3005

Disassembly and Reassembly of Major Components - 112 -

9.3.41. Oil level gauge
● Assemble the oil level gauge and
guide tube on the oil pan.

EQM3005I

9.4. Breaking-in
Refer to “Breaking-in” in chapter of “Commissioning and Operation”.

- 113 - Disassembly and Reassembly of Major Components

10. Maintenance of Major Components

10.1. Cooling System

10.1.1. 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 combus-
tion 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 tempera-
ture 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.

Thermostart Water pipe

R
a Cylinder head
d
i
a
t
o Cylinder block
r

Water pump Oil cooler

ED5OM006

● Specification

Item Specification
1. Water pump Centrifugal type
type
Delivery About 280 liter/min
Pumping speed 2,234 rpm
Pumping back pressure 760 mmHg
2. Thermostat
Operating temperature 71 ~ 85°C / 83 ~ 95°C
3. Cooling fan and belt
Fan diameter - Number of blades Ø 755 - 7
Fan belt tension 15mm / deflection by thumb

Maintenance of Major Components - 114 -

10.1.2. 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

9
Par latex coating
11
4

5 13

10
7
12
8
11

16 15 14

ED5OM007

<Construction of water pump>

1. Water pump housing 8. Ball bearing 13. Spline shaft
4. Shaft 9. Spacer 14. Gasket
5. Mechanical seal 10. Ball bearing 15. Housing cover
6. Impeller 11. Bearing cover 16. Bolt
7. Oil seal 12. Socket bolt

- 115 - Maintenance of Major Components

10.1.3. Thermostat
● General descriptions and main data
The thermostat maintains a constant
To radiator
temperature of coolant (71 ~ 85°C / 83
~ 95°C) and improves thermal efficiency
of the engine by preventing heat loss.
Namely, when the temperature of cool-
ant is low, the thermostat valve is
closed to make the coolant bypass to Bypass
From cooling valve
directly enter the water pump; when the To bypass tube
water pipe
coolant temperature rises to open wide
EAMC002I
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 71 °C 83 °C
Open wide at 85 °C 85 °C
Valve lift 8mm or more

● Inspecting
(1) Check the wax pallet and spring for
damage.
(2) Put the thermostat in a container of Ruler
Thermometer
water, then heat the water slowly
and check temperature with a ther-
mometer. If the valve lift is 0.1 mm Woodplate
(starting to open) at temperature of
71 °C / 83 °C and 8 mm or more
(opening wide) at temperature of 85
EFM2055I
°C / 95 °C, the thermostat is normal.

● 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 varia-
tion 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.

Maintenance of Major Components - 116 -

10.1.4. Diagnostics and troubleshooting

Complaints Possible causes Corrections

1. Engine overheating ● Lack of coolant
● Replenish coolant
● Radiator cap pressure valve
● Replace cap
spring weakened
● Fan belt loosened or broken
● Adjust or replace fan belt
● Fan belt fouled with oil
● Replace fan belt
● Thermostat inoperative
● Replace thermostat
● Water pump defective
● Repair or replace
● Restrictions in water pas-
● Clean radiator and water
sages due to deposit of
passages
scales
● Adjust injection timing cor
● Injection timing incorrect
● Clean exterior of radiator
rectly
● Replace cylinder head gas-
● Restriction in radiator core
ket
● Gases leaking into water

jacket due to broken cylinder

head gasket
2. Engine overcooling ● Thermostat inoperative ● Replace thermostat

● Ambient temperature too low ● Install radiator curtain

3. Lack of coolant ● Correct or replace

● Radiator leaky
● Retighten clamps or replace
● Radiator hoses loosely con-
hoses
nected or damaged
● Replace cap
● Radiator cap valve spring

weakened
● Repair or replace
● Water pump leaky
● Tighten or replace hoses
● Heater hoses loosely con-

nected or broken
● Replace cylinder head gas-
● Cylinder head gasket leaky
ket
● Cylinder head or cylinder
● Replace cylinder head block
block cracked

4. Cooling system noisy ● Water pump bearing defec-

● Replace bearing
tive
● Retighten or replace fan
● Fan loosely fitted or bent
● Replace fan
● Fan out of balance
● Replace fan belt
● Fan belt defective

- 117 - Maintenance of Major Components

10.2. Lubricating System

10.2.1. 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 cyl-
inder 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 Item Specifications

Lubricating system
Forced pressure Oil filter type Full flow
Oil pump type circulation
Relief valve opening pres- Gear type Bypass for filter element
sure 10 ± 1.5 kg/cm2 Valve opening pressure 1.8 ± 2.3 kg/cm2
Bypass for oil cooler Bypass for entire oil filter
Opening pressure 5 + 1 kg/cm2 Valve opening pressure 4.0 ~ 4.8 kg/cm2
Adjusting valve for spray
nozzle 1.5 ± 1.8 kg/cm2
Opening pressure

● 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
Oil cooler Oil filter Oil pump

Relief valve
4.4bar Valve Valve Valve
10bar
5bar 3bar

ED5OM008

Maintenance of Major Components - 118 -

10.2.2. Oil pump
● Disassembly

(1) Disassembly of oil pump drive gear

a) Unscrew the screw and disassem-
ble 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..
(mm)
End play 0.025 ~ 0.089 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.
(mm)
Backlash 0.50 ~ 0.64

EQM4009I

- 119 - Maintenance of Major Components

 (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.
(mm)
Limit Ø 16.95

b) Measure the inside diameter of

the pump body bushing to deter-
mine the clearance between the
bushing and shaft, and compare
the measured value with the
standard value to determine
whether to replace or not.
(mm)
Clearance 0.032 ~ 0.077

● Reassembly

(1) For reassembly, reverse the disas-

sembly sequence.

10.2.3. 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

Maintenance of Major Components - 120 -

10.2.4. Diagnostics and troubleshooting

Complaints Possible causes Corrections

1. Oil consumption ● Use suggested oil

excessive ● Poor oil ● Replace

● Oil seal or packing leaky ● Replace pistons and/or piston

● Pistons or piston rings worn rings

● Cylinder liner worn ● Replace cylinder liner

● Piston rings sticking ● Replace pistons and/or piston

● Valve guide oil seals or valve rings

guides, or valve stem worn ● Replace

2. Oil pressure too low ● Poor oil

● Use suggested oil
● Relief valve sticking
● Replace
● Restrictions in oil pump
● Clean strainer
strainer
● Replace
● Oil pump gear worn
● Replace
● Oil pump feed pipe cracked
● Correct or replace
● Oil pump defective
● Correct or replace
● Oil pressure gauge defective
● Replace
● Various bearings worn

3. Oil deteriorates ● Replace filter element

● Restriction in oil filter
quickly ● Replace piston rings and cylinder
● Gases leaking
liner
● Wrong oil used
● Use suggested oil

- 121 - Maintenance of Major Components

10.3. Fuel Injection Pump

10.3.1. 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.

5
1 2

1a 3 7

13

12

10

9 11

EA8O3004

1. Fuel filter 7. Delivery pipe

1a. Fuel water drain plug 8. Fuel pipe (manual pump → filter)
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

Maintenance of Major Components - 122 -

10.3.2. 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 : Ø 12, right hand helix 30 lead
Delivery valve :120 mm3/st ( Ø 8 x 2.4mm)
Fuel feed pump : NP-FP/K-P(105207-1400)
Pre-stroke : 4.7 mm
(2) Nozzle holder assem-
: 65.10101-7300(105160-4351)
bly
: 65.10102-6046(105029-1330)
(3) Nozzle
: 65.10301-7004B
(4) Injection pipe
: 1-5-3-6-2-4
(5) Injection order
: BTDC 12 °C
(6) Injection timing
(7) Calibration data

Pump
Adjusting Rack position Injection volume Variation Basic Fixing
speed Ref.
point (rpm) (mm3 / 1,000st) rate (%) point point
(rpm)
A 10.8 900 129±2 ± 2
B 11 875 (135)±3
C Approx. 6.4 250 14.5±1.5 ± 15
D - 10 193.5±10

Adjusting
Content Specification Engine Application
point
Nozzle holder assembly 105780-8140 65.10101-7300
Nozzle 105780-0000 65.10102-6046
Nozzle holder 105780-2080 -
Adjusting
Opening pressure 175 kg/cm2 220 kg/cm2
conditions
Injection pipe Ø 8 x Ø 3 - 600 mm Ø 6 x Ø 2.2 - 650 mm
Fuel delivery pressure 1.6 kg/cm2 -
Fuel temperature 35 ~ 45 °C 35 ~ 45 °C

- 123 - Maintenance of Major Components

 (8) Governor adjustment

Rack limit
over 14

D
RACK POSITION (mm)

11.0 B

10.8 A
Idle spring
0
Set : 6.5 -0.5 mm

6.5
6.4 C
0
45 -10

0
250 400+20
_
900+5
_

PUMP SPEED (rpm)

EA8M4001

Maintenance of Major Components - 124 -

2) P126TI / P126TI-1 / P126TI-II

(1) Main data and specifications

Part No. : 65.11101 -7310 (106674-4130 ZEXEL)
Model : NP-PE6P120/700RS3S (106067-6020)
Governor : Ghana Control (DWA-2000)
Plunger & barrel : Ø 12, right hand double helix 30 lead
Delivery valve : 90 mm3/st ( Ø 7 x 2.35mm)
Fuel feed pump : NP-FP/KD-PS (105237-5470)
Pre-stroke : 3.9 ± 0.05 mm
(2) Nozzle holder assembly : 65.10101-7101 (105101-852A)
(3) Nozzle : 65.10102-6073 (105025-285A)
(4) Injection pipe : 65.10301-6042A, 65.10301-6043A
(5) Injection order : 1-5-3-6-2-4
(6) Injection timing : P126TI (BTDC 16°) / P126TI-1 (BTDC 12°)

Nozzle & Holder Ass’y 105101-852A Opening pressure : 175 kg/cm2

(A) Test condi-
Injection pipe(ID ,OD
tion for injec- - Ø 3.0 x Ø 8.0 - 600 mm
,L)
tion pump
Test oil ISO4113 Temperature :40 ± 5 °C
65.10101-7101 Nozzle (5 x Ø 0.37)
(B) Engine stan- Nozzle & holder Ass’y 1st pressure : 160 kg/cm2
65.10102-6073
dard 2nd pressure : 220 kg/cm2
parts Injection pipe(ID, OD 65.10301-6042A
Ø 2.2 x Ø 6.35 - 650mm
,L) 65.10301-6043A
Rack diagram and setting valve at each point
Injection Q’ty on RIG
Rack Pump (mm3 / 1,000 st)
Check Press.
position speed (A) Test condition (B) Engine
point (mmHg)
(mm) (rpm) for inj. standard
pump parts
B 900 260 ± 2 -
Standby power
- - - - - -
- - - - - -
- - - - - -
- - - - - -

- 125 - Maintenance of Major Components

 3) P126TI (EDIOE)

(1) Main data and specifications

Part No. : 65.11101 -7310 (106674-4130 ZEXEL)
Model : NP-PE6P120/700RS3S (106067-6020)
Governor : Ghana Control (DWA-2000)
Plunger & barrel : Ø 12, right hand double helix 30 lead
Delivery valve : 90 mm3/st ( Ø 7 x 2.35mm)
Fuel feed pump : NP-FP/KD-PS (105237-5470)
Pre-stroke : 3.9 ± 0.05 mm
(2) Nozzle holder assembly : 65.10101-7104 (105101-853A)
(3) Nozzle : 105025-291A
(4) Injection pipe : 65.10301-6042A, 65.10301-6043A
(5) Injection order : 1-5-3-6-2-4
(6) Injection timing : BTDC 16°

Nozzle & Holder Ass’y 105101-853A Opening pressure : 175 kg/cm2

(A) Test condi-
Injection pipe(ID ,OD
tion for injec- - Ø 3.0 x Ø 8.0 - 600 mm
,L)
tion pump
Test oil ISO4113 Temperature :40 °C ± 5 °C
65.10101-7104 Nozzle (5 x Ø 0.35)
(B) Engine stan- Nozzle & holder Ass’y 1st pressure : 160 kg/cm2
-
dard 2nd pressure : 220 kg/cm2
parts Injection pipe(ID, OD 65.10301-6042A
Ø 2.2 x Ø 6.35 - 650mm
,L) 65.10301-6043A
Rack diagram and setting valve at each point
Injection Q’ty on RIG
Rack Pump (mm3 / 1,000 st)
Check Press.
position speed (A) Test condition (B) Engine
point (mmHg)
(mm) (rpm) for inj. standard
pump parts
B 900 260 ± 2 -
Standby power
- - - - - -
- - - - - -
- - - - - -
- - - - - -

Maintenance of Major Components - 126 -

4) PU126TI

(1) Main data and specifications

Injection pump : 65.11101 -7310 (106674-4130 ZEXEL)
Model : NP-PE6P120/700RS3S (106067-6020)
Governor : Ghana Control (DWA-2000)
Fuel feed pump : NP-FP/KD-PS (105237-5470)
Cam Lift : 12 mm
Injection timing : BTDC 14° ± 1
Injection order : 1-5-3-6-2-4
Rotating Direction : Clockwise (Viewed at driving gear side)
Pre-stroke : 3.9 ± 0.05 mm
(2)Calibration data

Opening pressure : 175 kg/

(A) Test condition Nozzle & Holder Assíy 105101-8530
cm2
for injection
Injection pipe(ID ,OD ,L) - Ø 3.0 x Ø 8.0 - 600 mm
pump
Test oil ISO4113 Temperature :40 ± 5 °C
65.10101-7057 Nozzle (5 x Ø 0.40)
Nozzle & holder Ass’y 1st pressure : 160 kg/cm2
(B) Engine standard 65.10102-6050
2nd pressure : 220 kg/cm2
parts
65.10301-6043A
Injection pipe(ID, OD ,L) Ø 2.2 x Ø 6.35 - 650mm
65.10301-6042A
Rack diagram and setting valve at each point
Injection Q’ty on RIG
Rack Pump
Check (mm3 / 1,000 st) Press.
position speed
point (A) Test condition (B) Engine (mmHg)
(mm) (rpm)
for inj. pump standard parts
Refer to (3) A 12.5 1,000 187 ± 2 - ≤ 675
Rack Diagram B 6.1 350 10 ± 1.5 - -
C 12.5 500 - ≤ 675
D 11.9 500 - -
E 7.5 1,100 - -
250 -
Boost pressure dependent full-load stop (boost compensator spring operation point)
Injection Q’ty on RIG
Rack Pump
Check (mm3 / 1,000 st) Press.
position speed
point (A) Test condition (B) Engine (mmHg)
Refer to (4) (mm) (rpm)
for inj. pump standard parts
Boost Pressure
P1 11.9 500 - 525
P2 12.5 500 - 675
- - - - -
Min. speed 1:1.2
Weight Weight = 740g Lever ratio (min/max)
Max.speed 1:1.2
Governor spring k = 70.6 mpa Plunger Ø 12, 30 lead
Idle sub spring k = 11.8 mpa Delivery valve retraction volume 2.45 mpa
Start spring k = 0.098 mpa Delivery valve opening pressure k = 8.53 mpa
Boost compensator k = 8.24 mpa Delivery valve spring 105237-5470
Adapter spring k = 63.7 mpa Feed pump

- 127 - Maintenance of Major Components

 (1) Rack Diagram

16 above
BSC Stroke : 0.6 0.1 mm
C A
12.5 Governor Spring Set.
11.9
D
Rack Position (mm)

7.5
E

6.1 B

0 350 1000
1100
Injection Pump Speed (mm)

EI6OM013

(2) Boost Compensator Pressure

13.1

P2
12.5
Rack Position (mm)

12.0
11.9
P1
11.5

11.0
0 100 200 300 400 500 600 700
525 675

Boost Pressure (mmHg)

EI6OM014

Maintenance of Major Components - 128 -

10.3.3. Governor System (P126TI / P126T-I / P126TI-II)

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

10.3.3.1. Integral actuator

102
159 (4.016)
(6.260) 89
48.5 (3.504)
(1.909) 68
(2.677)
36
9.5 SPLINE (36 TEETH) (1.417)

(1.102)

(1.417)
28
( 0.375)

36
4- 6.4

(2.559)
(0.252)

65

(6.535)
166
(6.083)
154.5

(2.598)
66
(3.563)
90.5
BEARING RETAINER
KIT ASS'Y
KT275,3000 PUMP

(1.150)
29.2
250

63
(2.480)
85
(0.197)
102
(4.016)
EC2OM316

<Construction of water pump>

Fig. No. Description Q’ty Remark
1 Frame 1
2 Bearing retainer kit Ass’y 1
3 Mounting bar 1
8 SWP connector 1 Mg610320
11 Front cover 1 T3.2
13 Shaft 1
15 Return spring guide Ass’y 1
16 Oil seal 1 SC 0283 E0
17 Allen screw 8 M5 x 0.8 x L12
23 Manual stop device Ass’y 1
30 Stop plate 1 T3.2
52 Return shaft Ass’y 1
54 Stop level 1
62 Lead wire LG 16AWG
63 Corrugate tube Dia. 10, L250 ± 10

- 129 - Maintenance of Major Components

10.3.3.2. Speed control unit for governor system
(DWC-2000 SERIES SPEED CONTROL UNIT)
<Introduction>
This speed control unit performs the electronic function of the engine governing system. The speed
control unit senses the pulses from the magnetic speed sensor, compares them with the speed con-
trol unit's set point and supplies the appropriate current output to the actuator to control the engine's
fuel system.
An integral, independent single element speed switch is provided internally which can be used to
initiate engine shutdown in the event that an overspeed condition is reached. The performance of
the speed control unit is fast and responsive in either isochronous or droop operation.
Adjustments are provided for: operating speed, idle speed, overspeed shutdown setting, droop, run
ramp, crank ramp, starting fuel, speed ramping and two performance adjustments(gain and stability).
All adjustments are accessible from the front cover. The primary features of the DWC-2000 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 attain engine operating
speed. The speed control unit also includes other features such as adjustable droop and idle oper-
ation, inputs for accessories used in multi-engine or special applications and protection against
reverse voltage polarity, transient voltages and accidental short circuit of the actuator. Loss of bat-
tery supply, loss of speed sensor and overspeed signaling are built-in to provide engine shutdown.

<Description>

Battery DROOP
SWITCH
- +
E F K L
A
Droop Adjustment
Pulse/second = Hz

D
Output PID
Actuator Circuit Controller FV
Converter
C
Speed Adjustment
B
Starting Fuel IDLE Speed 0.45 mm
Adjustment Adjustment
Gain Adjustment
Speed Ramp
Adjustment Stability Adjustment

M G

CONTROL UNIT
EC8OM007
Figure 1. Governor system schemetic

Maintenance of Major Components - 130 -

The engine speed signal is usually obtained from a magnetic speed sensor mounted in close
proximity to the teeth of a ferrous ring gear that is driven by the engine. The frequency of the
speed sensor signal is proportional to the engine speed. The speed control unit will accept
any signal if the frequency is proportional to engine signal, and in the frequency range of the
speed control unit (1K to 7.5K Hz.). The speed sensor is typically mounted in close proximity to
an engine driven ferrous gear, usually the engine ring gear. As the teeth of the gear pass the
magnetic sensor, a signal is generated which is proportional to engine speed. The signal
strength must also be within the range of the input amplifier. An amplitude of 1 to 120 volts
RMS is required to allow the unit to function within its design specifications. The speed control
unit has an input impedance of 20K-ohms between the speed sensor input terminals. ("C" &
"D"). Terminal "D" is connected internally to the battery negative. Only one end of the shielded
cable should be connected.
When a speed sensor signal is received by the controller, the signal is amplified and shaped by
an internal circuit to form constant area pulses. If the speed sensor monitor does not detect a
speed sensor signal, the output circuit of the speed control unit will turn off all current to the
actuator.
The summing point of the speed sensor and the speed adjust control is the input to the
dynamic control section of the governor. The dynamic control circuit, of which the gain and sta-
bility adjustments are part, has a control function that will provide isochronous and stable perfor-
mance for most engine types and fuel systems.
The speed control unit circuit is influenced by the gain and stability performance adjustments.
The governor system sensitivity is increased with clockwise rotation of the gain adjustment. The
gain adjustment has a non-linear range of 33:1. The stability adjustment, when advanced clock-
wise, increases the time rate of response of the governor system to match the various time con-
stants of a wide variety of engines. The speed control unit is a PID device, the "D", derivative
portion can be varied when required.(See Instability section.)
During the engine cranking cycle, STARTING FUEL can be adjusted from an almost closed, to
a nearly full fuel position. Once the engine has started, the speed control point is determined,
first by the IDLE speed set point and the SPEED RAMPING circuit, After engine speed ramp-
ing has been completed, the engine will be at its governed operating speed. At the desired gov-
erned engine speed, the actuator will be energized with sufficient current to maintain the desired
engine speed, independent of load (isochronous operation).
The output actuator current switching circuit provides current to drive the actuator. The output
transistor is alternately switched off and on at a frequency of 300Hz. which is well beyond the
natural frequency of the actuator, hence no visible motion from the switching results. Switching
the output transistors reduces its internal power dissipation for efficient power control. The output
circuit can provide current of up to 10amps continuous at 25°£C for 24VDC battery systems.
The actuator responds to the average current to position the engine fuel control lever.
In standard operation, the speed control unit performance is isochronous. Droop governing can
be selected by connecting terminals K & L and the percent of droop governing can be varied
with the droop adjustment control. The droop range can be decreased by connecting Terminals
G and H.
The speed control unit has several performance and protection features which enhance the gov-
ernor system. A speed anticipation circuit minimizes speed overshoot on engine startup or when
large increments of load are applied to the engine.

- 131 - Maintenance of Major Components

 1) Specification
● Performance

Isochronous Operation / Steady State Stability ............................................... ±0.25% or better

Speed Range/Governor ......................................................................... 1K~7.5 K Hz continuous
Speed Drift with Temperature ........................................................................... ±0.5% Maximum
Idle Adjust CW ................................................................................................. 60% of set speed
Idle Adjust CCW .............................................................................................. Less than 1200Hz
Droop Range ..................................................................................................... 1-5% regulation *
Droop Adj. Max.(K-L Jumpered) ....................................... 450 Hz., ± 90 Hz. per 1.0A change
Droop Adj. min.(K-L Jumpered) ............................................ 20 Hz., ± 8 Hz. per 1.0A change
Speed Trim Range ......................................................................................................... ±210 Hz
Remote Variable Speed Range ............ 500~7.5 Hz. or any part thereof Terminal Sensitivity
J .......................................................................... 100 Hz ± 15 Hz/Volt @ 6.0K Impendence
L ....................................................................... 680 Hz ± 50 Hz/Volt @ 165K Impendence
N ........................................................................... 135 Hz ± 10 Hz/Volt @ 1M Impendence
P ....................................................................................... 10 VCD Supply @ 20 [mA] Max.
● Environmental
Ambient Operating Temperature Range .................................................................... -40 ~ 85°C
Relative Humidity .......................................................................................................... up to 95%
All Surface Finishes ....................................................... Fungus Proof and Corrosion Resistant
● Power input

Supply ............................. 24VDC Battery System(Transient and Reverse Voltage Protected)**

Polarity ....................................................................................... Negative Ground(Case Isolated)
Power Consumption ..................................................... 50[mA] continuous plus actuator current
Maximum controllable actuator current at 25°C-(Inductive Load) .............. 10{A} continuous***
Magnetic Speed Sensor Signal ............................................................................ 1~120[V] RMS
● Reliability
vibration ............................................................................................................. 1G @ 20~100 Hz
Testing .................................................................................................. 100% Functionally Tested
● Physical

Dimensions ..................................................................................................... See Outline(Dia. 1)

Weight ........................................................................................................................... 705 grams
Mounting ..................................................................................... Any Position, Vertical Preferred

* Droop is based on a speed sensor frequency of 4000Hz. and an actuator current change
of 1amp from no load to full load. Applications with higher speed sensor signals will
experience less percentage of droop. See droop description for specific details on opera-
tion 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 short is removed.

Maintenance of Major Components - 132 -

 6.25 154
9.5
15

1 2 3 4 5 6 7 8 9 Run
Reset
Crank
Overspeed Run Crank Speed Test
Gain
D1
: DWC-2000
: DC24V ON OFF Stability
: 65.11220-7006
:
Starting
139

GHANA CONTROL
826-1 Kuro 3-Dong, Duro-Gu Seoul 152-053 KOREA(DONG-IL TECKNO-TOWN)
MADE IN KOREA Fuel
D2
Speed
ON OFF Ramping
Idle Idle
Speed Trim Droop
Droop
Autuator Pic-up Battery
- +
AUX 10V

A B C D E F G H J K L M N P
15

32
10V POWER
ACTUATOR AUX.
ADD JUMPER FOR 12V
BATTERY OR ACTUATOR
CURRENTS ABOVE 5A
GND

Magnetic CLOSE FOR DROOP

Pick up

CW
FUSE
BATTERY CLOSE FOR IDLE
15A MAX
SPEED TRIM
OPTIONAL ACTUATOR CONTROL-5K
CABLE SHIELDING TO
MEET CE DIRECTIVE

EC8OM008
Diagram 1. DWC-2000 Wiring and Outline

- 133 - Maintenance of Major Components

 2) Application and installation information
The speed control unit is rugged enough for mounting in a control cabinet or engine mounted
enclosure or in a remote console up to 20 meters(65ft.) from the engine. Care should be taken
to insure that the speed control unit, mount it vertically so that condensation will not accumu-
late in the speed control unit.

<Warning>
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 over speed. A Secondary shutoff device, such as
a fuel solenoid must be used.

3) Wiring
Wiring to the speed control unit should be as shown in Diagram 1. Wire leads to the battery and
actuator from the speed control unit terminals A, B, E and F should be #16 AWG(1.3 mm sq.) or
larger. Long cables require an increased wire size to minimize voltage drops. An external 15amp
fuse is recommended in series with terminal F, the positive (+) battery input terminal.
The magnetic speed sensor leads must be twisted and/or shielded for their entire length. If
shielded cables are used, connect all the shields to terminal D only. The shield should be insu-
lated 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.(0.45mm). Usually, gear tooth will achieve a satisfactory air gap. The
magnetic speed sensor voltage should be at least 1 VAC RMS during cranking.

4) Adjustments
● Before starting engine

Confirm the following adjustment positions. The adjustments are factory pre-set as follows :
Check to insure the GAIN and STABILITY adjustments, and if applied, the external SPEED
TRIM CONTROL are set to mid position.

Preset the DWC-2000 as follows:

Gain ........................................................
Minimum CCW
Stability ...................................................
Mid-range
Speed Adjust
3650Hz
..........................................
1950Hz
Idle .........................................................
Maximum CCW (minimum setting)
Droop .....................................................
Maximum CW
Overspeed ..............................................
Maximum CW
Run Ramp ..............................................
Maximum CW
CRANK Ramp ........................................

Maintenance of Major Components - 134 -

● Start engine

The speed control unit governed speed setting is factory set at approximately engine idle speed.
Crank the engine with DC power applied to the governor system. The actuator will energize
to the maximum fuel position until the engine starts. The governor system should control the
engine at a low idle speed. If the engine is unstable after starting, turn the GAIN and STA-
BILITY adjustments counterclockwise until the engine is stable.

● Governor speed setting

The governed speed set point is increased by clockwise rotation of the SPEED adjustment
control. Remote speed adjustment can be obtained with an optional 5K Speed Trim Control.
(See Diagram 1.)

● Governor performance

Once the engine is at operating speed and at no load, the following governor performance
adjustment can be made.

A. At no load, turn the gain control CW until instability results. Then back-off slightly CCW (1/
8 turn) beyond the point where stability returns.
B. Turn the stability control CW until instability results. Then back-off slightly CCW (1/8 turn)
beyond the point where stability returns. Excellent performance should result from these
adjustments.

If instability cannot be corrected or further performance improvements are required, refer to

the section on SYSTEM TROUBLESHOOTING.

● Starting fuel adjustment

The engine's exhaust smoke at start-up can be minimized by completing the following adjust-
ments.
A. Place the engine in idle by connecting Terminals M & G.
B. Adjust the IDLE speed for as low a speed setting as the application allows.
C. Adjust the STARTING FUEL CCW until the engine speed begins to fall. Increase the
STARTING FUEL slightly so that the idle speed is returned to the desired level.
D. Stop the engine.

One of two methods of operation for the DWC-2000 may now be selected.

Method 1 : Start the engine and accelerate directly to the operating speed(Gen Sets, etc.).
Remove the connection between Terminals M & G. Start the engine and adjust the
SPEED RAMPING for the least smoke on acceleration from idle to rated speed. If the
starting smoke is excessive, the STARTING FUEL may need to be adjusted slightly
CCW. If the starting time is too long, the STARTING FUEL may need to be adjusted
slightly CW.

- 135 - Maintenance of Major Components

 Method 2 : Start the engine and control at an idle speed for a period of time prior to accelerating
to the operating speed. This method separates the starting process so that each may
be optimized for the lowest smoke emissions.
Replace the connection between Terminals M & G with a switch, usually an oil pressure
switch. Start the engine. If the starting smoke is excessive, the STARTING FUEL may
need to be adjusted slightly CCW. If the starting time is too long, the STARTING FUEL
may need to be adjusted slightly CW.
When the switch opens, adjust the SPEED RAMPING for the least amount of smoke
when accelerating from idle speed to rated speed.

● Idle speed setting

If the IDLE speed setting was not adjusted as detailed in "Starting Fuel Adjustment" section,
then place the optional external selector switch in the IDLE position. The idle speed set
point is increased by clockwise rotation of the IDLE adjustment control. When the engine is
at idle speed, the speed control unit applies droop to the governor system to insure stable
operation

● Speed droop operation

Droop is typically used for the parallel-

ing of engine driven generators.
Adjust the DROOP adjustment
Place the optional external selector
SPEED
switch in the DROOP position, DROOP No load Load up DROOP width
(Below 10% of the set-speed)
is increased by clockwise rotation of the Set speed
DROOP adjustment control. When in Full load

droop operation, the engine speed will

decrease as engine load increases. The TIME
percentage of droop is based on the
EC8OM009
actuator current change from engine no
load to full load. A wide range of droop
is available with the internal control.
Droop level requirements above 10%
are unusual.

● Accessory input

The AUXiliary Terminal N accepts input signals from load sharing units, auto synchronizers, and
other governor system accessories, DWC accessories are directly connected to this terminal. It is
recommended that this connection from accessories be shielded as it is a sensitive input terminal.
If the auto synchronizer is used alone, not in conjunction with a load sharing module, a 3M ohm
resistor should be connected between Terminals N and P. This is required to match the voltage
levels between the speed control unit and the synchronizer.
when an accessory is connected to Terminal N, the speed will decrease and the speed adjustment
must be reset.
when operating in the upper end of the control unit frequency range, a jumperwire or frequency
trim control may be required between Terminals G and J. This increases the frequency range of
the speed control to over 7000Hz.

Maintenance of Major Components - 136 -

● Accessory supply

the +10 volt regulated supply, Terminal P, can be utilized to provide power to DWC- 2000 governor
system accessories. Up to 20ma of current can be drawn from this supply. Ground reference is
Terminal G. Caution : a short circuit on this terminal can damage the speed control unit.

● Wide range remote variable speed operation

Simple and effective remote variable speed can be obtained with the DWC-2000 Series con-
trol unit.
A single remote speed adjustment potentiometer can be used to adjust the engine speed
continuously over specific speed range. Select the desired speed range and the correspond-
ing potentiometer value.(Refer to TABLE 1.) If the exact range cannot be found, select the
next higher range potentiometer. An additional fixed resistor may be placed across the
potentiometer to obtain the exact desired range. Connect the speed range potentiometer as
shown in Diagram 2.
To maintain engine stability at the minimum speed setting, a small amount of droop can be
added using the DROOP adjustment. At the maximum speed setting the governor perfor-
mance will be near isochronous, regardless of the droop adjustment setting.

TABLE 1. Variable Speed Range Potentiometer Value

Speed Range Potentiometer Value

900 Hz 1K
2,400 Hz 5K
3,000 Hz 10K
3,500 Hz 25K
3,700 Hz 50K

● OVERSPEED shutdown setting

DWC-2000 has a Test switch to determine the OVERSPEED set point and test the engine
shutdown function. If you want to adjust the OVERSPEED set point at the speed about 10%
higher than the RUN set speed, use the Test switch. When the engine is operating at the
Run set speed in pushing the Test switch, rotate the Overspeed Adjust. by CCW until the
Overspeed shutdown function is operated. When the Test switch is pushed, the Overspeed set
point is reduced to 10/11 of the real set point.

● RUN ramp turn-On speed setting

When the engine is operating at the Run set speed, adjust the Run lamp adjustment CCW
until the lamp is on. Then, more rotate 1/2 turn by CCW.

● CRANK ramp turn-on speed setting

When the engine is operating at the Idle set speed(800rpm), adjust the Crank lamp adjust-
ment CCW until the lamp is on. Then, more rotate 1.5 turns by CCW.

- 137 - Maintenance of Major Components

 5) System troubleshooting
● 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 nor-
mal 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.

PROBABLE CAUSE OF ABNORMAL READ-

STEP TERMINALS NORMAL VALUE
ING
1. DC battery power not connected. Check for
Battery Supply blown fuse.
1 F(+) & E(-)
Voltage(24V) 2. Low battery voltage.
3. Wiring error.
1. Gap between speed sensor and gear teeth
too great. Check gap.
1.0VAC RMS min., 2. Improper or defective wiring to the speed
2 C & D
while cranking sensor. Resistance between terminals C and
D should be 30 to 1200ohms
3. Defective speed sensor.
1. Short on terminal P.
10VDC,
3 P(+) & G(-) (This will cause a defective unit.)
Internal Supply
2. Defective Speed Control.
1. SPEED adjustment set too low.
2. Short/open in actuator wiring.
1.0 - 2.0 VDC
4 F(+) & A(-) 3. Defective speed control.
while cranking
4. Defective actuator.
See Actuator Troubleshooting.

Maintenance of Major Components - 138 -

● Unsatisfactory performance

If the governing system functions poorly, perform the following tests.

SYMPTOM TEST PROBABLE FAULT

Actuator goes to full fuel. then, disconnect speed
sensor at Terminals C & D.
Do not crank. Apply DC ● If actuator still at full fuel → speed control unit

power to the governor deffective.

system. ● If actuator at minimum fuel position →

errorneousspeed signal.
Engine Check speed sensor data.
overspeeds Manually hold the 1. If the voltage reading is 4.0to6.0VDC
engine at the desired a) SPEED adjustemnt set above desired speed
running speed. Mea- b) Defective speed control unit.
sure the DC voltage 2. If the voltage reading is above 6.0VDC.
between Terminals A(-) a) Actuator or likage binding.
& F(+) on the speed 3.If the voltage reading is below 4.0VDC.
control unit. 4. Gain set too low.
Measure the voltage at
If the voltage is less than 15V for a 24V system,
the battery while crank-
replace the battery if it is weak or undersized.
ing.
Actuator does
1. Actuator or battery wiring in error.
not energize Momentarily connect
2. Actuator or linkage binding.
fully. Terminals A and F. The
3. Defective actuator.See actuator troubleshooting.
actuator should move to
4. Fuse opens. Check for short in actuator or
the full fuel position.
actuator wiring harness.
1. If voltage measurement is within approximately 3
Engine
Measure the actuator volts of the battery supply voltage, then fuel
remains
output. Terminals A&B, control restricted from reaching full fuel position.
below desired
while running under Possibly due to interference from the mechanical
governed
governor control governor, carburetor spring or linkage alignment.
speed.
2. Speed setting too low.

● Insufficient magnetic speed sensor signal

A strong magnetic speed sensor signal will eliminate the possibility of missed or extra pulses.
The speed control unit will govern well with 0.5volts RMS speed sensor signal. A speed sensor
signal of 3 volts RMS or greater at governed speed is recommended. Measurement of the
signal is made at Terminals C and D.
The amplitude of the speed sensor signal can be raised by reducing the gap between the
speed sensor tip and the engine rind gear. The gap should not be any smaller than 0.020
in (0.45mm). when the engine is stopped, back the speed sensor out by 3/4 turn after
touching the ring gear tooth to achieve a satisfactory air gap.

- 139 - Maintenance of Major Components

 ● Electromagnetic compatibility (EMC)

EMI SUSCEPTIBILITY - The governor system can be adversely affected by large inter-fering
signals that are conducted through the cabling or through direct radiation into the control circuits.
All DWC-2000 speed control units contain filters and shielding designed to protect the units
sensitive circuits from moderate external interfering sources.
Although it is difficult to predict levels of interference, applications that include magnetos, solid state
ignition systems, radio transmitters, voltage regulators or battery chargers should be considered
suspect as possible interfering sources.
If it is suspected that external fields, either those that are radiated or conducted, are or will
affect the governor systems operation, it is recommended to use shielded cable for all including
the speed sensor shield, is connected to a single point on the case of the speed control unit.
Mount the speed control unit to a grounded metal back plate or place it in a sealed metal box.
Conduction is when the interfering signal is conducted through the interconnecting wiring to
the governor system electronics. Shielded cables and installing filters are common remedies.
As an aid to help reduce the levels of EMI of a conductive nature, a battery line filter and
shielded cables are conveniently supplied by DWC.

● Instability

Instability in a closed loop speed control system can be categorized into two general types.
PERIODIC appears to be sinusoidal and at a regular rate. NON-PERIODIC is a random
wandering or an occasional deviation from a steady state band for no apparent reason.
Switch D1 controls the Differential function. When the position of switch D1 is "ON", the function
is operated. Move the switch to the "OFF" position if there is fast instability in the system.
The PERIODIC type can be further classified as fast or slow instability. Fast instability is a
3Hz. or faster irregularity of the speed and is usually a jitter. Slow periodic instability is
below 3Hz., can be very slow, and is sometimes violent.
If fast instability occurs, this is typically the governor responding to engine firings. Raising the
engine speed increases the frequency of instability and vice versa. In this case, placing switch
D1 in the "OFF" position will reduce the speed control unit's sensitivity to high frequency signals.
Should instability still be present, placing switch D2 to the "OFF" position may help stabilize the
engine. Again, readjust the GAIN and STABILITY for optimum control. Interference from powerful
electrical signals can also be the cause. Turn off the battery chargers or other electrical equip-
ment to see if the system disappears.
Slow instability can have many causes. Adjustment of the GAIN and STABILITY usually cures
most situations by matching the speed control unit dynamics. If slow instability is unaffected by
this procedure, evaluate the fuel system and engine performance. Check the fuel system linkage for
binding, high friction, or poor linkage. Be sure to check linkage during engine operation. Also look at
the engine fuel system. Irregularities with carburetion or fuel injection systems can change engine
power with a constant throttle setting. This can result in speed deviations beyond the control of the
governor system. Adding a small amount of droop can help stabilize the system for troubleshooting.
NON-PERIODIC instability should respond to the GAIN control. If increasing the gain reduces
the instability, then the problem is probably with the engine. Higher gain allows the governor to
respond faster and correct for disturbance. Look for engine mis-firings, an erratic fuel system, or
load changes on the engine generator set voltage regulator. If the throttle is slightly erratic, but
performance is fast, move switch D1 to the "OFF" position. This will tend to steady the system.

Maintenance of Major Components - 140 -

10.3.4. Fuel feed pump
1) General descriptions and construction

Priming pump

Check valve

Check valve

Outlet
Inlet
side
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 com-
pressed, resulting in interrupting further delivery of fuel as shown in (C).

- 141 - Maintenance of Major Components

 (A) (B) (C)
Inlet side Outlet side 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.

Maintenance of Major Components - 142 -

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 plug (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.

- 143 - Maintenance of Major Components

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

the other end of it into the fuel tank as

Feed pump
illustrated.
Hold the feed pump in position about
1m 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 illus-
trated. 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
Compressed Mass cylinder
pump and apply compressed air of 2 air 2kg / cm2
kg/cm2 into the inlet side.
Submerge the feed pump in a container
of diesel fuel and check for air leak.

Feed pump
EQM4023I

Maintenance of Major Components - 144 -

10.3.5. 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
2. Adjusting screw 3
3. Spring
4. Push rod 5
4
5. Connector
6. Retaining nut 9

7. Needing valve
7
8. Nozzle
9. Nozzle holder 8

EI6OM004

- 145 - Maintenance of Major Components

 (2) Reassembly
● After removing carbon deposit,
submerge 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 adjust-
ing screw. EA0M3003

● 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 noz-
zle tester and pressure of 20 ~ 21
MPa (200 ~ 210 bar) applied, check
the nozzle for fuel leakage.

EAMC022I

Maintenance of Major Components - 146 -

3) 2-spring type
(1) Disassembly

31

30
2

10

11
3
12
13

15 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 Eye bolt
11. Secondary spring A. Nozzle
12. Spring Seat

- 147 - Maintenance of Major Components

 (2) Inspection and adjustment
a. Adjusting the primary opening pres-
sure. 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 EQM4030I
holder without flange should be
directly installed onto a vise.

b. With the nut, install the two pins

on the plate.

1
c. Install the nozzle holder body (1)
onto the plate with the cap nut
side facing downward.

EQM4031I

d. Assemble adjusting shim (10), sec-

12
ondary spring (11), and spring seat
11
(12) on the nozzle holder body in
10
the order as described.

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 noz-
15
zle holder body.
14
13

EQM4033I

Maintenance of Major Components - 148 -

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

EQM4034I

g. After installing the gasket (6:157892-

1500) on the nozzle, use the cap
nut (7:157892-4000 : SW22mm) to
fix the nozzle onto the nozzle holder. 6 1

NOTE :
7
While tightening the cap nut,
keep checking to see if the lock pin
comes all the way into the nozzle.
EQM4035S

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 kg⋅m

EQM4036I

i. With the cap nut facing upward,

install the nozzle holder on the
plate.

- 149 - Maintenance of Major Components

 j. Assemble the push rod (2), primary
7
spring (3), and adjusting screw (4) on 6
the nozzle holder in the order 3
described. 4

k. Install the gasket (6) and cap nut

(7) onto the adjusting screw(4). 2

l. Assemble the nozzle and nozzle

holder assembly to the nozzle
60
40

80
20

tester (105785-1010). 0
100

EQM4039I

m. Adjust the primary opening pres-

sure 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 speci-
fied torque.

Torque 3.0 ~ 4.0 kg⋅m

EQM4041I

Maintenance of Major Components - 150 -

● 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(157892-4100 :

SW12 mm) 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).
(mm)
Part No. Limit
157892-4200 160
157892-4300 110

NOTE : EQM4045I

“L” means the length of the pin

except the threaded portion.

- 151 - Maintenance of Major Components

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

NOTE :
Fix the dial gauge so that a stroke
of 2 mm or so can be measured.

NOTE :
Overtightening the nut may cause
a sticking of the dial gauge seat.

EQM4046S

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

L
increase the tester pressure up to
350 ~ 450 kgf⋅cm2 in order that
Amount of lift

the needle valve can be fully

lifted. Then, record the full lift
value “L”.

NOTE :
0
This testing is to be made in order Tester pressure EQM4048I
to check the nozzle seat portion for
unusual wear or whether the nozzle
assembly is a standard item.

Maintenance of Major Components - 152 -

 ● Inspection of pre-lift

a. If the nozzle tester handle is

released with the needle valve
engaged in a full lift condition, 200 300

the tester pressure drops, being

100 400
accompanied by decrease in the
needle valve lift value (indicated
500
value on the dial gauge). 0
2
kgf / cm

EQM4049I

Amount of lift

0
Tester pressure
EQM4050I

b. Take the indicated value on the

Push rod.
Second spring
dial gauge at the point of time
Spring seat
when the secondary spring com-
pletes its operation and the nee-
dle valve puts an end to descent
(the position of needle valve lift
value ìî as shown in the above Lift piece
and right figures) and check that
Spacer
the value is within the specified EQM4051I
Needle valve
limit.

Measuring point for pre-lift

Take the indicated value on the dial
L
gauge at a point of primary opening
pressure approx. + 10 kgf⋅cm2.
Amount of lift

NOTE :
Locate the point of primary opening
pressure approx. + 10 kgf⋅cm2 while
dropping the pressure. 0
Primary opening pressure
Tester pressure EQM4050I

- 153 - Maintenance of Major Components

 c. If the measured pre-lift value devi-
ates from the specified limit, 13 14
15
replace the pin (14, 16), lift piece 16
(13), spacer (15), and nozzle
assembly (A) with a new “nozzle A

service kit”.

EQM4053I

● Inspection of secondary opening pressure

a. After confirming the pre-lift, oper-

L
ate the nozzle tester and increase
the internal pressure up to 350 ~
450 kgf⋅cm2 to fully lift the needle

Amount of lift
valve. +0.05

b. Release the nozzle tester handle

0
to decrease the tester pressure, Primary Secondary 350~450
opening opening pressure kgf/cm2
then take a note of the move- Tester pressure EQM4054I
ments of the dial gauge.

c. Take the indicated value on the

pressure gauge at the point of
time when the needle of the dial 40
60

0 80
20

gauge indicates the specified nee-

100
0

dle valve lift value. (In general,

pre-lift "ℓ " + 0.05mm. Refer to fol-
lowing figure).

EQM4055I

Read the pressure

Lift of needle valve values of gauge
0 ℓ+ 0.05 ㎜
90 300
10 200

80
20 100 400

70
30
500
0
60
40
50

Max. lift of needle valve

Dial Gauge Pressure Gauge
EQM4056I

Maintenance of Major Components - 154 -

 ● 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
EQM4040I
up to the top limit of the standard
vague, and then measure the sec-
ondary opening pressure.
- If the secondary opening pressure is
higher than the standard value: In a
reverse manner, readjust the pri-
mary opening pressure down to the
bottom limit of the standard value.

b. If the secondary opening pressure

still deviates from the specified limit 10

in spite of the readjusting the pri-

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

c. If the secondary opening pressure EQM4058I

is higher than the standard value, fit
a thinner adjusting shim than the
existing one.
d. After replacing the existing adjust-
ing shim, measure the secondary
opening pressure and continue the
adjustment until a value satisfying
the standard value.

Adjusting shim for secondary opening pressure

(Out diameter = Ø 9.5 , Inner diameter = Ø 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

- 155 - Maintenance of Major Components

 ● Retaining nut

a. Take out the dial gauge, nut,

holder and gasket from the cap
nut (7).
b. Remove the adjusting retaining
nut and gasket, and install the
original retaining nut(SW 19mm).
7

Cap nut
Tightening 6.0 ~ 8.0 kg⋅m
torque
EQM4036I

● Inspection at completion

a. Assemble the nozzle holder to a

nozzle tester and check the pri-
60
40

80
20

mary opening pressure, spray pat- 0

100

terns, oil tightness of seat portion,

and oil leakage from each part.

EQM4039I

b. When replacing the nozzle,

13
replace it with a new “nozzle ser-
vice kit” integrated with a nozzle, 15
lift piece, and spacer as a com-
plete set.
A

NOTE :
If only a nozzle is replaced, the
amount of pre-lift will deviate from EQM4060I
the specified value.

Maintenance of Major Components - 156 -

10.3.6. Diagnostics and troubleshooting

Complaints Possible causes Corrections

1. Engine won’t start

(1) Fuel pipes clogged or air into pipe line Correct
1) Fuel not being
(2) Feed pump valve defective Replace
pumped out from feed
(3) Feed pump piston or push rod sticking Disassemble, correct
pump

2) Fuel not being (1) Fuel filter element restricted

Clean
injected from injec- (2) Air in fuel filter or injection pump
Bleed
tion pump (3) Plunger and/or delivery valve sticking or
Disassemble, correct
defective

3) Fuel injection timing (1) Injection pump not properly installed on Check, correct
incorrect pump bracket
(2) Injection pump tappet incorrectly adjusted Check, correct
(3) Cams on cam shaft worn excessively Replace

4) Injection nozzles (1) Needle valves sticking Correct or replace

inoperative (2) Fuel leaking past clearance between noz- Correct or replace
zle and needle valve
(3) Injection pressure incorrect Adjust

2. Engine starts but (1) Pipe from feed pump to injection pump Clean
stalls immediately clogged or filter clogged
(2) Air in fuel Bleed
(3) Feed pump delivery insufficient Disassemble, correct
(4) Fuel delivery insufficient due to clogging of Replace breather
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

4. Engine knocking (1) Injection timing too fast Adjust

(2) Nozzle injection pressure too high Adjust
(3) Nozzles not working normally Disassemble, correct

5. Engine knocks seri- (1) Injection timing incorrect Adjust

ously 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

- 157 - Maintenance of Major Components

 Complaints Possible causes Corrections

6. Engine output unsta- (1) Supply of fuel insufficient

ble (2) Air in fuel Check feed pump
(3) Water in fuel Bleed
(4) Operation of plungers unsmooth Replace fuel
(5) Movement of control rack sluggish Disassemble, correct
(6) Nozzles defective Disassemble, correct
(7) Injection starting pressure of each barrel Disassemble, correct
incorrect Adjust
(8) Automatic timer defective Disassemble, correct

7. Engine does not (1) Nozzles not working normally Disassemble, correct
reach maximum speed (2) Governor defective Disassemble, correct

8. Engine idling unstable (1) Movement of control rod sluggish Disassemble, correct
(2) Operation of plungers unsmooth Disassemble, correct
(3) Control pinions not engaged with control Disassemble, correct
rod correctly

Maintenance of Major Components - 158 -

10.4. Turbocharger

10.4.1. Main data and specifications

1) Main data and specifications

P126TI / P126TI-1 / P126TI-

Specification DE12T
II / PU126TI

Turbocharger Model Allied Signal T45 Allied Signal TV51

Air pressure at compressor 50Hz: Approx. 1.1 kg/cm2 50Hz: Approx. 1.5 kg/cm2
outlet 60Hz: Approx. 1.2 kg/cm2 60Hz: Approx. 1.8 kg/cm2

At maximum 50Hz: Approx. 12.5 m3/min 50Hz: Approx.18.0 m3/min

Air suction volume
output 60Hz: Approx. 15.0 m3/min 60Hz: Approx. 23.6 m3/min

50Hz: Approx 79.270 rpm 50Hz: Approx. 75910 rpm

Speed of turbine revolution
60Hz: Approx. 86.850 rpm 60Hz: Approx. 83150 rpm

Maximum allowable speed 110,072 rpm 105,414 rpm

Max. allowable temperature of exhaust

750 °C 750 °C
gas at turbine inlet

Lubricating system External oil supply External oil supply

Weight 14 kg 14 kg

2) Operating principle

Turbine wheel and Oil inlet

shaft assembly
Compressor
housing
Exhuast pipe Exhuast gas discharge Fresh air inlet

Compressed air flow

Oil outlet Compressor wheel

EA0M8001

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.

- 159 - Maintenance of Major Components

 3) Construction

22

30 29 28
31

8
24

32 25 9
33 10
34
11

17 15
18 1
23
12 2
14
16 7
19 45
20 36
21

EA8M4002

1. Turbine housing 14. Retainer ring 24. Rear plate

2. Plug 15. Retainer ring 25. Bolt
5. Crank 16. Bearing 26. Compressor wheel
7. V-band 17. Thrust collar 27. Nut
8. Wheel 18. Screw 28. Bolt
9. Piston ring 19. Thrust bearing 29. Clamp
10. Wheel shroud 20. Thrust space 30. Compressor housing
11. Center housing 21. Piston ring 32. Elbow
12. Retainer ring 22. Seal ring 38. Retainer
13. Bearing 23. Seal ring 45. Bolt

Maintenance of Major Components - 160 -

10.4.2. 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”.

10.4.3. 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 pre-
vent the leak of compressed air or lubricating oil.

- 161 - Maintenance of Major Components

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

Operations Precautions Reasons

When starting 1) Check oil level
the engine 2) Crank the engine with starter to check the 2) Abrupt starting of the engine
increase in oil pressure(until the needle of causes the engine to rotate with
pressure gauge starts to move or pressure oil not being distributed not only
indicator lamp is actuated) before starting the to each part but also to the tur-
engine. bocharger, resulting in abnormal
wear or seizure on the bearing
due to insufficient supply of oil.
3) When having replaced oil, oil filter element, 3) In the case of the engine
or lubricating parts, or when having stopped stopped for extended time or in
the engine for extended period of time, or in a cold place, oil fluidity within
a cold place, loosen the oil pipe connections the pipes can be deteriorated.
and operate the starter motor until oil is dis-
charged. After completing the operation, be
sure to retighten the oil pipe connections
portion before starting the engine.
Immediately 1) Run the engine at idle for 5 minutes after 1) Applying load abruptly If load is
after starting starting off. abruptly applied with the engine
and turbocharger rotating
unsmoothly, such parts that a suf-
ficient amount of oil has not
reached can be seized up.
2) Check each part for leakage of oil, gas, and 2) Leakage of oil, gas, and air
air, and take proper measure. (especially, oil leak) causes drop
in oil pressure and loss of oil.
resulting in seizure of the bearing.
During Check the followings: 1) Excessively low oil pressure
operation 1) Oil pressure causes unusual wear or seizure
At idle: 0.8 kg/cm2 or more of the bearing. Too high pressure
At full load: 3.0 ~ 4.8 kg/cm2 causes oil leakage.
2) If unusual sound or vibration is heard or felt, 2) The engine is operated continu-
reduce engine revolutions slowly and locate ously with unusual sound or vibra-
the cause. tion not corrected, it can be
damaged beyond repair.
When 1) Run the engine at idle for 5 minutes before 1) If the engine is put to a stop after
stopping stopping. being operated at high load, heat
the engine 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.

Maintenance of Major Components - 162 -

10.4.5. 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 stop-
per 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 lubricat-
ing system. Deteriorated engine oil affects adversely not only the engine but torso the turbo-
charger. Suggested engine oils for the turbocharger-mounted engine are as follows:
● SAE 15W30

● API grade CD or CE

- 163 - Maintenance of Major Components

10.4.6. 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

Turbine wheel chamber
Magnetic vise

Move the turbine

shaft in axial
direction
Dial gauge

Standard : 0.117 ~ 0.20mm

Limit of werar : 0.24mm
EA8M4003

(2) Rotor radial play

Dial gauge
Magnetic vise

Oil outlet

Radial play Move the turbine shaft

Standard : 0.075 ~ 0.11mm in both direction
Limit of wear : 0.12mm simultaneousty

Oil inlet

EA8M4004

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

Maintenance of Major Components - 164 -

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.

(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 ordi-

nary steel bolts and nuts when performing reassembly operation. Apply anti-seizure coat-
ing to the bolts and nuts.
● Assemble each joint on the exhaust pipes securely to prevent gas leaks

- 165 - Maintenance of Major Components

10.4.7. Diagnostics and troubleshooting

Complaints Possible causes Corrections

1. Excessive 1) Air cleaner element clogged Replace or clean
black smoke 2) Restrictions in air duct Check and correct
3) Leakage at intake manifold Check and correct
4) Turbocharger seized up and not rotating Disassemble/repair or replace
5) Turbine blades and compressor blades coming Disassemble/repair or replace
in contact with each other or damaged
6) Exhaust piping deformed or clogged Check and correct
2. Excessive 1) Oil leak into turbine and compressor Disassemble/repair or replace
white smoke 2) Worn or damaged seal ring due to excessive Disassemble/repair or replace
wear of bearing
3. Low engine 1) Gas leak at each part of exhaust system
Check and correct
output 2) Air cleaner element restricted
Replace or clean
3) Turbocharger fouled or damaged
Disassemble/repair or replace
4) Leakage at discharge port on compressor
Check and correct
side
4. Unusual 1) Rotor assembly coming in contact Disassemble/Repair or replace
sound contact 2) Unbalanced rotation of rotor Disassemble/Repair or replace
3) Seized up Disassemble/Repair or replace
4) Each joint loosened Check and correct

Maintenance of Major Components - 166 -

11. Special Tool List

No Part no. Figure Tool name

1 DPN-5337 Nozzle tube insert ass’y

2 EF.123-082 Nozzle tube extractor

3 EF.123-015 Injection pump setting ass’y

4 EF.123-173 Oil seal(NOK) insert ass’y (FR)

5 EF.123-194A Oil seal(NOK) insert ass’y (RR)

6 EF.123-317A Oil seal(NOK)puller ass’y (FR)

7 EF.123-316A Oil seal(NOK) puller ass’y (RR)

8 EF.123-347 Cylinder pressure tester adapter

- 167 - Special Tool List

 No Part no. Figure Tool name

9 EF.123-087 Cylinder liner puller ass’y

10 EF.123-066 Valve stem seal punch

11 EU.2-0131 Valve clearance adjust ass’y

12 EF.123.-065 Valve spring press

13 EU.2-0647 Crankshaft gear punch

14 60.99901-0027 Feeler gauge

15 T7610001E Snap ring plier

16 T7621010E Piston ring plier

17 EF.120-208 Piston Ring Compressor

Special Tool List - 168 -

Appendix
● Tightening torque for major parts

Screw Strength
Major Parts Tightening Torque Remarks
(Diameter x pitch) (grade)
1st : 6 kg⋅m
2nd : 90°
Cylinder head bolt M14 x 1.5 10.9T 3rd: 90° Dodecagon
Finished : 90°
(angle torque)
Cylinder head cover bolt M8 8.8T 1.2 kg⋅m
1st : 15 kg⋅m
Connecting rod bearing cap bolt M16 x 1.5 12.9T 2nd : 22 kg⋅m
3rd : 30 kg⋅m
1st : 15 kg⋅m
Crankshaft main bearing cap bolt M16 x 1.5 12.9T 2nd : 25 kg⋅m
3rd : 30 kg⋅m
Balance weight fixing bolt M14 x 1.5 10.9T 14.0 kg⋅m Split type
Flywheel fixing bolt M14 x 1.5 10.9T 18.0 kg⋅m
Crankshaft pulley fixing bolt M12 x 1.5 12.9T 13.4 kg⋅m
Oil spray nozzle M6 8.8T 1.0 kg⋅m

● Tightening torque for injection pump system

Screw Strength
Major Parts Tightening Torque Remarks
(Diameter x pitch) (grade)
Injection nozzle holder nut M6 8.8T 1.0 kg⋅m
Injection pump bracket M10 8.8T 4.4 kg⋅m
Injection pump coupling bolt M10 - 6.0 kg⋅m
Injection pump driving gear nut M24 x 1.5 8.8T 25.0 kg⋅m
High pressure injection pipe fixing
M14 x 1.5 8.8T 3.0 kg⋅m
cap nut
Injection pump delivery valve
- - 13 ~ 14 kg⋅m
holder

- 169 - Appendix
● Standard bolt tightening torque table
Refer to the following table for bolts other than described above.

Degree of strength
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)
Limit value for elasticity (kg/mm2)
20 24 32 30 40 36 49 54 64 90 108
Tightening torque (kg⋅m)
M5 0.15 0.16 0.25 0.22 0.31 0.28 0.43 0.48 0.5 0.75 0.9
M6 0.28 0.30 0.45 0.4 0.55 0.47 0.77 0.85 0.9 1.25 0.5
M7 0.43 0.46 0.7 0.63 0.83 0.78 1.2 1.3 1.4 1.95 2.35
M8 0.7 0.75 1.1 1 1.4 1.25 1.9 2.1 2.2 3.1 3.8
M8 x 1 0.73 0.8 1.2 1.1 1.5 1.34 2.1 2.3 2.4 3.35 4.1
M10 1.35 1.4 2.2 1.9 2.7 2.35 3.7 4.2 4.4 6.2 7.4
M10 x 1 1.5 1.6 2.5 2.1 3.1 2.8 4.3 4.9 5 7 8.4
M12 2.4 2.5 3.7 3.3 4.7 4.2 6.3 7.2 7.5 10.5 12.5
M12 x 1.5 2.55 2.7 4 3.5 5 4.6 6.8 7.7 8 11.2 13.4
M14 3.7 3.9 6 5.2 7.5 7 10 11.5 12 17 20
M14 x 1.5 4.1 4.3 6.6 5.7 8.3 7.5 11.1 12.5 13 18.5 22
M16 5.6 6 9 8 11.5 10.5 17.9 18.5 18 26 31
M16 x 1.5 6.2 6.5 9.7 8.6 12.5 11.3 17 19.5 20 28 33
M18 7.8 8.3 12.5 11 16 14.5 21 24.2 25 36 43
M18 x 1.5 9.1 9.5 14.5 12.5 18.5 16.7 24.5 27.5 28 41 49
M20 11.5 12 18 16 22 19 31.5 35 36 51 60
M20 x 1.5 12.8 13.5 20.5 18 25 22.5 35 39.5 41 58 68
M22 15.5 16 24.5 21 30 26 42 46 49 67 75
M22 x 1.5 17 18.5 28 24 34 29 47 52 56 75 85
M24 20.5 21.5 33 27 40 34 55 58 63 82 92
M24 x 1.5 23 25 37 31 45 38 61 67 74 93 103

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.

Appendix - 170 -
● Maintenance specification table
Unit : mm
Stand value Limit
Group Part Inspection item Correction Remark
for assembly for use
Measure unworn
Inside diameter of cylin- Ø 123 ~ Ø
Replace liner portion beneath the
der liner for wear Ø 123.023 123.223
rim of upper side
Cylinder Projected portion of liner 0.03 ~ 0.08 -
block &
The upper surface of cylin- Correct with a Per distortion
liner 0.05 / 200 -
der block for distortion surface grinder length for 200 mm
Hydraulic test for 1
4 -
Engine minute (kg/cm2)
body In case of new
Intake 0 ~ 0.3 0.55
Valve seat valve and seat
depression
Cylinder Exhaust 0 ~ 0.3 0.55
head &
Replace cylin-
valve Height 114.95 ~ 115 113.9
der head
Hydraulic test for 1 Water temperature
4 - Replace if leaky
minute (kg/cm2) 70 °C
Piston diameter
Ø 122.433 ~
(18 mm from the lower -
Ø 127.863
side)
Clearance between
0.109 ~ 0.166 -
piston and liner

Top ring 3.5 - Replace piston if

Major Width of
groove width is
moving Piston piston ring 2nd ring 3.060 ~ 3.080 -
beyond specified
parts grooves
Oil ring 4.040 ~ 4.060 - value

Measure unworn
Piston projection from
0 ~ 0.12 - portion beneath the
cylinder block upper surface
rim of upper side
Permissible weight
±15 g Max. 96 g Replace piston
difference of each piston

- 171 - Appendix
 Unit : mm
Stand value Limit
Group Part Inspection item Correction Remark
for assembly for use
Top ring 0.30 ~ 0.45 1.5 Standard gauge
Piston ring
2nd ring 0.35 ~ 0.50 1.5 inside diameter :
gap
Oil ring 0.30 ~ 0.50 1.5 Ø 123

Top ring 0.105 ~ 0.155 -

Piston Piston ring Limit for use if for
ring Replace ring or
groove 2nd ring 0.07 ~ 0.102 0.15 standard clear-
piston
clearance ance
Oil ring 0.05 ~ 0.085 0.15

Install ring
Direction of ring gap - -
by 120°
Axial run-out of journal Correct In horizontal and
0.05 0.1
and pin with a grinder vertical directions
Outside diameter of Ø 95.966 ~ Replace crank-
Ø 95 Ø 96 g6
Major journal Ø 95.988 shaft
moving Ø 82.966 ~ Replace crank-
parts Outside diameter of pin Ø 82 Ø 83 g6
Ø 82.988 shaft
Out of round of journal & pin 0.008 0.025
Permissible radial run out
0.01 0.03
of journal & pin
Crank
Permissible taper of
shaft 0.01 0.03
journal & pin
Clearance between Measure in the
0.072 ~ 0.142 0.25 Replace bearing
crankshaft and bearing position of crown
Replace
End play of crankshaft 0.15 ~ 0.325 0.5
thrust bearing
Adjust by a press No.4 bearing
Run-out of crankshaft 0.05 0.1 or less
if bent (holding no. 1 & 7)
Check dynamic Measure at
Balance of crankshaft 60 60 or less
balance 400 rpm

Appendix - 172 -
 Unit : mm
Stand value Limit
Group Part Inspection item Correction Remark
for assembly for use
Tightening torque of No foreign matters
journal bearing cap bolt 30 - Apply oil to bolt on bearing cap
(kg⋅m) installing surface
Measure by
Crank
tightening metal
shaft Journal bearing crush 0.15 ~ 0.25 -
cap & then loosen-
ing one stud bolt
Replace oil seal Replace with new
Oil seal for wear - -
if oil leaking one, use shim
Clearance between con-rod
0.032 ~ 0.102 0.20 Replace bearing
bearing & crank pin
End play of con-rod
0.22 ~ 0.319 0.5 Replace con.-rod
crush
Clearance between small
0.050 ~ 0.080 0.12
end bush & piston pin
After completing
installation of
Connecting Connecting rod bearing
0.086 ~ 0.116 - bearing, loosen
rod crush height
one stud bolt and

Major measure
moving Permissible weight
parts difference of each con- ±18 g -
rod
Tightening torque of
con-rod bearing cap bolt 28 - Apply oil to bolt
(kg⋅m)
Outside diameter of cam Ø 59.860 ~
Ø 59.52 Ø 60
shaft Ø 59.880
Cam Clearance between cam
0.050 ~ 0.128 0.20
shaft shaft and bush
Replace thrust
Axial play of camshaft 0.13 ~ 0.27 0.30
plate
Clearance between idle
gear shaft and inserting 0.025 ~ 0.091 0.15
hole
End play of idle gear Replace thrust
Timing 0.043 ~ 0.167 0.3
shaft collar
gear
Between crank gear &
0.16 ~ 0.28 0.35
idle gear
Replace gear
Between idle gear &
0.16 ~ 0.20 0.35
camshaft gear

- 173 - Appendix
 Unit : mm
Stand value Limit
Group Part Inspection item Correction Remark
for assembly for use
Outside diameter Ø 8.950 ~ Replace valve
Ø 0.02
of intake valve stem Ø 8.970 Replace valve & guide together
Outside diameter Ø 8.935 ~ valve guide when replacing
Ø 0.02
of exhaust valve stem Ø 8.955 valve

Clearance Replace
between Intake 0.03 ~ 0.065 0.15
valve & guide
valve stem
and valve Exhaust 0.045 ~ 0.080 0.15 Replace
guide

Thickness Intake 1.5 1 or more

Replace
of valve Exhaust 1.5 0.9 or more

Valve Perm. radial

Valve Intake 0.04 ~ 0.07 0.2
system run-out
between
Replace
valve stem
& valve Exhaust 0.06 ~ 0.09 0.25
head
Clearance between
Apply oil to valve
valve guide & cylinder 0.01 ~ 0.39 -
guide & press in
head installing hole
Clearance
between Intake 22 -
valve guide
& valve
Exhaust 22 -
spring seat

Appendix - 174 -
 Unit : mm
Stand value Limit
Group Part Inspection item Correction Remark
for assembly for use
Free length 75.5 72
Spring tension
Intake (set length : 37 mm) 61.8 ~ 68.3 61.8
spring kg
Straightness
1.0 2.0
(against free length)
Free length 65 61.75
Spring tension
Replace
(set length : 36.1 ~ 39.9 36.1
valve spring
Inner 34mm) kg
Straightness
(against free 1.0 2.0
Exhaust length)
spring Free length 75.5 72
Spring tension
Replace
Valve (set length : 61.8 ~ 68.3 61.8
valve spring
Outer 37mm) kg
Straightness
Valve
(against free 1.0 2.0
sys-
length)
tem
Valve clearance Intake 0.3 -
Adjust
(at cold) Exhaust 0.3 -
Correct or
replace if
Contacting face of valve stem
- - severely pitted
& rocker arm
on tip of arm
and stem
Clearance between rocker arm Replace bush
0.020 ~ 0.093 0.25
shaft & rocker arm bush or shaft
Rocker arm shaft for wear Ø 23.978 ~ Ø 23.959 Ø 23.75 Replace
Permissible taper of push rod 0.3 - Replace
Clearance between tappet &
0.035 ~ 0.077 0.1 Replace tappet
cylinder block
Outside diameter of tappet Ø 19.944 ~ Ø 19.965 19.89 Replace tappet
Tap-
Replace if
pet
Contacting face of tappet & excessively
- -
cam worn of
deformed

- 175 - Appendix
 Unit : mm
Stand value Limit
Group Part Inspection item Correction Remark
for assembly for use
Correct oil leak-
Oil pressure age and clearance
4.5 or less 3.5
Oil (normal speed) (kg/cm2) between each
pressure part
Oil pressure (idling) Use suggested
0.8 ~ 1.4 0.6
kg/cm2 oil
Max. permissible
Oil - 105 Temperature
oil temperature (°C)
tempera- above this not
Permissible oil tempera-
ture - 120 allowable
ture in short time (°C)
Axial play
0.055 ~ 0.105 -
of oil pump gear Replace gear
Clearance between gear or cover
0.032 ~ 0.068 -
shaft & oil pump over hole
Clearance between drive Replace bush-
0.040 ~ 0.082 -
gear bushing & cover hole ing or cover
Outside diameter of gear Ø 16.950 ~
- Replace gear Ø 17e7
shaft Ø 16.968
Outside diameter Ø 27.939 ~
Oil - Replace bushing Ø 28e7
of drive gear bushing Ø 27.960
pump
Between
Lubricating
crank gear &
system 0.15 ~ 0.25 0.8
oil pump
drive gear
Backlash Between oil Adjust backlash
pump drive
gear & 0.8
intermediate
gear
Oil pressure control
4.3 ~ 4.7 -
valve (kg/cm2)
By-pass valve for filter Replace valve
1.8 ~ 2.3 -
element (kg/cm2)
By-pass valve for full oil
Valve 4.0 ~ 4.8 -
filter (kg/cm2)
opening
By-pass valve for oil
pressure 5 ~ 6 -
cooler (kg/cm2)
Relief valve for oil
8.5 ~ 11.5 -
pump (kg/cm2)
Control valve for spray
1.5 ~ 1.8 -
nozzle (kg/cm2)
Oil Oil filter element for Clean or replace
- -
filter damage

Appendix - 176 -
 Unit : mm
Stand value Limit
Group Part Inspection item Correction Remark
for assembly for use
Radiator & water pump
Correct or
for corrosion, damage & - -
replace
improper connecting
Submerge in
Test for leakage water and
1.0 -
(air pressure) (kg/cm2) replace if air
Radiator bubbles found
Pressure valve for
opening pressure 0.5 -
(kg/cm2)
Negative pressure valve for
opening pressure 0.2 -
(kg/cm2)
Delivery volume l / min
Cooling - Pumping speed 2,234 rpm Approx.
-
system - Operating temp. 71 ~ 85 °C 350ℓ
Water - Back pressure : 1 kg/cm2
pump Replace if
Clearance between
contacted
pump impeller & pump 0.3 ~ 0.6 -
impeller &
body
pump body
Temperature
Operating temperature
Cooling 90 ~ 95 95 above this not
(permissible temp.) (°C)
water allowable
temp Permissible temperature
103 103
in a short time (°C)
Thermostat opening
Replace if
temperature (°C) 83 -
Thermostat defective
(under atmospheric pressure)
Full operating temp. (°C) 95 or lower - Stroke :min. 8mm

- 177 - Appendix
 Unit : mm
Stand value Limit
Group Part Inspection item Correction Remark
for assembly for use

Piping Correct or
Gap of spark plug - -
and the replace
other Gap of spark plug - - Clean or replace
Injection pressure of injection
220 - Adjust by shim 1st : 160, 2nd : 220
nozzle (kg/cm2)
Fuel
Opening pressure of overflow
System 1.6 - Replace valve
valve (kg/cm2)
Height of projected nozzle on the Replace cylinder
4.3 -
cyl. head (mm) head and nozzle
Clearance between injection pump
0.2 ~ 0.4 -
coupling and coupling (mm)
Retighten head
Refer to supple-
Running-in the engine - - bolt
ment “running-in”
after running in
Inspection
Cylinder compression
at Overhaul the
pressure of cylinder 25 ~ 28 24 or less
comple- Cylinder engine
(kg/cm2)
tion pres-
Compression pressure ±10% or less
sure at 200 rpm or
difference of each cylin- against - Correct
more (20 °C)
der average

Appendix - 178 -