VOLTAR

65.99892-8051

Operation Manual
GENERATOR DIESEL ENGINE

DE12T
POLUS

P126TI
 FOREWORD

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

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

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

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

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

Engine Export Team,

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

Or to your local DEALER or DISTRIBUTOR.

DAEWOO Heavy Industries LTD.

July. 1999
 CONTENTS

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

1.1. Engine specification 1.2. Engine assembly

2. Safety regulations...................................................................................................................... 6
2.1. General notes 2.4. Regulations designed to prevent pollution
2.2. Regulations designed to prevent accidents 2.5. Notes on safety in handling used engine oil
2.3. Regulations designed to prevent damage

3. Technical information.............................................................................................................. 10
3.1. Engine model and serial number 3.7. Intercooler
3.2. Engine type 3.8. Fuel system
3.3. Engine timing 3.9. Cooling system
3.4. Valves 3.10. V-belt tension check and adjust
3.5. Lubrication system 3.11. Turbocharger
3.6. Air cleaner 3.12. Electrical equipment

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

4.1. Preparation 4.4. Operation in winter
4.2. Breaking-in 4.5. Tuning the engine
4.3. Inspection after starting

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

5.1. Periodical inspection and maintenance 5.5. Fuel system
5.2. Lubrication system 5.6. Injection nozzle maintenance
5.3. Cooling system 5.7. Turbocharger
5.4. Air intake system

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

6.1. Adjustment of valve clearance 6.4. Cylinder compression pressure
6.2. Adjustment of injection timing 6.5. V-belts
6.3. Tightening the cylinder head bolts

• Appendix.................................................................................................................................... 49

• WORLDWIDE NETWORK
1. General information

1.1. Engine specification

Engine Model DE12T P126TI P126TI-I

Items
Water-cooled, 4 cycle in-line Water-cooled, 4 cycle in-line
Engine type type
type Turbo charged Turbo charged & intercooled
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 (mm) 4 - 123 x 155
Total piston displacement (cc) 11,051
Compression ratio 17.1 : 1
Engine dimension (length x width x height) (mm) 1,365.5 x 870 x 1,046 1,383 x 870 x 1,207
Engine weight (kg) 910
Rotating direction (from flywheel) Counter clockwise
Fuel injection order 1-5-3-6-2-4
Fuel injection timing (B.T.D.C static) 12°
Injection pump type Zexel in-line “P” type
Governor type Mechanical governor type(RSV) Electric governor type(GAC)
Injection nozzle type Multi-hole type (5 hole) Multi-hole type (5 hole)
Fuel injection pressure (kg/cm )
2
220 1st : 160, 2nd : 220
Compression pressure (kg/cm )
2
28 (at 200 rpm)
50Hz 60Hz 50Hz 60Hz 60Hz
Condition (1,500rpm) (1,800rpm) (1,500rpm) (1,800rpm) (1,800rpm)
280PS 336PS
Continuous - - (206kW) (247kW) -
Power (ISO 3046)
205PS 245PS 328PS 378PS 356PS
Prime (151kW) (180kW) (241kW) (278kW) (262kW)
226PS 270PS 370PS 405PS 392PS
Stand by (166kW) (199kW) (272kW) (298kW) (288kW)
Intake and exhaust valve clearance (at cold) (mm) 0.3
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)
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 (max./min.) (lit) 23/20
Oil cooler type Water cooled
Water pump Gear driven impeller type
Cooling Method Pressurized circulation
Cooling water capacity (engine only) (lit) 19
Thermostat type Wax pallet type (83 ~ 95 °C)
Alternator voltage - capacity (V - A) 24 - 45
Starting Motor voltage - output (V - kW) 24 - 6.0

-1-
1.2. Engine assembly

1.2.1. Engine sectional view (Longitudinal)

2 3 4 5 6 7 8 9

10 11 12 13 14 15 16 17 18

EA8M1002

1. Cooling fan 7. Piston pin 13. Crankshaft

2. Exhaust valve 8. Piston 14. Oil pan
3. Valve spring 9. Combustion chamber 15. Connecting rod
4. Oil filter 10. Crankshaft pulley 16. Camshaft
5. Tappet 11. Vibration damper 17. Flywheel housing
6. Push rod 12. Oil pump 18. Flywheel

-2-
1.2.2. Engine sectional view (Cross)

7 8 9

1 10

2
11
3
12

EA8M1003

1. Intake manifold 7. Injection nozzle assembly

2. Fuel filter 8. Rocker arm
3. Oil cooler 9. Cylinder head cover
4. Injection pump 10. Exhaust manifold
5. Cylinder block 11. Piston ring
6. Oil filter 12. Turbocharger

-3-
1.2.3. Engine assembly views

1) DE12T

1 2 3 12 4 27 13 18

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

-4-
 2) P126TI

1 2 3 4 5 12 13

7 6 8 9 10 11
14 15 16 17 18 19

24

22 25
23
20 21
EA8M1005

1. Cooling fan 8. Oil pan 18. Injection pipe

2. Cooling water pipe 9. Starter 19. Thermostat
3. Air pipe 10. Flywheel housing 20. Injection pump
(Intercooler Intake manifold) 11. Flywheel 21. Oil level gauge
4. Air pipe 12. Exhaust manifold 22. Mounting bracket
(Air cleaner Turbocharger) 13. Injection nozzle assembly 23. Vibration damper
5. Turbocharger 14. Oil filter 24. Water pump
6. Oil drain valve 15. Breather hose 25. Fan drive
7. Air pipe 16. Oil cooler
(Intercooler Intake manifold) 17. Intake manifold

-5-
2. Safety regulations

2.1. General notes

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

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

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

2.2. Regulations designed to prevent accidents

2.2.1. During commissioning, starting and operation

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

• For reasons of safety we recommend you attach a notice to the door of the engine room
prohibiting the access of unauthorized persons and that you draw the attention of the
operating personal to the fact that they are responsible for the safety of persons who enter
the engine room.
• The engine must be started and operated only by authorized personnel. Ensure that the
engine cannot be started by unauthorized persons.
• When the engine is running, do not get too close to the rotating parts. Wear close-fitting
clothing.
• Do not touch the engine with bare hands when it is warm from operation risk of burns.
• Exhaust gases are toxic. Comply with the installation instructions for the installation of
DAEWOO generator diesel engines which are to be operated in enclosed spaces. Ensure
that there is adequate ventilation and air extraction.
• Keep vicinity of engine, ladders and stairways free of oil and grease.
Accidents caused by slipping can have serious consequences.

-6-
2.2.2. During maintenance and care

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

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

• Take into account the amount of oil in the sump. Use a vessel of sufficient size to ensure that
the oil will not overflow.
• Open the coolant circuit only when the engine has cooled down. If opening while the engine
is still warm is unavoidable, comply with the instructions In the chapter entitled “Cooling”.
• Neither tighten up nor open pipes and hoses (lube oil circuit, coolant circuit and any additional
hydraulic oil circuit) during the operation. The fluid which flow out can cause injury.
• Fuel is inflammable. Do not smoke or use naked lights in its vicinity. The tank must be filled
only when the engine is switched off.
• Keep service products (anti-freeze) only in containers which can not be confused with drinks
containers.
• Comply with the manufacturer’s instructions when handling batteries.

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

2.2.3. When carrying out checking, setting and repair work

• Checking, setting and repair work must be carried out by authorized personnel only.
• Use only tools which are in satisfactory condition. Slip caused by the worn open-end wrench
could lead to Injury.
• When the engine is hanging on a crane, no-one must be allowed to stand or pass under it.
Keep lifting gear in good condition.
• When checking injectors, do not put your hands under the jet of fuel.
Do not inhale at atomized fuel.
• When working on the electrical system disconnect the battery earth cable first. Connect it up
again last in prevent short circuits.

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

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

-7-
 2) If faults occur, find the cause immediately and have it eliminate in order to prevent more
serious of damage.
3) Use only genuine DAEWOO spare parts. DAEWOO will accept no responsibility for damage
resulting from the installation of other parts which are supposedly “just as good”.
4) In addition to the above, note the following points.
• Never let the engine run when dry, i.e. without lube oil or coolant. Use only DAEWOO-
approved service products (engine oil, anti-freeze and anticorrosion agent).
• Pay attention to cleanliness, The Diesel fuel must be free of water. See “Maintenance and
care”.
• Have the engine maintained at the specified intervals.
• Do not switch off the engine immediately when it is warm, but let it run without load for about
5 minutes so that temperature equalization can take place.
• Never put cold coolant into an overheated engine. See “Maintenance and care”.
• Do not add so much engine oil that the oil level rises above the max. marking on the dipstick.
Do not exceed the maximum permissible tilt of the engine. Serious damage to the engine may
result if these instructions are not adhered to.
• Always ensure that the testing and monitoring equipment (for battery charge, oil pressure, and
coolant temperature) function satisfactorily.
• Comply with instructions for operation of the alternator. See “Commissioning and operation”.
• Do not let the water pump run dry. If there is a risk of frost, drain the water when the engine
switched off.

2.4. Regulations designed to prevent pollution

2.4.1. Engine oil, filter element, fuel filter

• Take old oil only to an oil collection point. Take strict precautions to ensure that oil does not
get into the drains or into the ground.
• The drinking water supply may be contaminated.
• Oil and fuel filter elements are classed as dangerous waste and must be treated as such.
2.4.2. Coolant

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

• When disposing of spent coolant comply with the regulations of the relevant local authorities.

2.5. Notes on safety in handling used engine oil

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

-8-
 Health precautions

• Avoid prolonged or repeated skin contact with used engine oil.

• Protect your skin by means of suitable agents (creams etc.) or wear protective gloves.
• Clean skin which has been in contact with engine oil.
- Wash thoroughly with soap and water, A nailbrush is an effective aid.
- Certain products make it easier to clean your hands.
- Do not use petrol, Diesel fuel, gas oil, thinners or solvents as washing agents.
• After washing apply a fatty skin cream to the skin.
• Change oil-soaked clothing and shoes.
• Do not put oily rags into your pockets.

Ensure that used engine oil is disposed of properly.

- Engine oil can endanger the water supply -

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

-9-
3. Technical information

3.1. Engine model and serial number

Engine Number
The engine model and serial number is
located on the engine as illustrated. These
numbers are required when requesting
warranty and ordering parts. They are also
referred to as engine model and serial
number because of their location.

EA8O3001

• Engine serial No. (example 1 : DE12T)

EBHGA900001

Serial No. MODEL BORE mm

SPEED 1500/1800 rpm STROKE mm
Production Year(19x9)
STAND-BY VOLUME cc
Engine Model Suffix
PRIME YEAR
SERIAL NUMBER
DAEWOO HEAVY INDUSTRIES LTD.

EA9O2002

< Name Plate : General >

• Engine serial No. (example 2 : P126TI)

EDIGA900001
DAEWOO HEAVY INDUSTRIES LTD.
IMPORTANT ENGINE INFORMATION ENGINE AND MATERIAL DIV.
6, MANSECOK-DONG, DONG-GU
INCHEON, KOREA
THIS DAEWOO HEAVY-DUTY DIESEL MODEL IS CERTIFIED TO OPERATE ON TYPE 2-D DIESEL FUEL.
EPA AND CARB STANDARDIZED ENGINE FAMILY DESIGNATION IS
Serial No. TUNE-UP SPECIFICATIONS AND ADJUSTMENTS

Production Year(1999)
Engine Model Suffix

EA9O2003

< Name Plate : EPA & CARB >

- 10 -
3.2. Engine type
The Engines DE12T/ P126TI are in-line vertical water-cooled 6-cylinder four-stroke diesel
engines with direct injection. DE12T is turbo-charged engine, and P126TI model is 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 individual cylinder heads with struck-in valve seat rings and replaceable valve guides,

3.2.2. Piston con-rod / crankshaft

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

- 11 -
3.3. Engine timing
Camshaft, oil pump and injection pump are driven by a gear train arranged at the front end.

Injection pump gear 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

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

- 12 -
3.5. Lubrication system
The engine is equipped with force-feed lubrication.
The pressure is produced by a gear pump whose drive gear is in direct mesh with the
crankshaft gear at the front end of cylinder block.
The oil pump draws the oil from the oil sump and delivers it through the oil cooler and oil filter
to the main distributor gallery and from there to the main bearings, big-end bearings and
camshaft bearings as well as to the small-end bearings and the rocker arms.
The injection pump and the turbocharger are also connected to the engine lubricating system.
The cylinder walls and timing gears are splash-lubricated.
Each cylinder has an oil jet provided for cooling the underside of the pistons.
The lube oil is cleaned in a full-flow oil filter.

OPENING PRESSURE
4.0 ~ 5.0 kg/cm2

RELIEF VALVE CYLINDER BLOCK MAIN GALLERY TURBO CHARGER

CAM SHAFT BEARING

BY - PASS VALVE OIL FILTER
1.8 ~ 2.3 kg/cm2

IDLE GEAR SHAFT ROCKER ARM SHAFT

OIL SPRAY VALVE
BY - PASS VALVE 1.5 ~ 1.8 kg/cm2
5.0 ~ 6.0 kg/cm2
OIL COOLER
SPRAY NOZZLE CRANK JOURNAL INJECTION PUMP

IDLE GEAR FACE VALVE ROCKER ARM

RELIEF VALVE
10 + 1.5 kg/cm2
CRANK PIN
OIL PUMP

TAPPET VALVE
OIL STRAINER

EA8O3003

3.5.1. Recommend of lubricating oil

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

- 13 -
 Engine oil viscosity - ambient temperature

SAE 20, 20W SAE 40, 50

Single SAE 30
grade SAE 10W

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

3.5.2. Oil cooler

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

3.5.3. Oil filter

Check for oil pressure and oil leaks, and

repair or replace the oil filter if necessary.
Change the oil filter cartridge simultaneously
at every replacement of engine oil.

Oil filter (Cartridge)

Oil filter head

EQM4010I

- 14 -
3.6. Air cleaner
In case that elements are deformed, damaged
or if the air cleaner has a crack, replace it.
By the definite interval, the elements must be
cleaned and replaced.

- Cleaning of air cleaner element: Every 200

hours.
- Changing of air cleaner element: Every 600
hours.
EFM1002I

3.7. Intercooler
The intercooler is air to air type and has a large cooling fan capacity. The intercooler life and
performance depends on the intake air condition greatly. Fouled air pollutes and clogs the air
fins of intercooler. As a result of this, the engine output is decreased and engine malfunction is
occurred. So you always check whether the intake air systems like air filter element are worn
or polluted.

Air/air intercooler
with downstream
radiator
(Combined radiator)

Cooling air

Hot charge air

from compressor

Recooled charge air

to intake pipe (max. 50 C)

EA5O4003

- Cleaning of intercooler fins: Every 600 hours.

- 15 -
3.8. Fuel system
The fuel is delivered by the fuel feed pump via the fuel filter to the injection pump and from
there to the injection nozzles.
The fuel is sprayed into the cylinders through nozzles fitted in screw-fit injection nozzle holders
in the cylinder heads.
Excessively delivered fuel and leak fuel from the nozzle flow through the return pipe back to
the tank.
A strainer is arranged ahead of the fuel feed pump.

1 2 5

4
1a 3 7

13

8
12

10

9 11

EA8O3004

1. Fuel filter 7. Delivery pipe

1a. Full 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

- 16 -
3.8.1. Injection pump

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

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

1) Integral Actuator

2) Speed control unit for governor system

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

Engine model P126TI

GAC governor model ACE 175A
Speed control unit model ESD5550

- 17 -
 6.00 (152)
5.25 (133)
O 0.27 (7)

C1 OFF ON C2
LEAD CIRCUIT SOFT COUPLING
ON OFF

OVERSPEED
OVERNORS
GA MERICA 1 2 3 RESET TEST
C ORP
OVERSPEED
SPEED CONTROL UNIT

MODEL : ESD5550 SPEED

S/N
GAIN
MADE IN AGAWAM, MA U.S.A

STABILITY
6.05 (165)

6.00 (152)

STARTING SPEED
E2
FUEL RAMPING
E1 E3
DEAD TIME
CAUTION DROOP COMPENSATION
ENGINE SPEED CONTROL
COMPONENT WHEN INSTALLING
OR SERVICING REFER TO
JUMPER
PRODUCT PUBLICATION

PICK-UP _ + IDLE
BATTERY 10V
ACTUATOR
AUX OUTPUT
A B C D E F G H J K L M N P

OPTIONAL ACTUATOR ACCESSORY POWER 1.03 (26)

CABLE SHELDING TO SUPPLY
MEET CE DIRECIVE ACCESSORY INPUT
* ADD JUMPER FOR 12V
BATTERY OR ACTUATOR
ACTUATOR CURRENTS ABOVE 5A
CW GROUND REFERENCE
MAGNETIC
CLOSE FORDROOP
PICK-UP
SPED TRIM
_ CONTROL - 5K CLOSE FOR IDLE
+ S1
FUSE
BATTERY 15A MAX

* SEE SPECIFIC ACTUATOR PUBLICATION FOR PROPER

WIRING OF ACTUATOR BASED ON BATTERY VOLTAGE

EA6M4004

- 18 -
3.8.2. Fuel filter

This fuel filter has two functions not only oil

filtering but also water separating. 1
Before entering the suction chamber of the
3
injection pump, the fuel is cleaned in a
strainer of fuel feed pump and a fuel filter. 4 5
Drain water in cartridge with loosening the 2
cock under filter manually (6) from time to
time.
The fuel filter should be replaced at every
6 EA2O4009

1,200 hours.

3.8.3. Fuel requirements

DAEWOO marine diesel engines was designed to use Number 2-D diesel fuel or equivalent
that meets specification DIN 51601-DK. For maximum fuel economy, Number 2-D fuel
whenever possible. When temperatures are below -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 kerosene has been added, the engine should be run for several
minutes to mix the fuel.

3.8.4. How to select fuel oil

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

- 19 -
Fuel oil selection chart

General Fuel ASTM No. 1 No. 2

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.

- 20 -
3.9. Cooling system
The engine has a liquid-cooling system. The fresh water pump is a maintenance-free by gear
from the crankshaft.
Depending on the agreed extent of delivery and the design of the engine, the coolant circuit
can be equipped with temperature monitors which, in the event of loss of coolant, shut the
engine down.

• Check the coolant level of the expansion tank by removing the expansion tank filler cap, and
add coolant if necessary.
• When injecting antifreeze solution, first drain out the old coolant from the cylinder block and
radiator, and then clean them with cleaning solution.
• Be sure to mix soft water with antifreeze solution.

Water pipe

Thermostat

R Cylinder head
a
d
i
a
Reserve tank t
o
r

Water pump Cylinder block

EJM4001I

- 21 -
3.9.1. Coolant pressure cap

Check the pressure valve opening pressure

using a expansion tank cap tester. Replace
the filler cap assembly if the measured valve
does not reach the specified limit. (pressure Rediater Cap

valve opening pressure : 0.9 kg/cm2)

Note : Because it is dangerous to open

the pressure cap quickly when Rediater

coolant is hot, after lowering the

inside pressure of the tank by
slow-opening at first open it fully.

EA5O3002

3.9.2. Anti-freeze

The anti-freeze, 50% of the whole coolant,

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

Ambient
Cooling water (%) Anti-freeze (%)
Temperature (˚C)
Over -10 85 15
-10 80 20
-15 73 27
-20 67 33
-25 60 40
-30 56 44
-40 50 50

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

- 22 -
3.10. V-belt tension check and adjust
By the finger-pressure the belt is pressed by
here
Press hear
10mm ~ 15mm between the fan pulley and
15mm
the alternator pulley in normal condition. For
Alternator Fan
the adjustment of the tension, loosen the Pulley
Pulley
adjusting bolts which support the alternator,
adjust the tension and tighten the bolts
V-belt
again.

Crank Pulley EA8O3005

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

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

- 23 -
3.12. Electrical equipment

3.12.1. Alternator

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

24V x 45A
P-TAB : KET GP 890545
TACHOMETER CHARGE INDICATOR
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,

To Battery +
nevertheless, it must be protected against
dust and, above all, against moisture and Regulator

water.

RRLL = 150~250 OHM

Operate the alternator according to the
instructions given in the chapter.

EA8O3007

- 24 -
3.12.2. Starter motor

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

24V x 6.0kW

TERMINAL "B" TERMINAL S/W

24V x 6.0kW
M10 x P1.5 M5 x P0.8

EA8O3008

Always protect starter motor against moisture.

Warning : Always disconnect the

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

2.5A(20oC 24V)
EA8O3009

- 25 -
4. Commissioning and operation

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

• Oil filler neck on cylinder head cover

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

Note : The oil required to fill the oil fillers and pipes depends upon the engine and use and
must be determined individually at the time of initial commissioning. (Make the Max
and Min. marks of the determined quantity on the oil level gauge.)

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

4.2. Breaking-in

4.2.1. Operation of a new engine (Break-In)

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

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

• Engine should be run at fast idling until the temperature of the engine becomes normal
operating condition.
• Overload or continuous high speed operation should be avoided.
• High speed operation with no load should be prevented.
• Abrupt start and stop of the engine should be avoided.
• Engine speed must be under 70% of its maximum speed.
• Maintenance and inspection must be accomplished thoroughly.

- 26 -
4.2.2. Check points for break-in

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

Note : If you have a problem getting a good oil level reading on dipstick, rotate dipstick 180˚
and re-insert for check.

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

Note : Oil pressure will rise as RPM increases, and fall as RPM decreases. In addition, cold
oil will generally show higher oil pressure for any specific RPM than hot oil. Both of
these conditions reflect normal engine operation.

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

<Engine Oil capacity>

Oil pan (only)

DE12T 23 liter
P126TI 23 liter

4.2.3. Operating after break-in

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

- 27 -
4.3. Inspections after starting
During operation the oil pressure in the engine lubrication system must be monitored. If the
monitoring devices register a drop in the lube oil pressure, switch off the engine immediately.
And the charge warning lamp of the alternator should go out when the engine is running.

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

• If, during operation, the battery charge lamp suddenly lights up, stop the engine immediately
and remedy the fault in the electrical system!
• Engine should be stopped if the color, the noise or the odor of exhaust gas is not normal.
• Confirm the following things through warning lamps and gauge panel.
4.3.1. Pressure of lubricating oil

The normal pressure comes up to 1 kg/cm2 (1.0 bar) at idling and 3 ~ 5 kg/cm2 (3.0 ~ 4.9
bar) at maximum speed. If the pressure fluctuates at idling or does not reach up to the
expected level at high speed, shut down the engine immediately and check the oil level and
the oil line leakage.

4.3.2. Temperature of cooling water

The cooling water temperature should be 78 ~ 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
prevent the engine from excessive cooling. If the temperature of coolant does not reach to
normal condition (78 ~ 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”.

- 28 -
4.5. Tuning the engine
The purpose of an engine tune-up is to restore power and performance that’s 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
it’s seldom advisable to attempt an improvement in performance by correction of one or two
items only. Time will be saved and more lasting results will be obtained by following a definite
and thorough procedure of analysis and correction of all items affecting power and
performance.
Economical, trouble-free operation can better be ensured if a complete tune-up is performed
once every years, preferably in the spring. Components that affect power and performance to
be checked are:

• Components affecting fuel injection ;

Nozzle, delivery valve, fuel filter, water separator, etc.
• Components affecting Intake & exhaust ;
Air filter, inter-cooler, turbo, silencer, etc.
• Components affecting lubrication & cooling ;
Air & oil filter, anti- freeze, etc.

- 29 -
5. Maintenance and care

5.1. Periodical inspection and maintenance

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

• Daily inspections in below figure should be checked every day.

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

5.2. Lubrication system

5.2.1. Exchanging of lubrication oil

Engine oil and the oil filter are important factors affecting engine life. They affect ease of
starting, fuel economy, combustion chamber deposits and engine wear. Refill and drain oil
pan every 50 hours of operation or 6 months whichever occurs first. At the end of the 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
EA4O4001
contamination of the oil smeared at the
dipstick replace the engine oil if
necessary.

Caution : Do not add so much engine oil that the oil level rises above the max. marking on
the dipstick. Over lifting will result in damage to the engine.

- 30 -
5.2.3. Oil exchange procedure

While the oil is still hot, exchange oil as

follows:
• Take out the oil dip dipstick.
• Remove the drain valve from oil pan and
the drain plug form oil filter head, then
drain out the engine oil into a container.

Drain Plug
EA8O5001

• Reassemble the drain valve with the oil

pan and the drain plug with oil filter head
after draining out the engine oil.

EA2O4001
EA2O4001

• Refill with new engine oil at the oil filler

neck on the head cover and the lubricating
oil in accordance with the oil capacity of
the engine through oil filler. Be careful
about the mixing of dust or contaminator
during the supplement of oil. Then confirm
that oil level gauge indicates the vicinity of
its maximum level.
• For a few minutes, operate the engine at EA7O5003
idling in order to circulate oil through
lubrication system.

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

- 31 -
5.2.4. Replacement of oil filter cartridge

At the same times of oil exchanges, replace

the oil filter cartridge.
• Drain engine oil by loosening the drain
plug on the filter head.
Cartridge

Caution : 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
properly. Drain plug
EA7O5004
• Lightly oil the O-ring and turn the oil filter
until sealing face is fitted against the O-ring. Turn 1-1/4 turns further with the filter wrench.

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

5.3. Cooling system

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

5.3.1. Coolant draining

a) Remove the pressure cap.

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

Drain Valve
EA5O4002

- 32 -
 c) Loosen the coolant drain plug.
Loosen the coolant drain plug of the cylinder
block.

EAMD001I

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

5.3.2. Cleaning of the cooling inside system circuit (by authorized specialist personnel)

When the cooling system circuit are fouled with water scales or sludge particles, the cooling
efficiency will be lowered.
Investigations have shown that in many cases the poor condition of the coolant and /or the
cooling system accounts for damage to the water pump mechanical seal, The poor condition of
the cooling system is normally due to use of unsuitable or no anti-freezing agents and corrosion
inhibitor or defect, not early enough replaced covers for filler neck and working valves.
If twice in a short time the water pump of an engine develops leases or the coolant is heavily
contaminated (dull, brown, mechanically contaminated, grey or black sings of a leakage on
the water pump casing) clean the cooling system prior to removing that water pump as
follows.
a) Drain coolant.
b) Remove thermostats, so that the whole cooling system is immediately flown through when
cleaned.
c) Fill the cooling system with a mixture of potable water and 1.5% by volume of cleaner.
(Henkel P3T5175)
d) Warm up engine under load. After a temperature of 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.

- 33 -
5.3.3. Intercooler

The intercooler is air to air type and has a large cooling fan capacity. The intercooler life and
performance depends on the intake air condition greatly. Fouled air pollutes and clogs the air
fins of intercooler. As a result of this, the engine output is decreased and engine malfunction
is occurred. So you always check whether the intake air systems like air filter element are
worn or polluted.

Air/air intercooler
with downstream
radiator
(Combined radiator)

Cooling air

Hot charge air

from compressor

Recooled charge air

to intake pipe (max. 50 C)

EA5O4003

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

Cleaning of intercooler fins : Every 600 hours.

- 34 -
5.4. Air intake system

1. Connection port, fouling indicator

2. Cleaner housing 1 2 3 4 5 6 7
3. Clamp
4. Element
5. Hexagon nut
6. Cover
7. Dust bowl

EA6O5012

5.4.1. Maintenance (only when engine is switched off)

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

5.4.2. Changing filter element

Caution : Do not allow dirt to get into the

clean air end.

On removing the hexagon nut, take out the

dirty cartridge and renew or clean.
Wipe the cleaner housing with a damp
cloth, in particular the sealing surface for
the element.

EA6O5013
Notice : Unless the maximum number of
cleanings (up to 5 x) have been
done, the filter cartridge should
be renewed every two years or
4,000 hours operation.

- 35 -
5.4.3. Cleaning filter elements

• By compressed air (Wear goggles)

For the purpose, the air gun should be
fitted with a nozzle extension which is bent
90˚ at the discharge end and which is long
enough to reach down inside to the bottom
of the element.
Moving the air gun up and down, blow out
the element from the inside (maximum
500kPa - 5 bar) until no more dust comes EA6O5014
out of the filter pleats.

• By washing
Before washing, the element should be
precleaned by means of compressed air,
as described above.
Then allow the element to soak in
lukewarm washing solvent for 10 minutes,
and then move it to and for in the solvent
for about 5 minutes.
Rinse thoroughly in clean water, shake out EA6O5015
and allow drying at room temperature. The
cartridge must be dry before it is reinstalled.
Never use steam sprayers, petrol (gasoline), alkalis or hot liquids etc. to clean the filter elements.

• Knocking out dirt by hand

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

• Checking the filter cartridge

Before reinstalling the cartridge, it must be
checked for damage e.g. to the paper
pleats and rubber gaskets, or for bulges
and dents etc. in the metal jacket.
Cracks and holes in the paper pleating can
be established by inspecting the cartridge
with a flashlight.
Damaged cartridges should not be reused
under any circumstances. In cases of doubt,
EA6O5016
discard the cartridge and install a new one.

- 36 -
5.5. Fuel system

5.5.1. Fuel filter

• After every 1,200 hour of operation, drain

the water and sediment from the fuel-
water separator. 1
• Shut off the engine. Use your hand to 3
open the drain valve 6 . 5
4
• Turn the valve counter clockwise
approximately 2 ~ 3 turns until draining
2
occurs. Drain the filter sump of water until
close fuel is visible. 6 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 .
EA7O5008
• Install the new thread adapter seal ring
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.

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

- 37 -
5.5.3. Fuel system checks

Fill the tank with the recommended fuel. Keeping tanks full reduces water condensation and
helps keep fuel cool, which is important to engine performance.
Make sure fuel supply valves (if used) are open.
To insure prompt starting and even running, the fuel system must be primed with the fuel
feed pump manually before starting the engine the first time, or after a fuel filter change.
Refill at the end of each day’s operation to prevent condensation from contaminating the fuel.
Condensation formed in a partially filled tank promotes the growth of microbial organisms
that can clog fuel filters and restrict fuel flow.

If the engine is equipped with a fuel water separator, drain off any water that has
accumulated. Water in fuel can seriously affect engine performance and may cause engine
damage. DAEWOO recommends installation of a fuel water separator on generator
units.

5.5.4. Fuel Contamination and water trap

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

Notice : A galvanized steel tank should never be used for fuel storage, because the fuel oil
reacts chemically with the zinc coating to form powdery flakes which can quickly
clog the fuel filters and damage the fuel pump and injection nozzles.

5.5.5. Priming pump strainer cleaning

Clean the priming pump strainer every 200

operation hours.
The strainer is incorporated in the priming
pump inlet side joint bolt.
Clean the strainer with the compressed air
Strainer(Inner)
and rinse it in the fuel oil.

EA7O5009

- 38 -
5.5.6. Bleeding the fuel system

After the cleaning of the fuel filter or after the

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

• Press the feed pump cap repetitively until

the fuel without bubbles comes out from EA9O4005

the bleeding valves.

• After the whole air is pulled out, close the
valve of the filter.
• Confirm the resistance of fuel delivery by the repetition pressing of the feed pump cap,
Pressure and turn the feed pump cap simultaneously to close it.

5.5.7. Injection pump

• Check the fuel injection pump housing for cracks or breaks, and replace if damaged.
• Check and see if the lead seal for idling control and speed control levers have not been
removed.
• No alterations must be made to the injection pump. If the lead seal is damaged the warranty
on the engine will become null and void.
• We strongly recommended that any faults developing in the injection pump should be taken
care of by authorized specialist personnel.

5.6. Injection Nozzle Maintenance (by authorized specialist personnel)

The injectors are designed to spray the fuel
delivered by the injection pump directly into
the spherical combustion chamber in the
piston crown.
The injector consists of the nozzle and the
nozzle holder.
A copper seal fitted to the injector ensures
gas-tight seating and good heat dissipation.
The opening pressure of the nozzle is
EA0M3003
adjusted by means of shims at the
compression spring.

- 39 -
 Normal Abnormal Abnormal
EFM1006I

• Install a nozzle to a nozzle tester.

• Check injection pressure, and adjust the nozzle using the adjusting shim if the pressure does
not meet the specified limit.
• Check nozzle spray patterns and replace if damaged.
DE12T P126TI
1st : 160kg/cm2
Injection Nozzle pressure 220kg/cm2
2nd : 220kg/cm2

Caution : The injection lines are designed for high operating pressures and should thus be
handled with particular care.

• When mounting the pipes to the engine take care of good fitness.
• Do not bend pipes to permanent deformation (not for replacing the nozzles either).
• Do not mount any heavily bent pipes.
• Avoid bending the pipes at the ends by more than 2 to 3 degrees.

In case of faults in the injection system which might have resulted in excessive operating
pressures, not only the failed part but also the injection line has to be replaced.

5.7. Turbocharger

5.7.1. Maintenance (by authorized specialist personnel)

The turbochargers do not call for any specific maintenance.

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

- 40 -
 soak in a vessel with solvent and to clean it then with a stiff brush. In doing so, take care to
see that only the compressor wheel is immersed and that the turbocharger is supported on
the bearing casing and not on the wheel.

5.7.2. Special hints

It is recommended that the radial and axial

clearances of the rotor be checked after 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 Move the turbine
shaft to axial
damage is caused to the rotor and bearings. direction
Dial gauge

Wear limit : 0.20mm

EA4M2017
• Measuring rotor axial clearance
Axial clearance 0.2 mm

• Measuring radial clearance

Radial clearance 0.65 mm

Dial gauge
Magnetic vise

Oil
Outlet

Radial play Move the turbine shaft

Limit of wear : 0.57mm in both directions
simultaneously

Oil inlet

EA4M2018

- 41 -
6. Checking and setting

6.1. Adjustment of valve clearance

6.1.1. General information

The valve clearances are to be adjusted at the times of the following situations.

• After initial 50 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.
The valve clearance of the cold engine are as follows.
- Intake valves : 0.3mm
- Exhaust valves : 0.3mm

6.1.2. Adjusting order of the valve clearance

1) After letting the #1 cylinder’s piston come at the compression top dead center by turning
the crankshaft, adjust the valve clearances.
2) Loosen the lock nuts of rocker arm adjusting screws and push the feeler gauge of
specified value between a rocker arm and a valve stem and adjust the clearance with
adjusting screw respectively and then tighten with the lock nut.
3) As for the valve clearance, adjust it when in cold, as follow.

Model Intake Valve Exhaust Valve

DE12T
0.3 mm 0.3 mm
P126TI

- 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.

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

- 42 -
 Flywheel Intake Valve Exhaust Valve Cylinder No. Cooling
Cylinder Fan
Fan

1 2 3 4 5 6

EA8O6001

6.1.3 Method of adjusting the valve clearance

1) Loosen the lock-nuts 1 using a ring

spanner.
4
2) Insert a thickness gauge of 0.3mm
between valve stem 2 and rocker arm
3 . 1

3) Turn the adjusting bolts 4 using a screw

driver until the gauge can be pulled out
3
with some restriction.
4) After the adjustment fix the adjusting bolt 2
EA0O4014
not to rotate and tighten the lock-nut at the
same time.
5) Measure the clearance one more time
and if necessary adjust again.

- 43 -
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
Fuel injection timing
(B.T.D.C static) 12° 12°

Injection timing Flywheel

notch mark ring gear

EA8O6002

• Turn the timer until the notch mark of the

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

EA9O5002

- 44 -
 • 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. Tightening the cylinder head bolts

• The cylinder head bolts are to be tightened

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

<Cylinder Head Bolts>

EAMD102I
Type 1 Type 2

TY TY
Specification 12.9T 10.9T

8 2 3 9
M14x1.5x153 M14x1.5x150
Torque 24.5 kg.m 6 kg.m +180°+150° 12 13
1 4
11 14

7 6 5 10
EAMD103I

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

- 45 -
6.4. Cylinder compression pressure
1) Stop the engine after warming it up, then
remove the nozzle assemblies.

EA9O5003

2) Install a special tool (gauge adapter) in

nozzle holder hole and connect the
compression pressure gauge to the
adapter.

3) Cut off fuel circulation, rotate the starter,

then measure compression pressure of
each cylinder.
EA9O5004

Standard 24~28 kg/cm2

Limit 24 kg/cm2 or less

Allowance among cylinders L10% or less

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

- 46 -
6.5. V-belts
The tension of the V-belts should be checked after every 2,000 hours of operation.

(1) Change the V-belts if necessary

If in the case of a multiple belt drive, wear or differing tensions are found, always replace the
complete set of belts.

(2) Checking condition

Check V-belts for cracks, oil, overheating and wear.

(3) Testing by hand

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

Crank Pulley EA8O3005

(4) Measuring tension

1 Lower indicator arm (1) into the scale.

• Apply tester to belt at a point midway
between two pulleys so that edge of
1
contact surface (2) is flush 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
EA6O6011
has disengaged a false reading will be
obtained!

2 Reading of tension
• Read of the tensioning force of the belt 3
at the point where the top surface of
the indicator arm (1) intersects with the
scale.
• Before taking readings make ensure
that the indicator arm remains in its
position. 2
EA6O6012

- 47 -
 Tensioning forces on the tester

new installation
Type Drive belt width When servicing after
After 10 min. long running time
Installation
running time
M 9.5 mm 50 kg 45 kg 40 kg

A 11.8 mm 55 kg 50 kg 45 kg
*
B 15.5 mm 75 kg 70 kg 60 kg

C 20.2 mm 75 kg 70 kg 60 kg

* : Adopted in DE12T and P126TI

(5) Tensioning and changing V-belt
• Remove fixing bolts. (1)
• Remove lock nut. (2)
• Adjust nut (3) until V-belts have correct
tensions. (2)
• Retighten lock nut and fixing bolts. (3)
(1)
To change the V-belts loosen mounting
bolts (1) and lock nut (2) and push
tension pulley inwards by turning
adjusting nut (3). EA8O6004

- 48 -
• Appendix
1. General engine inspection cycle
: Check & adjust : Replace

Every Every Every Every Every

Inspection Daily Remark
50hrs 200hrs 600hrs 800hrs 1200hrs
Check for leakage(hoses, clamp)
Check the water level
Cooling Change the coolant water
System Every
Adjust the V-belt tension 2,000hrs
Clean the radiator
Check for leakage
Check the oil level gauge
Lubrication
Change the lubricating oil 1st
System

Replace the oil filter cartridge

1st
Check the leakage for intercooler
(hoses, clamp)
Intake & Clean and change
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 Replace the fuel filter element
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

- 49 -
2. Diagnosis and remedy

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

- 50 -
 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

- 51 -
 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

- 52 -
 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

- 53 -
 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.)

- 54 -
 6. Oil Consumption Excessive

Cause according to use conditions

1. Excessive oil infusing
2. Continuous operation in low or
extremely cold state

Inspect oil leakage

Inspect air cleaner

Normal Oil leakage Clean Replace

Check oil quality External Internal

Replace with Retighten Check compressed

specified oil Replace pressure

Engine disassembly Normal

(piston cylinder liner)

Disassemble
cylinderhead
(valve stem seal)

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

- 55 -
 8. Battery Discharge

Battery Wiring Switch Generator

Check electrolytic Inspect cut wire Check fan belt

liquid amount shorts and loose tension & damage
connections

Repair Replace

Normal

Electrolytic Battery room Battery self Battery over

liquid's damage discharge charging
standard
Inspect generator
Replenish Replace Charging Voltage regulator

Normal Abnormal

Check charged stated Adjust

Replace

Discharging

Disassemble
generator Voltage
regulator

- 56 -
 Condition Causes Remedies

1) Starting difficult • Valve’s 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 • Valve tightness poor Repair
insufficient • 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 Adjust or replace

improper or stuck

• 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 • Compression pressure Disassemble engine

when in acceleration insufficient
• Injection timing incorrect Adjust
• Fuel injection amount insufficient Adjust injection pump
• Injection pump timer’s function Repair or replace
insufficient
• Nozzle infection pressure, infection Repair, replace
angle improper
• Supply pump’s function lowered Repair or replace
• Air intake amount insufficient Clean or replace air
cleaner

4) Overheating • Engine oil insufficient or poor Replenish or replace

• Cooling water insufficient Replenish or replace

• Fan belt loosened, worn, damaged Adjust or replace

• Cooling water 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

- 57 -
 Condition Cause Remedies

5) Engine noisy For noises arise compositely such asrota

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

(1) Crankshaft • As the wear of bearing or crankshaft Replace bearing &

progress, the oil clearances increase. grind crankshaft

• Lopsided wear of crankshaft Grind or replace

• Oil supply insufficient due to oil Clean oil passage

passage clogging

• Stuck bearing Replace bearing &

Grind

(2) Con rod and • Lopsided wear of con rod bearing Replace bearing
Con rod bearing • Lopsided wear of crank pin Grind crankshaft

• Connecting rod distortion Repair or replace

• Stuck bearing Replace &

grind crankshaft

• Oil supply insufficiency as clogging Clean oil passage

at oil passage progresses

(3) Piston, piston pin & • Piston clearance increase as the wear Replace piston &
piston ring of piston and piston ring progresses piston ring

• Wear of piston or piston pin Replace

• Piston stuck Replace piston

• Piston insertion poor Replace piston

• Piston ring damaged Replace piston

(4) Others • Wear of crankshaft, thrust bearing Replace thrust

bearing

• Camshaft end play increased Replace thrust plate

• Idle gear end play increased Replace thrust

washer

• Timing gear backlash excessive Repair or replace

• Valve clearance excessive Adjust valve

clearance

• Abnormal wear of tappet, cam Replace tappet, cam

• Supercharger inner part damaged Repair or replace

6) Fuel Consumption • Injection timing incorrect Adjust

Exttive • Fuel injection amount excessive Adjust injection
pump

- 58 -
 Condition Cause Remedies

7) Oil Consumption
Excessive
(1) Oil level elevated • Clearance between cylinder iner & Replace
piston

• Wear of piston ring, ring groove Replace piston,

piston ring
• Piston ring’s damage, stick, wear Replace piston ring
• Piston ring opening’s disposition Correct position
improper
• Piston skirt part damaged or Replace piston
abnormal wear
• 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 parts’ packing poor Replace packing
• Oil seal poor Replace oil seal

- 59 -
 DAEWOO HEAVY INDUSTRIES &
MACHINERY LTD. AROUND THE WORLD

FRAMERIES
(Belgium)
CARDIFF
(U.K.)
XINJIANG
DUSSELDORF (China) SEATTLE CLEVELAND
(Germany) TAIANJIN SEOUL(Korea) (U.S.A) (U.S.A)
(China)
TOKYO ATLANTA NEW JERSEY
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(China) (Japan)
TRAPPES
(France)
TAIPEI
(Taiwan R.O.C)
BOGOTA
(Colombia)

SAO PAULO
(Brazil)
JOHANNESBURG SYDNEY
(South Africa) (Australia)

Head Office Daewoo Heavy Industries America Cleveland Office

Hwasu-Dong 7-11, Dong-Gu, Incheon, Korea. 4530 Renaissance Parkway, Warrensville Heights, OH 44128,
Tel : 82-32-760-1114 Fax : 82-32-762-1546 U.S.A
Tel : 1-216-595-1212 Fax : 1-216-595-1214
Seoul Office
8th floor Daewoo Heavy Industries & Machinery Bidg, 14-34, Daewoo Rep. C/O Boeing Co.
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Tel : 82-2-2167-3114 Fax : 82-2-785-2677 Tel : 1-425-266-0478 Fax : 1-425-266-0518
ASIA & OCEANIA EUROPE
Daewoo Heavy Industries Australia Pty. Ltd Euro Daewoo U,K Ltd
Suite 5, Level 4,20 Charles St., Parramatta NSW 2150, Australia
Tel : 61-2-9633-4544 Fax : 61-2-9633-5266 Daewoo House, Unit 6.3 Nantgarw Park, Cardiff
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Daewoo Machinery Co., Ltd
No.83 WenHwa 1st. Road, Kueishan Hsiang, Taoyuan Hsien, Daewoo Maschinen Vertriebs GmbH
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Xinjiang Daewoo Machinery Co., Ltd Euro Daewoo S. A

No, 178, Hetanbei Road, Wurumuqi, Xinjiang, China 1A Rue Achille Degrace 7080 Frameries Belgium
Tel : 86-991-463-2217 Fax : 86-991-461-8641 Tel : 32-65-61-3231 Fax : 32-65-61-3238

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No.87 Gongxing Road, Tanggu, Tianjin, china 2Eme Etage, 1/3 Avenue Pavlov, Z.A.I. Des Bruyeres 78190
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Tel : 33-1-3016-2140
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#28, Wuzhishan Road, Eco. & Tech, Development Zone,
Yantai, Shandong, China SOUTH AMERICA
Tel : 86-535-638-2000 Fax : 86-535-638-2004
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 65.99897-8050

Maintenance Manual
GENERATOR DIESEL ENGINE

DE12T
POLUS

P126TI
 FOREWORD

This maintenance manual is designed to serve as a reference for DAEWOO Heavy Industries Ltd’s
(here after DAEWOO’s) customers and distributors who wish to gain basic product knowledge on
DAEWOO’s DE series generator diesel engines (DE12T and POLUS P126TI)
These economical and high-performance diesel engines (6 cylinders, 4 strokes, in-line, direct injec-
tion type) have been so designed and manufactured to be used for the generator application. They
meet all the requirements such as low noise, fuel economy, high engine speed, and durability.
To maintain the engine in optimum condition and retain maximum performance for a long time, COR-
RECT OPERATION and PROPER MAINTENANCE are essential.

In this manual, the following symbols are used to indicate the type of service operations to be per-
formed.

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;

• Take old oil to an old oil disposal point only.

• Ensure without fail that oil and diesel fuel will not get into the sea or rivers and canals or the ground.
• Treat undiluted anti-corrosion agents, antifreeze agents, filter element and cartridges as special waste.
• The regulations of the relevant local authorities are to be observed for the disposal of spent coolants and spe-
cial 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 ser-
vices.

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

DAEWOO Heavy Industries LTD.

July. 1999
 CONTENTS

1. GENERAL INFORMATION .........................................................................................................1

1.1. General repair instructions 1.3. Engine assembly

1.2. Engine characteristics 1.4. Engine specifications

2. MAJOR MAINTENANCE.............................................................................................................8
2.1. Preventive maintenance 2.3. Engine inspection
2.2. Diagnosis and remedy

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

3.1. Disassembly 3.3. Reassembly
3.2. Inspection 3.4. Breaking-in

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

4.1. Cooling system 4.3. Fuel injection pump
4.2. Lubricating system 4.4. Turbocharger

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

• Appendix..................................................................................................................................130

• Worldwide Network
1. General information
1.1 General repair instructions

1. Before Performing service operation, disconnect the grounding cable from the battery for

reducing the chance of cable damage and burning due to short-circuiting.

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

3. Engine oil and anti-freeze solution must be handled with reasonable care as they cause

paint damage.

4. The use of proper tools and special tools where specified is important to efficient and

relaible service operation.

5. Use genuine DAEWOO parts necessarily.

6. Used cotter pins, gaskets, O-rings, oil seals, lock washer and self-lock nuts should be dis-

carded and new ones should be prepared for installation as normal function of the parts can

not be maintained if these parts are reused.

7. To facilitate proper and smooth reassemble operation, keep disassembled parts neatly in

groups. Keeping fixing bolts and nut separate is very important as they vary in hardness

design depending on position of lnstallation.

8. Clean the parts before inspection or reassembly. Also clean oil ports, etc. using compressed

air to make certain they are free from restrictions.

9. Lubricate rotating and sliding faces of parts with oil or grease before installation.

10. When necessary, use a sealer on gaskets to prevent leakage.

11. Carefully observe all specifications for bolts and nuts torques.

12. When service operation is completed, make a final check to be sure service has been

done property.

-1-
1.2. Engine characteristics

1.2.1 OMEGA combustion bowl

The OMEGA combustion bowl is a unit

designed to perform high efficiency, low
emission combustion. As the rim around the
combustion bowl port of the upper of the
piston has been machined in a smaller size
than the interior of the combustion bowl,
strong swirl is produced in the combustion
bowl and strong squish flow makes the fuel
be mixed more sufficiently with air.
Due to the application of OMEGA combus-
tion system and optimal utilization of intake
and exhaust port configuration within the
cylinder head, the POLUS P126TI and
DE12T (DE12 series) generator diesel
engines discharge very low level of haz-
ardous exhaust gases such as smoke,
nitrogen oxide, hydrocarbon, or carbon
monoxide and thus ensure high perfor-
mance and low fuel consumption.

EA8M1001

1.2.2. Oil gallery cooling type pistion(P126TI)

Oil gallery cooling is used for the piston of

P126TI generator engine.
When thermal loading is high, piston cool-
ing by means of an oil gallery in the crown
is normally necessary to prevent crown
cracking and ring sticking. The design of
the gallery, the design and location of the
oil spary nozzel and the quantity of oil flow-
ing in the gallery are critical in order to
achieve the desired temperature reduction.
The cross section shape of the gallery
should be designed to achieve sufficient oil
movement to maximize cooling efficiency.

-2-
1.3. Engine assembly

1.3.1. Engine sectional view (longitudinal)

2 3 4 5 6 7 8 9

10 11 12 13 14 15 16 17 18

EA8M1002

1. Cooling fan 7. Piston pin 13. Crankshaft

2. Exhaust valve 8. Piston 14. Oil pan
3. Valve spring 9. Combustion chamber 15. Connecting rod
4. Oil filter 10. Crankshaft pulley 16. Camshaft
5. Tappet 11. Vibration damper 17. Flywheel housing
6. Push rod 12. Oil pump 18. Flywheel

-3-
1.3.2. Engine sectional view (cross)

7 8 9

1 10

2
11
3
12

EA8M1003

1. Intake manifold 7. Injection nozzle assembly

2. Fuel filter 8. Rocker arm
3. Oil cooler 9. Cylinder head cover
4. Injection pump 10. Exhaust manifold
5. Cylinder block 11. Piston ring
6. Oil filter 12. Turbocharger

-4-
1.3.3. Engine assembly views

1) DE12T

1 2 3 12 4 27 13 18

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

-5-
 2) P126TI

1 2 3 4 5 12 13

7 6 8 9 10 11
14 15 16 17 18 19

24

22 25
23
20 21
EA8M1005

1. Cooling fan 8. Oil pan 18. Injection pipe

2. Cooling water pipe 9. Starter 19. Thermostat
3. Air pipe 10. Flywheel housing 20. Injection pump
(Intercooler Intake manifold) 11. Flywheel 21. Oil level gauge
4. Air pipe 12. Exhaust manifold 22. Mounting bracket
(Air cleaner Turbocharger) 13. Injection nozzle assembly 23. Vibration damper
5. Turbocharger 14. Oil filter 24. Water pump
6. Oil drain valve 15. Breather hose 25. Fan drive
7. Air pipe 16. Oil cooler
(Intercooler Intake manifold) 17. Intake manifold

-6-
1.4. Engine specifications

Engine Model DE12T P126TI P126TI-I

Items
Water-cooled, 4 cycle in-line Water-cooled, 4 cycle in-line
Engine type type
type Turbo charged Turbo charged & intercooled
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 (mm) 4 - 123 x 155
Total piston displacement (cc) 11,051
Compression ratio 17.1 : 1
Engine dimension (length x width x height) (mm) 1,365.5 x 870 x 1,046 1,383 x 870 x 1,207
Engine weight (kg) 910
Rotating direction (from flywheel) Counter clockwise
Fuel injection order 1-5-3-6-2-4
Fuel injection timing (B.T.D.C static) 12°
Injection pump type Zexel in-line “P” type
Governor type Mechanical governor type(RSV) Electric governor type(GAC)
Injection nozzle type Multi-hole type (5 hole) Multi-hole type (5 hole)
Fuel injection pressure (kg/cm )
2
220 1st : 160, 2nd : 220
Compression pressure (kg/cm )
2
28 (at 200 rpm)
50Hz 60Hz 50Hz 60Hz 60Hz
Condition (1,500rpm) (1,800rpm) (1,500rpm) (1,800rpm) (1,800rpm)
280PS 336PS
Continuous - - (206kW) (247kW) -
Power (ISO 3046)
205PS 245PS 328PS 378PS 356PS
Prime (151kW) (180kW) (241kW) (278kW) (262kW)
226PS 270PS 370PS 405PS 392PS
Stand by (166kW) (199kW) (272kW) (298kW) (288kW)
Intake and exhaust valve clearance (at cold) (mm) 0.3
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)
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 (max./min.) (lit) 23/20
Oil cooler type Water cooled
Water pump Gear driven impeller type
Cooling Method Pressurized circulation
Cooling water capacity (engine only) (lit) 19
Thermostat type Wax pallet type (83 ~ 95 °C)
Alternator voltage - capacity (V - A) 24 - 45
Starting Motor voltage - output (V - kW) 24 - 6.0

-7-
2. Major maintenance
2.1. Preventive maintenance
The preventive maintenance means that the operator performs the servicing of engine to
obtain long life and best performance from DAEWOO diesel engine.

2.1.1. Cooling water

• Regarding the cooling water that is to be used for engine, the soft water not the hard water
must be used.
• The engine cooling water can be used diluting it with antifreezing solution 40% and the addi-
tive for rust prevention (DCA4) 3 ~ 5 %.
• The density of above solution and additive must be inspected every 500 hours to maintain it
properly.

Note : The proper density control of antifreezing solution and rust preventing additive will be
able to prevent the rusting effectively and maintain the stable quality of engine.
For the improper control might give the fatal damage to the cooling water pump
and cylinder liners, detail care is needed.

• Since DE12T and POLUS P126TI (generator diesel engine of DE12 series) cylinder liner is
dry type, particularly the cooling water control should be applied thoroughly.
• The density of antifreezing solution and additive for rust prevention is able to be confirmed by
the cooling water test kit. (Fleetguard CC2602M)
• How to use the cooling water test kit
1) When the cooling water temp. of engine is in the range of 10 ~ 55 °C, loosen the plug for
cooling water discharge and fill the plastic cup about a half.

Note : In taking the cooling water sample, if the water in auxiliary tank were taken, it is hard
to measure the accurate density. Take the cooling water sample necessarily loosen-
ing the cooling water discharge plug.

2) At the state of a test paper soaked in the sampled water, after taking the paper out
through water agitation, shake off the water.
3) Wait for about 45 sec. till the color change of test paper.

Note : However, it should not elapse longer than 75 sec, and if it did, the hue would change.

-8-
 4) Make the numerical value by comparing the test paper which hue has changed with the
color list of label on storage bottle.
5) By comparing the hue changed into yellowish green or so with the green color indication
of test paper storage bottle, confirm the density. (Then, the density indication must be in
the hue range of 33% to 50%).
6) The brown at the middle of test paper and the lower pink color indication represent the
additive state for rust prevention, and the proper range is that the meeting numerical
value of brown (vertical) and pink color (horizontal) locates in the range of 0.3 to 0.8 at
the color list of label on the test paper storage bottle.
7) In case of less than 0.3, replenish the additive for rust prevention (DCA4), and in case of
more than 0.8, pour out the cooling water about 50% and then readjust the density after
refilling with clean fresh water.

• Amount of Anti-freeze in winter

Ambient
Cooling water (%) Anti-freeze (%)
Temperature (˚C)
Over -10 85 15
-10 80 20
-15 73 27
-20 67 33
-25 60 40
-30 56 44
-40 50 50

2.1.2. Fan belt

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

• Check the fan belt for belt tension.

If belt tension is lower than the specified limit, adjust the tension by relocating the alterna-
tor. (specified deflection: 10 ~ 15 mm when pressed down with thumb)

2.1.3. Engine oil

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

• Check the oil level with the engine cooled. If the engine is warm, allow time for 5 ~ 10
minutes for oil drain into the crankcase before checking oil level. The oil level must be
between Max and Min. lines on the gauge.
• Engine oil should be changed at the specified intervals. (800 hr) Oil in the oil filter should
be changed simultaneously.
- First oil change : 50 hr operating
• The oil viscosity grades should be selected SAE NO.15W40 and API CD or CE.

-9-
2.1.4. Oil filter

• Check for oil pressure and oil leaks, and

repair or replace the oil filter if neces-
sary.
• Change the oil filter cartridge simultane-
ously at every replacement of engine oil.

Oil filter (Cartridge)

Oil filter head

EQM4010I

2.1.5. Fuel filter

• Drain water in cartridge with loosening

the cock under filter manually (6) from
1
time to time.
• The fuel filter should be replaced at 3
every 1,200 hours.
4 5
2

6 EA2O4009

2.1.6. Air cleaner

• In case that elements are deformed,

damaged or if the air cleaner has a
crack, replace it.
• By the definite interval, the elements
must be cleaned and replaced.

EFM1002I

- 10 -
2.1.7. Intercooler

The intercooler is air to air type and has a large cooling fan capacity. The intercooler life
and performance depends on the intake air condition greatly. Fouled air pollutes and clogs
the air fins of intercooler. As a result of this, the engine output is decreased and engine
malfunction is occurred. So you always check whether the intake air systems like air filter
element are worn or polluted.

Air/air intercooler
with downstream
radiator
(Combined radiator)

Cooling air

Hot charge air

from compressor

Recooled charge air

to intake pipe (max. 50 C)

EA5O4003

- Cleaning of intercooler fins: Every 600 hours.

2.1.8. Valve clearance adjust procedure

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

• Loosen the lock nuts of rocker arm adjusting screws and push the feeler gauge of specified
value between a rocker arm and a valve stem and adjust the clearance with adjusting screw
respectively and then tighten with the lock nut.

- 11 -
• As for the valve clearance, adjust it when in cold, as follow.

Model Intake Valve Exhaust Valve

DE12T
0.3 mm 0.3 mm
P126TI

- 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. Cooling Fan

1 2 3 4 5 6

EA8O6001

- 12 -
2.1.9. Cylinder compression pressure

• Stop the engine after warming up, and

take out nozzle holder assembly.

EA9O5003

• Install the special tool (compression

gauge adapter) at the nozzle holder
hole, and connect the compression pres-
sure gauge there.

Standard value 28kg/cm2 over

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

• Condition : Water temperature 20˚C,

Engine rotation 200rpm (10 rotation)

2.1.10. Injection nozzle

EFM1006I
Normal Abnormal Abnormal

• IInstall a nozzle on the nozzle tester.

• If the inspected injection pressure is less than the specified value, adjust using the adjust-
ing shims.

Engine Model DE 12T P126TI

1st : 160kg/cm2
Injection nozzle pressure 220kg/cm2
2nd : 220kg/cm2

• Check the atomizing state and repiace it if abnormal.

- 13 -
2.1.11. Fuel injection pump

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

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

2.1.12. Battery

• Inspect for any leakage of electrolytic solution owing to battery crack, and replace the bat-
tery in case of poor condition.
• Inspect for amount of electrolytic solution, and replenish if insufficient.

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

1,100
1,200
1,300 UPPER LEVEL
LOWER LEVEL

EFM1007I

2.1.13. Air removal of fuel system

The suction room of fuel injection pump has the function of air removal continuously during the
operation through a relief valve.
In case that the suction room lacks fuel at all, for instance, in case of new installation of
injection pump, after loosening the air removing screws of cartridge filter respectively,
remove the air by operating the manual pump of fuel supply pump until bubble will disappear.

2.1.14. Fuel supply pump

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

- 14 -
2.1.15. Supercharger

The supercharger needs not arty special equipment

Every time of engine replacement, a leakage or clogging of oil pipes should be inspected.
Air cleaner should be maintained carefully for nut or foreign material not to get in. Periodic
inspection should be applied on the compressed air and exhaust gas pipes, For leaking air
will bring the overheat engine, an immediate repair must be done.
During the operation that is surrounded by the dust and oil mixed air, frequent cleaning
must be done on the impellers. Tear down the impeller casing (attention: be careful not to
bend) and must clean with non-acid solvent solution. If necessary, use plastic scraper If
impeller is severely polluted, dip the impeller into solution and may be better to clean it with
stiff brush.
Then one thing to beware is to dip only impeller part and so do not support by impeller but
bearing housing.

2.1.16. Starting motor

In case of engine maintenance, clean pinion and ring gear thoroughly putting in the fuel, and
coat them with grease.
Also, In case of washing car and so forth, inspect the wiring state being careful for not to
get.

- 15 -
2.2. Diagnosis and remedy

1. Engine Starting Impossible

Starting motor operation poor Starting motor revolution

Inspection of battery electorlytic 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

- 16 -
 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 Repair
Damage
radiator Replace

Check cooling Repair

Normal
water pump Replace

Clean cooling
Normal
water passage

Engine
disassembly

- 17 -
 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

- 18 -
 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

- 19 -
 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.)

- 20 -
 6. Oil Consumption Excessive

Cause according to use conditions

1. Excessive oil infusing
2. Continuous operation in low or
extremely cold state

Inspect oil leakage

Inspect air cleaner

Normal Oil leakage Clean Replace

Check oil quality External Internal

Replace with Retighten Check compressed

specified oil Replace pressure

Engine disassembly Normal

(piston cylinder liner)

Disassemble
cylinderhead
(valve stem seal)

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

- 21 -
 8. Battery Discharge

Battery Wiring Switch Generator

Check electrolytic Inspect cut wire Check fan belt

liquid amount shorts and loose tension & damage
connections

Repair Replace

Normal

Electrolytic Battery room Battery self Battery over

liquid's damage discharge charging
standard
Inspect generator
Replenish Replace Charging Voltage regulator

Normal Abnormal

Check charged stated Adjust

Replace

Discharging

Disassemble
generator Voltage
regulator

- 22 -
 Condition Causes Remedies

1) Starting difficult • Valve’s 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 • Valve tightness poor Repair
insufficient • 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 Adjust or replace

improper or stuck

• 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 • Compression pressure Disassemble engine

when in acceleration insufficient
• Injection timing incorrect Adjust
• Fuel injection amount insufficient Adjust injection pump
• Injection pump timer’s function Repair or replace
insufficient
• Nozzle infection pressure, infection Repair, replace
angle improper
• Supply pump’s function lowered Repair or replace
• Air intake amount insufficient Clean or replace air

4) Overheating • Engine oil insufficient or poor Replenish or replace

• Cooling water insufficient Replenish or replace

• Fan belt loosened, worn, damaged Adjust or replace

• Cooling water pump’s function lowered Repair or replace

• Water temp. regulator’s operation poor Replace

• Valve clearance incorrect Adjust

• Exhaust system’s resistance clean or replace

increased

- 23 -
 Condition Cause Remedies

5) Engine noisy For noises arise compositely such asrota

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

(1) Crankshaft • As the wear of bearing or crankshaft Replace bearing &

progress, the oil clearances increase. grind crankshaft

• Lopsided wear of crankshaft Grind or replace

• Oil supply insufficient due to oil Clean oil passage

passage clogging

• Stuck bearing Replace bearing &

Grind

(2) Con rod and • Lopsided wear of con rod bearing Replace bearing
Con rod bearing • Lopsided wear of crank pin Grind crankshaft

• Connecting rod distortion Repair or replace

• Stuck bearing Replace &

grind crankshaft

• Oil supply insufficiency as clogging Clean oil passage

at oil passage progresses

(3) Piston, piston pin & • Piston clearance increase as the wear Replace piston &
piston ring of piston and piston ring progresses piston ring

• Wear of piston or piston pin Replace

• Piston stuck Replace piston

• Piston insertion poor Replace piston

• Piston ring damaged Replace piston

(4) Others • Wear of crankshaft, thrust bearing Replace thrust

bearing

• Camshaft end play increased Replace thrust plate

• Idle gear end play increased Replace thrust

washer

• Timing gear backlash excessive Repair or replace

• Valve clearance excessive Adjust valve

clearance

• Abnormal wear of tappet, cam Replace tappet, cam

• Supercharger inner part damaged Repair or replace

6) Fuel Consumption • Injection timing incorrect Adjust

Exttive • Fuel injection amount excessive Adjust injection
pump

- 24 -
 Condition Cause Remedies

7) Oil Consumption
Excessive
(1) Oil level elevated • Clearance between cylinder iner & Replace
piston

• Wear of piston ring, ring groove Replace piston,

piston ring
• Piston ring’s damage, stick, wear Replace piston ring
• Piston ring opening’s disposition Correct position
improper
• Piston skirt part damaged or Replace piston
abnormal wear
• 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 parts’ packing poor Replace packing
• Oil seal poor Replace oil seal

- 25 -
2.3. Engine inspection

2.3.1. Stopping Engine

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

2.3.2. General Engine inspection cycle

: Check & adjust : Replace

Every Every Every Every Every

Inspection Daily Remark
50hrs 200hrs 600hrs 800hrs 1200hrs
Check for leakage(hoses, clamp)
Check the water level
Cooling Change the coolant water
System Every
Adjust the V-belt tension 2,000hrs
Clean the radiator
Check for leakage
Check the oil level gauge
Lubrication
Change the lubricating oil 1st
System

Replace the oil filter cartridge

1st
Check the leakage for intercooler
(hoses, clamp)
Intake & Clean and change
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 Replace the fuel filter element
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

- 26 -
2.3.3. Use of original parts for repair and replacement

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

- 27 -
3. Disassembly and reassembly of major components
3.1. Disassembly

3.1.1. General precautions

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

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

3.1.2. Cooling water

• Remove the radiator cap. Open the drain

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

CAUTION : When removing radiator

filler cap while the engine is
still hot, cover the cap with a
rag, then turn it slowly to
release the internal steam
pressure This will prevent a
person from scalding with
hot steam spouted out from
the filler port.
Drain Valve
EA5O4002

• Remove the drain plug from the cylinder

block and drain out the cooling water into a
container.

EQM3002I

- 28 -
3.1.3. Engine oil

• Take out the oil dip dipstick.

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

Drain valve
EA8O5001

3.1.4. Alternator belt

• Loosen the tension adjusting nut installed

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

EA8M3001
3.1.5. Cooling fan

• Remove the flange fixing bolts, then take

off the flange and cooling fan.

EQM3004I
3.1.6. Alternator

• Remove the alternator fixing bolt and dis-

assemble the alternator.
• Remove the tension adjusting bolt and
bracket.

- 29 -
3.1.7. Oil level gauge guide tube

• Loosen the flange nut installed on the oil

pan to remove the guide tube.

EQM3005I

3.1.8. Fuel filter

• Remove fuel hoses connected to the fuel

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

EA8M3013

3.1.9. Breather

• Loosen the clamp screw to remove the

rubber hose.

3.1.10. Intercooler

• Tear down the various hoses and air

pipes from the inter cooler.
• Remove the intercooler fixing bolts and
tear it down.

EA6M2001

- 30 -
3.1.11. Injection pipe

• Unscrew the hollow screws to disassem-

ble the fuel return pipe.
• Remove the nuts installed on the fuel
injection pump and nozzles, then disas-
semble the injection pipe.

EQM3009I

3.1.12. Intake manifold

• Remove the air hose connected to the

fuel injection pump.
• Loosen the intake manifold fixing bolts,
then disassemble the intake manifold.

EQM3011I

3.1.13. Turbo charger

• Release the clamp screw of the rubber

hose connected to the intake manifold,
and take off the intake pipes both simul-
taneously.
• Unscrew the exhaust pipe bracket fixing
bolts, release the nuts installed on the
turbocharger, then disassemble the
exhaust pipe.
• Remove the turbocharger after removing
the oil supply pipe and return pipe and
releasing the fixing nuts.

- 31 -
3.1.14. Exhaust manifold

• Release the exhaust manifold fixing

bolts, disassemble the exhaust manifold,
then remove the heat shield and gasket.

NOTE : Make sure to release the nuts

one after another because the
exhaust manifold will be
removed if you unscrew two
nuts simultaneously.

3.1.15. Thermostat

• Remove the by-pass pipe connected to

the water pump, unscrew the thermostat
fixing bolts, then disassemble the ther-
mostat housing.
• Disassemble the thermostat housing and
remove the thermostat.
• Disassemble the water pipe by unscrew-
ing the bolts and nuts installed on the
cylinder head.
EAMD014I

3.1.16. Starter

• Unscrew the starter fixing bolts, then dis-

assemble the starter.

EAMD017I

- 32 -
3.1.17. Water pump

• Remove the water pipe connected to the

expansion tank.
• Remove the water pipe and hoses con-
nected to the water pump.
• Unscrew the water pump fixing bolts and
remove the water pump.

3.1.18. Injection pump

• Remove the oil supply pipe and return

pipe connected to the fuel injection pump.
• Unscrew the bolts connecting the cou-
pling and drive shaft, loosen the injection
pump attaching bolts, then disassemble
the injection pump.

NOTE : As far as possible, place the

No.1 cylinder in ‘OT’ position to
disassemble the injection pump. EAMD021I

• Release the pump fixing bracket bolts to

disassemble the bracket from the cylin-
der block.

NOTE : Do not interchange the shims as

they must be installed in their
original positions at reassembly.

EAMD022I

3.1.19. Oil filter

• Using a filter remover wrench, remove

the oil filter cartridge.
• Remove the pipe connected to the oil
cooler.
• Loosen the oil filter fixing bolts and dis-
assemble the oil filter head from the
cylinder block.

- 33 -
3.1.20. Fan drive pulley

• Remove the bolts and disassemble the

fan drive pulley.

3.1.21. Vibration damper

• Unscrew the pulley fixing bolts and dis-

assemble the pulley-vibration damper
assembly.
• Unscrew the vibration damper fixing
bolts and disassemble the damper from
the pulley.

3.1.22. Timing gear case cover

• Disassemble the oil seal using an oil seal

removing jig.
• Remove the cover fixing bolts and disas-
semble the cover from the timing gear
case.

EAMD025I
3.1.23. Idle gear

• Unscrew the idle gear fixing bolts and

disassemble the thrust washer and idle
gear.
• Disassemble the idle gear pin using a
rubber hammer to prevent damage to
them.

- 34 -
3.1.24. Fuel injection pump drive assembly

• Unscrew the injection pump drive shaft

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

EAMD027I
3.1.25. Cylinder head cover

• Unscrew the cover fixing bolts and dis-

assemble the cover.
• Keep the bolts in an assembly state so
that the packings and washers may not
be lost, and keep the cover packing as
assembled with the cover.

EAMD028I
3.1.26. Rocker arm assembly

• Unscrew the rocker arm bracket bolts

and remove the rocker arm assembly.
• Take off the snap rings to remove the
washers and rocker arm, then unscrew
the bracket fixing bolts to take off the
bracket and springs.
• Take out the push rods.

EAMD029I

3.1.27. Injection nozzle

• Remove the nozzle fixing nuts and

extract the nozzles.
• Remove the nozzle tube using nozzle
tube removing jig.

Do not perform disassembly operation

unless coolant, gas, etc. leak out.

EAMD030I

- 35 -
3.1.28. Cylinder head

• Unscrew the cylinder head fixing borts

and take off the cylinder head.
• Remove the cylinder head gasket.

EAMD031I

3.1.29. Valve and valve stem seal

• Compress the valve spring retainer using

a jig and take off the valve cotter pins.
• Disassemble the valve springs and
retainers.
• Take off the valves.
• Remove and discard the valve stem seal
Valve spring
using a general tool as it should not be compressor
re-used.

EA0M4007

3.1.30. Oil cooler

• Remove the water pipe connected to the

water pump.
• Remove the oil pipe connected to the
cylinder block.
• Unscrew the oil cooler cover fixing bolts
and disassemble the oil cooler assembly
from the cylinder block.
• Unscrew the oil cooler fixing bolts and
remove the oil cooler from the oil cooler
EAMD033I
cover.

- 36 -
3.1.31. Oil pan

• Stand the engine with the flywheel hous-

ing facing the bottom.
• Release the oil pan fixing bolts, remove
the stiffeners then disassemble the oil
pan.

EAMD034I
3.1.32. Oil pump and oil pipe

• Unscrew the oil suction pipe bracket

bolts, releasing the pipe fixing bolts, then
disassemble the oil suction pipe assem-
bly.
• Disassemble the oil pipe feeding oil from
the oil pump to the cylinder block.
• Unscrew the oil pump fixing borts and
disassemble the oil pump.

EAMD035I

3.1.33. Relief valve

• Disassemble the relief valve.

EAMD036I

3.1.34. Piston and connection rod

• Disassemble the pistons by two cylin-

ders while turning the crankshaft.
• Unscrew the connecting rod fixing bolts
and take off the pistons and connecting
rods in the direction of piston.

EAMD037I

- 37 -
 • Remove the piston pin snap rings, take
off the piston pin, then disconnect the
connecting rod from the piston.

• Disassemble the piston rings using ring

pliers.

• Use care not to interchange the disas-

sembled parts and keep them in the
sequence of cylinder No.

3.1.35. Cylinder liner

• Disassemble the cylinder liner using a

liner puller.

EAMD040I
3.1.36. Flywheel

• Position the engine so that the head

installing surface of the cylinder block
faces down.
• Unscrew the flywheel fixing bolts and fit
a dowel pin.
• Install flywheel disassembling bolts in
the bolt holes machined on the flywheel,
and disassemble the flywheel.

EAMD041I

- 38 -
3.1.37. Oil seal

• Take off the rear oil seal using an oil seal

disassembling jig.
• If only the inside guide ring is removed,
use a special tool to take off the outside
seal.

3.1.38. Flywheel housing

• Loosen the housing fixing bolts disas-

semble the flywheel housing.

EAMD043I

3.1.39. Cam shaft and tappet

• Remove the cam shaft gear.

• Take off the cam shaft gear thrust washer.
• Take out the cam shaft using care not to
damage the cam shaft.
• Slide out the tappets by hand.

EAMD044I
3.1.40. Crankshaft gear and oil pump idle gear

• Loosen the socket head bolts and take

out the oil pump idle gear.
• Use a puller to remove the crankshaft
gear.

- 39 -
3.1.41. Timing gear case

• Unscrew the case fixing bolts and disas-

semble the timing gear case.

EAMD046I

3.1.42. Crankshaft

• Remove the bolts from bearing caps.

• Remove the main bearing cap fixing
bolts in the order of assembling.
• (Remove them in the same way of the
cylinder head bolts.)
• Maintain the removed bearing caps in
the order of cylinders.
• Temporarily install the bolts at the both
side of crankshaft, and lift the shaft with
EAMDO47S
a rope.

NOTE : Do not mingle with the metal

bearings and bearing caps ran-
domly. To prevent mixing, tem-
porarily assemble the metal
bearings to the corresponding
bearing caps in turn.

3.1.43. Oil spray nozzle

• Unscrew the fixing bolt and remove the

oil spray nozzles.

- 40 -
3.2. Inspection

3.2.1. Cylinder block

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

3.2.2. Cylinder head

1) Inspection

• Carefully remove carbon from the lower lace of the cylinder head using nonmetallic mater-
ial to prevent scratching of the valve seat faces.
• Check the entire cylinder head for very fine cracks or damage invisible to ordinary sight
using a hydraulic tester or a magnetic flaw detector.

2) Distortion at the lower face

• Measure the amount of distortion using
(t)
a straight edge and a feeler gauge at six
positions (A ~ F) as shown in the right
B
figure. A
• If the measured value exceeds the stan- C
D
dard value, retrace the head with grind-
ing paper of fine grain size to correct
E
such defect.
F
• If the measured value exceeds the max- EA3M2031
imum allowable limit, replace the cylin-
der head.

Lower face warpage and height

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

EA6M2002

- 41 -
 3) flatness
Measure flatness of the intake/exhaust
manifolds fitting surfaces on the cylinder
head using a straight edge and a feeler
gauge.

Standard Limit
0.05 mm 0.2 mm

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

3.2.3. Valve and valve guide

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

• Valve stem outer diameter

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

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

• Valve seat contacting faces

Check the valve seat contacting faces for
scratches or wear, and correct the faces
with grinding paper as necessary.
Replace if severely damaged.

- 42 -
 • Valve head thickness
Measure the valve head thickness, and
replace the valve if the measured value
is beyond the limit.

Dimension
Standard Limit
Description
Intake valve 1.5 mm 1 mm or less
Exhaust valve 1.5 mm 0.9 mm or less

EFM2037I

2) Valve guide

• Install the valve into the valve guide and

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

EA0M4052

Valve stem end play

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

• Install the valve into the cylinder head

valve guide, then check and see if it is
centered with the valve seat using a spe-
cial tool.

- 43 -
3) Valve seat

• Contacting face amount

Measure the contacting face between
the intake valve seat and exhaust valve
seat for valve seat wear, and replace if
the measured value exceeds the speci-
fied limit.
• Install the valve into the valve seat on
the cylinder head, and check the amount
of depression of the valve from the lower
portion of the cylinder head using a dial
gauge.

Valve depression

Standard Limit
Intake & EA0M4046
Exhaust 0 ~ 0.3 mm 0.55 mm

If the amount of depression is beyond the

specified limit, replace the valve seat.

• For removal of the valve seat, apply arc

welding work to two points of valve seat
Valve seat
insert, and pull out the valve seat insert insert
with inner extractor.

Cylinder head

Welding bead
EA3M2032

• Undercool a new valve seat with dry ice

for about 2 hours and press the valve
seat insert into position in the cylinder
head using a special tool (bench press).
• Apply valve lapping compound to the
valve head seating face on the valve
seat and lap the valve seat by turning it
until it is seated in position, then wipe out
the lapping compound.

- 44 -
 4) Valve spring

• Visual check
Visually check the exterior of the valve
springs for damage, and replace if nec-
essary.

• Functional check
- Measure free length and spring tension
with a valve spring tester.
1.0mm or less
(Refer to appendix)
- Measure the spring inclination with a

Free length
square.
- Compare the measured value with the
standard value to determine whether to
replace or repair.

EFM2039I
Standard Limit
Valve spring
inclination 1.0 mm 2.0 mm

3.2.4. Rocker arm shaft assembly

1) Rocker arm shaft

• Rocker arm shaft run-out

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

EDM2037I
Limit 0.2 mm

- 45 -
 • Rocker arm shaft diameter
With an outside micrometer, measure
the rocker arm shaft diameter at the
point where the rocker arms have been
installed.
Replace the rocker arm if the amount of
wear is beyond the specified limit.

Standard Limit
EA8M3002
23.978 ~ 23.959 mm 23.75 mm

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

• Diameter of the rocker arm bushing

Measure the inside diameter of the rock-
er arm bushing with an inside microme-
ter or vernier calipers, and compare the
measured values with the rocker arm
shaft diameter. If the clearance exceeds
the limit, replace either bushing or shaft,
whichever worn more.
<Clearance>
EA0M4059

Standard Limit
0.020 ~ 0.093 mm 0.2 mm

3) Tappet and push rod

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

Standard Limit
0.035 ~ 0.077 mm 0.15 mm

- 46 -
• Visual check of tappet
Visually check the face of the tappets in
contact with the cam for pitting, scores or
cracks, and replace if severely damaged.
If the amount of cracks or pitting is small,
(1) Unevenness (2) Crack (3) Normal
correct with an oil stone or grinding
paper.

(4) Abnormal
EA0M4070

• Outside diameter
With an outside micrometer, measure
the tappet outside diameter If the mea-
sured value is beyond the limit, replace
tappets.

Tappet Dia 19.944 ~ 19.965 mm

Standard Limit

Tappet EDM2061I
0.035~0.077mm 0.15mm
Clearance

• Push rod run-out

Limit 0.3 mm or less

Use a feeler gauge to measure the push

rod run-out.
Roll the push rod along a smooth flat sur-
face as shown in the figure.

Feeler gauge
EA0M4073

- 47 -
3.2.5. Cam shaft

1) Cam

• Cam lobe height

Standard Limit

Cam lobe height Intake 50.50~ 50.70 mm

49.5 mm
(C) Exhaust 50.70~ 50.90 mm
Cam journal diameter(A,B) 59.86~ 59.8 mm 59.52 mm

I II I II
Use a micrometer to measure the cam A

C B B
lobe height and journal diameter. D A

If the measured number is less than the EA0M4062

specified limit, the camshaft must

replaced.

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

2) Cam shaft
• Clearance between camshaft journal
and camshaft bush
- With an outside micrometer, measure
the camshaft journal diameter.
- Measure the inside diameter of the
camshaft bushing on the cylinder block Camshaft bearing
using a cylinder bore indicator, and
compare the measured value with the
camshaft outside diameter to deter-
mine the clearance.

<Clearance>

Standard Limit EA0M4063

0.050 ~ 0.128 mm 0.2 mm

Replace the bushing if the measured

value is beyond the specified limit.

- 48 -
 • Run-out
Support the camshaft on two V blocks
and check for run-out using a dial indi-
cator. Correct or replace the cam shaft if
the amount of run-out is beyond the
value indicating need for servicing.

Standard Limit
0.05 mm 0.2 mm

EA0M4066

3) Cam shaft end play

• Push the thrust plate toward the cam
gear.

• With a feeler gauge, measure the clear-

ance between the thrust plate and
camshaft journal.
• If the end play is excessive, replace the
thrust plate.

Standard Limit
0.13 ~ 0.27 mm 0.2 mm

EA0M4067

3.2.6. Crank shaft

1) Defect check

• Visually check the crankshaft journal and

crank pins for scores or cracks.
• Using a magnetic particle test and color
check, inspect the crankshaft for cracks,
and replace the crankshaft which has
cracks.

- 49 -
2) Wear

• With an outside micrometer measure the

diameter of the crankshaft journals and
pins in the directions as shown, and
compare the measured values to deter-
mine the amount of wear.
• If the amount of wear is beyond the limit,
have the crankshaft ground and install
undersize bearings. However, if the
amount of wear is within the limit, you
can correct the wear using an oil stone or
oiled grinding paper of fine grain size.
(Be sure to use grinding paper which has
been immersed in oil.) A

B B
Standard Limit
Journal diameter 95.966 ~ 95.988 mm 94.966 mm B B

Pin diameter 82.966 ~ 82.988 mm 81.966 mm

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.

Note : When regrinding the crankshaft

as described below, the fillet sec- "R"
tion ‘R’ should be finished cor-
rectly. Avoid sharp corners or
insufficient fillet. "R"

* Standard values of ‘R’

"R" "R" "R"
1 Crankshaft Pin ‘R’: 4.5
2 Crankshaft journal ‘R’: 4
EFM2048I

- 50 -
 3) Crankshaft run-out

• Support the crankshaft on V blocks.

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

Standard Limit
0.05 mm 0.1 mm

3.2.7. Crank shaft bearing and connection

rod bearing

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

2) Oil clearance between crankshaft and

bearing.
• Main bearing clearance
Install the main bearing in the cylinder
block, tighten the bearing cap to speci-
fied torque, then measure the inside
diameter.

Torque 30 kg•m

Standard Dia. 96.06~ 96.108 mm

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>

Standard Limit
0.072 ~ 0.142 mm 0.25 mm

- 51 -
 • Connecting rod bearing clearance
Install the connecting rod bearing in the
connecting rod bearing cap, tighten the
connecting rod cap bolts to the specified
torque, then measure the inside diame-
ter.

Torque 28 kg•m

Standard Dia. 83.02~ 83.092 mm

Compare the two values obtained

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

Standard Limit
0.049 ~ 0.119 mm 0.20 mm

EAMD060I

• If the clearance deviates from the

specified range, have the crankshaft
journals and pins ground and install
undersize bearings.

3) Bearing spread and crush

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

OA OB

Spread = O A - O B

EDM2047I

- 52 -
 • Crankshaft bearing crush
Install the bearing and cap in the cylinder
block, retighten the bolts to specified
torque, unscrew out one bolt completely,
then measure the clearance between the
bearing cap and cylinder block using a
feeler gauge.

Standard Dia. 0.15 ~ 0.25 mm

EA6M063I

• Connecting rod bearing crush

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

Standard 0.086 ~ 0.116 mm

EA6M064I

4) crank shaft end play

• Assemble the crankshaft to the cylin-
der block.
• With a dial gauge, measure crankshaft
end play.

Standard Limit
0.15 ~ 0.325 mm 0.5 mm

- 53 -
3.2.8. Piston

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

2) Clearance between the piston and

cylinder liner
• With an outside micrometer, measure
the piston outside diameter at a point
18mm away from the lower end of pis-
ton skirt in a direction at a right angle to
the piston pin hole.

Standard 122.854 ~ 122.886 mm

• Using a cylinder bore gauge, measure

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

Standard Limit
123 ~ 123.023 mm 123.223 mm

• The clearance is computed by sub-

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

Clearance between piston and liner

Standard 0.114 ~ 0.169 mm

- 54 -
3.2.9. Piston rings

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

2) Piston ring gap

• Insert the piston ring into the upper por-
tion 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 feel-

er gauge.

Standard Limit
Top ring 0.30 ~ 0.45 mm 1.5 mm
2nd ring 0.35 ~ 0.50 mm 1.5 mm
Oil ring 0.30 ~ 0.50 mm 1.5 mm

Replace piston rings with new ones if

the gap is beyond the limit

3) Piston ring side clearance

• Fit the compression ring and oil ring in

the piston ring groove.
Feeler gauge
• With a feeler gauge, measure side
clearance of each ring, and replace
either the ring or piston if the measured
value is beyond the specified limit.

Standard Limit
Top ring -
EA4M2007
2nd ring 0.07 ~ 0.102 mm 0.15 mm
Oil ring 0.05 ~ 0.085 mm 0.15 mm

- 55 -
 4) Piston ring tension

With a tension tester, measure piston ring

tension. Replace the piston ring if the
measured value is beyond the limit.

Standard
Top ring 2.27 ~ 3.41 kg
2nd ring 2.0 ~ 3.0 kg
Oil ring 4.03 ~ 5.57 kg

3.2.10. Piston pin

1) Wear

Measure the amount of wear on the pis-

ton pin at the points as shown. The mea-
sured values are beyond the limit (0.005
mm or greater), replace the pin

Standard Limit
44.995 ~ 45 mm 44.990 mm or less

EA0M4031

2) Clearance

Measure the clearance between the pis-

ton pin and connecting rod bushing, and
replace either of them, whichever dam-
aged more, if the measured value is
beyond the limit.

Limit 0.011 mm

EA3M2047

3) Condition check

Check the engaged condition of the pis-

ton and piston pin. If it is possible to force
the pin into the piston heated with piston
heater, the piston is normal. When replac-
ing the piston, be sure to replace the pis-
ton pin together.

- 56 -
3.2.11. Connecting rod

1) Distorsion

Check the connecting rod for distortion.

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

2) Holes alignment (parallelism)

Measure the alignment of the connecting

rod piston pin bushing holes with con-
necting rod big end holes. At this time
also, use both connecting rod tester and
feeler gauge.

Standard Limit
0.05 mm 0.1 mm or less EA0M4034

3) Wear
• Assemble the connecting rod to the
crankshaft and measure connecting
rod big end side clearance using a feel-
er gauge.
• Assemble the connecting rod to the
piston and measure connecting rod
small end side clearance.
• If the measured values are beyond the
limit, replace the connecting rod.

Limit 0.5 mm

- 57 -
3.3. Reassembly

3.3.1. General precautions

• Wash clean all the disassembled parts, particularly oil and water ports, using compressed air,
then check that they are free from restrictions.
• Arrange the general and special tools in order for engine assembly operation.
• To wet each sliding part, prepare the clean engine oil.
• Prepare service materials such as sealant, gaskets, etc.
• Discard used gaskets, seal rings, and consumable parts, and replace with new ones.
• Apply only the specified torque for bolts in the specified tightening order and avoid over-tight-
ening.
• Be sure to check that all the engine parts operate smoothly after being reassembled.
• Check the bolts for looseness after preliminary reassembly.
• After completing the engine reassembly operation, check if there is missing parts or shortage
of parts.
• Keep your hands clean during the working.

3.3.2. Cylinder block

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

3.3.3. Oil spray nozzle

Tighten and assemble the oil spray nozzle

flange with fixing bolts using the spray noz-
zle jig.

EDM3053I

3.3.4. Tappet and cam shaft

• Undercool a new bush with dry ice for

about 2 hours and press it into position in
the cylinder block using a bench press.
After the pressing operation, measure
the inside diameter of the cam bush to
check if it is not deformed.

- 58 -
 • Apply engine oil to the entire face of the
tappets and slide them into the tappet
holes on the cylinder block.

• Wet the cam bush inside diameter and

camshaft with oil, and carefully assem-
ble them while turning the camshaft.

• Check to see that the camshaft rotates

smoothly.

EDM2060I

3.3.5. Crankshaft

• Install the main bearing machined with

two holes in the cylinder block so that the Key groove
Oil port and passage
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

- 59 -
• Semi-tighten a bolt at both sides of the
crankshaft, apply engine oil to journals
and pins, then assemble the crankshaft
with the cylinder block by tightening the
fixing bolts.

• nstall the oiled thrust washers with the oil

groove facing outward.

• Install the bearing and thrust washers to

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

EAMD077I

• Install the bearing cap by matching the

cylinder block No. with the bearing cap
No.

7 6 5 4 3 2 1

EQM3058I

- 60 -
 • Apply oil to the entire part of the bearing
cap bolts, then tighten in tightening
sequence to specified torque.

Torque 30 kg•m

• After semi-tightening both bolts evenly,

tighten them diagonally to about 15kg.m
for the first stage and 25 kg.m for the EQM3059I
second stage respectively, then tighten
them completely to the specified torque
using a torque wrench.
• Tighten the bearing cap in the sequence
of 4-3-5-2-6-1-7.
• Check to see that the assembled crank-
shaft turns smoothly.

3.3.6. Flywheel housing

• Temporarily install the guide bar on the

cylinder block.
• Apply gasket to the cylinder block.

• Using the dowel pin and guide bar,

install the flywheel housing and tighten
the fixing bolts in a diagonal sequence
to specified torque.

Torque 12 kg•m
EQM3060I

3.3.7. Rear oil seal

• Apply lubricating oil to the outside of

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

- 61 -
3.3.8. Flywheel

• Install a guide bar into a bolt hole on the

crank shaft, and lift the flywheel to align
the dowel pin with the pin hole on the fly-
wheel for temporary assembly opera-
tion.
• 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 spec-
ified torque.

Torque 18 kg•m 4 8

6 1

2 5

7 3

EAMD097I

3.3.9. Timing gear case

• Mount gasket using dowel pin on the

cylinder block.
• Install the timing gear case by aligning
the dowel pin with the dowel pin hole on
the timing gear case.

EAMD082I

- 62 -
3.3.10. Fuel injection pump drive gear
assembly

• Mount gasket by aligning the bolt holes

with the pin holes on the bearing hous-
ing.
• Tighten up the fixing bolts in the direc-
tion of fuel injection pump.

EAMD027I

3.3.11. Timing gear

• Install the oil pump idle gear onto the

No.7 bearing cap.
• Install a thrust washer over the camshaft
and assemble the cam gear by aligning
Idle gear pin
it with camshaft key groove.

Torque 2.2 kg•m

EAMD083I

• With the oil port on the idle gear pin fac-

ing 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 gear,
Fuel injection Cam gear
and idle gear. pump drive gear 1 1
2 2
1
• Install a thrust washer on the idle gear 2
Idle gear
and tighten to specified torque.
Mark "1"
Torque 6.2 kg•m Crank
Mark "0"
gear
EA8M3005

- 63 -
 • Check and adjust the amount of back-
lash between gears using a feeler
gauge.

Backlash 0.15 ~ 0.25 mm

3.3.12. Timing gear case cover

• Install dowel pin on the timing gear case.

• Mount a gasket by aligning the fixing
bolt holes with those on the gasket.
• Align the dowel pin with the cover pin
hole, then install the cover with light tap.
• Tighten the fixing bolts beginning with
the oil pan fitting face.

3.3.13. Front oil seal

• Apply lubricating oil to the outside of the

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

Oil seal fitting jig

EAMD086I
3.3.14. Cylinder liner

• Stand the cylinder block so that the fly-

wheel 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.

- 64 -
3.3.15. Piston and connecting rod

• Use a piston heater to heat the piston

approximately 100 ˚C (212 ˚F) for 5 min-
utes.

• Align the piston pin hole with the oiled

connecting rod small end and press the
piston pin (by lightly tapping with a rub-
ber hammer) to assemble the connect-
ing rod with the piston.

EAMD088I

• Noting the direction of the piston, make

the longer side (machined with key
groove on the bearing) of the connecting
rod big end and the mark of ‘ ’
impressed on the inside of the piston
face each other in opposite directions.
106

On the piston head surface, the longer

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

• nstall the snap rings and check to see

that it is securely assembled.

• Install the piston ring in the piston using

piston ring pliers.

- 65 -
• Identify the mark “Y” or “TOP” on the
ring end to prevent the top and bottom of
the piston ring from being interchanged
and make the marked portion face
upward.

Marked with the name of piston ring

manulacturing company
EAMD090I

• Adjust the angle among individual piston

O O
ring gaps to 90( and fit a piston assem- 45 45
2nd ring gap Top ring gap
bling jig onto the piston, Use care not to
match the ring gaps with the pin direc-
tion.
O
90
• Install the bearing by aligning it with the
connecting rod key groove and apply oil Piston pin
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 rod EAMD092I

cap and apply oil.

• Make sure that the manufacture serial

numbers impressed on the connecting
rod cap and connecting rod big end are
identical, and install the connecting rod
cap by aligning it with dowel pin.
• Wet the fixing bolts with oil, semi-tight-
enthem with hand, tighten them to 15
kg.m for 1st stage and 22 kg.m for 2nd
stage respectively, and finally to speci-
fied torque.

Torque 28 kg•m

- 66 -
 • Move the bearing cap with hand, and
release and reassemble it if no move-
ment is detected.

EAMD094I

3.3.16. Relief valve

• Assemble the relief valve.

EAMD036I

3.3.17. Oil pump and oil pipe

• Install a dowel pin in the No.7 bearing

cap, then assemble the oil pump with
specified torque.

Torque 4.4 kg•m

• Assemble the oil suction pipe with the

delivery pipe, then install the bracket on
EAMD095I
the bearing cap.

- 67 -
3.3.18. Oil pan

• Mount gasket and put the oil pan there-

on.
• Place stiffeners and tighten bolts.

• Align the bolt holes with gasket holes to

prevent damage to the gasket and tight-
en to specified torque.

Torque 2.2 kg•m

EAMD034I

3.3.19. Intake and exhaust valves

• Identify the marks of “IN” and “EX”

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

• With a valve stem seal fitting jig, assem-

ble the valve stem seal with the valve
guide.

• After installing valve springs and spring

retainer, press the retainer with a jig,
then install cotter pin.
• Tap the valve stem lightly with a rubber
hammer to check that the valve is
assembled correctly.
Valve spring
compressor

EA0M4007

- 68 -
3.3.20. Nozzle tube

• Apply sealant (LOCTITE # 620) to the

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

• Install a guider of the nozzle tube insert

ass’y (Guider + Expander) the cylinder
head, then tighten the nozzle fixing nuts. Guider

EAMD098I

• Apply engine oil to an expander and

install it onto the special tool (guider). Expander

• Tighten the bolts until the expander is

forced out of the cylinder head bottom.

• After mounting the nozzle tube, make a EAMD099I

hydraulic test to check for water leaks.

Test pressure 2 kg/cm2

3.3.21. Cylinder head

• Install the injection nozzle fixing stud

bolts and water pipe fixing stud bolts.
• Clean the head bolt holes on the cylin-
der block with compressed air to remove
foreign substances and thoroughly
clean the gasket fitting face of the cylin-
der block.

- 69 -
• Install head gasket, with ‘TOP’ mark fac-
ing upward, on the cylinder block by
aligning the holes with dowels.

TOP

EAMD101I

• Check the inside of combustion cham-

ber for foreign substances, and carefully
mount the cylinder head assembly in the
block by aligning the dowel pin with the
dowel pin hole. Be careful not to dam-
age 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>

Type 1 Type 2

TY TY
12.9T 10.9T
Specification EAMD102I

M14x1.5x153 M14x1.5x150
Torque 24.5 kg.m 6 kg.m +180°+150°

8 2 3 9

12 13
1 4
11 14

7 6 5 10
EAMD103I

• Coat the push rod with engine oil and

insert it into the push rod hole.

- 70 -
• Adjust the valve clearance as following
guide.

<Guide for valve clearance adjustment>

After letting the #1 cylinder’s piston come at the compression top dead center by turning
the crankshaft, adjust the valve clearances.
Loosen the lock nuts of rocker arm adjusting screws and push the feeler gauge of specified
value between a rocker arm and a valve stem and adjust the clearance with adjusting screw
respectively and then tighten with the lock nut.

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

Model Intake Valve Exhaust Valve

DE12T
0.3 mm 0.3 mm
P126TI

- 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. Cooling Fan

1 2 3 4 5 6

EA8O6001

- 71 -
 • Adjust valve clearance with a feeler
gauge and tighten the fixing nuts to Valve clearance adjust
specified torque.

Torque 4.4 kg•m

EA8M3007
3.3.22. 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.

Torque 4.4 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

3.3.23. Injection nozzle

• Install the dust seal with its round portion

facing downward.
• Mount a seal ring (0.5 mm) on the seal
ring seating surface of the nozzle tube
and assemble nozzle holder assembly
with the stud bolt with the nozzle pipe
installing direction facing outward.

• Be sure to follow the specified torque.

EAMD105I
Torque 1.0 kg•m

- 72 -
3.3.24. Oil cooler

• Install the oil cooler onto the oil cooler

cover.
• Carefully apply the gasket to prevent oil
leakage.
• Do not damage the gasket and install
the cover onto the cylinder block.
• Connect a connection pipe between the
water pump and oil cooler.

EAMD106I
3.3.25. Oil filter

• Install the oil filter onto the cylinder

block, and tighten the fixing bolts.
• With the hollow screw, assemble the oil
pipe connected between the oil cooler
and cylinder block.
• Install a connection pipe between the oil
cooler and oil filter.
• Install the oil cooler connecting pipe.

• Install packing and assemble the car-

tridge using a filter wrench.

3.3.26. Injection pump

• Install the injection pump bracket in the

cylinder block.
• After measuring the amount of run-out
with an alignment setting jig, disassem-
ble the bracket, adjust the shims, then
reassemble it.

Run out 0.2 mm or less

EAMD107I

• Mount the top/bottom adjusting shims in

the bracket and then mount the fuel
injection pump.

• Tighten the fixing bolts in a diagonal

sequence to specified torque.

Torque 4.4 kg•m

- 73 -
• 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 show-
ing the notch mark of the right figure cor-
responding to the injection timing is
aligned with the pointer ( ) on the fly-
wheel housing.

DE12T P126TI
Fuel injection timing
(B.T.D.C static) 12° 12°

Injection timing Flywheel

notch mark ring gear

EA8O6002

• Turn the timer until the notch mark of the

indicator plate attached to the fuel injec-
Notch
tion pump is aligned with the notch mark mark
of the timer.

EA9O5002

- 74 -
 • 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.

3.3.27. Vibration damper end pulley

• Install the vibration damper on the

crankshaft pulley.
• Install the crankshaft pulley assembly on
the crankshaft, then tighten the bolts
and thrust washers.

Torque 13.4 kg•m

3.3.28. Fan drive pulley

• Install the fan drive pulley onto the tim-

ing gear case cover.

3.3.29. Water pump

• Mount a new O-ring.

• Install the water pump drive pinion over

the PTO (power take-off) spline.
• Connect water pipes and by-pass pipe
to the water pump.
• Connect a water pipe to the expansion
tank.

EAMD112I

- 75 -
3.3.30. Power take-off

• Assemble the power take-off sub assem-

bly.

EA8M3010

3.3.31. Exhaust manifold

• Install the exhaust manifold gasket over

the stud bolts by aligning the gasket with
the exhaust port on the cylinder head so
that the face and back of the gasket can
be positioned correctly.
• Semi-assemble the exhaust manifold
and install the heat resisting plate.
• First, install the nuts and then place an
additional nut on each of them to prevent
EQM3096I
looseness.

3.3.32. Turbocharger

• Fit a new gasket over the stud bolts of

the exhaust manifold before tightening
those turbocharger fixing bolts.
• Install the oil supply pipe and return pipe.

• Semi-assemble the bracket to the intake

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

EA8M3012

- 76 -
3.3.33. Starter

• Assemble the starter in position on the

flywheel housing.

EAMD121I

3.3.34. Intake manifold

• Fit a gasket on the intake manifold

before assembling the intake manifold.

EQM3011I

3.3.35. Injection pipe

• Semi-assemble a nut at both ends of the

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

Torque 13.4 kg•m

• Tighten hollow screws to assemble the

fuel return pipe.
• Assemble the fuel return hose on the fuel
EAMD120I
injection pump.

- 77 -
3.3.36. Fuel filter

• Assemble the fuel filter with the intake

manifold.
• Assemble the fuel feed hose according
to the direction of an arrow impressed on
the fuel filter head so that fuel can be fed
in the sequence of FUEL FEED PUMP
FUEL FILTER FUEL INJECTION
PUMP.

EA8M3013

3.3.37. Cylinder head cover

• Assemble the cover packing with the

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

Torque 1.5 kg•m

• Assemble the breather hose with PCV

valve.
EAMD126I

3.3.38. Alternator

• Install the alternator mounting bracket.

• Install the alternator with fixing bolts to

the mounting bracket.

- 78 -
3.3.39. Cooling fan

• Install the cooling fan and flange, then

tighten the fixing boltd.

EQM3106I

3.3.40. V- belt

• Install the V-belt on the crank pulley,

Press here
alternator pulley and fan drive pulley.
15mm
• Adjust the V-belt tension using the ten-
Alternator Fan
sion adjusting bolt. Pulley
Pulley

V-belt

Crank Pulley EA8O3005

3.3.41. Oil level gauge

• Assemble the oil level gauge and guide

tube on the oil pan.

EQM3005I

- 79 -
3.4. Breaking-in

3.4.1. Operation of a new engine (Break-In)

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

3.4.2. Check points for break-in

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

NOTE : If you have a problem getting a good oil level reading on dipstick, rotate dipstick
180( and re-insert for check.

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

NOTE : Oil pressure will rise as RPM increases, and fall as RPM decreases. In addition,
cold oil will generally show higher oil pressure for any specific RPM than hot oil.
Both of these conditions reflect normal engine operation.

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

<Engine Oil capacity>

Oil pan (only)

DE12T 23 liter
P126TI 23 liter

- 80 -
4. Maintenance of major components
4.1. Cooling system

4.1.1. General information

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

Thermostart Water pipe

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

Water pump Oil cooler

Air compressor
EQM4001I

• Specification
Item Specification
1. Water pump Centrifugal type
type
Delivery About 350 liter/min
Pumping speed 2,100 rpm
Pumping back pressure 760 mmHg
2. Thermostat
Operating temperature 83 ~ 95˚C
3. Cooling fan and belt
Fan diameter - Number of blades I755 - 7
Fan belt tension 15mm/ deflection by thumb

- 81 -
4.1.2. Water pump

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

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

Thickness 0.3 ~ 0.6

1
9
Par latex coating
11
4

5 13
10
7
12
8
11
14 13 12

EAMC001I

<Construction of water pump>

1.Water pump housing 8.Ball bearing 13.Spline shaft

4.Shaft 9.Space 14.Gasket
5.Mechanical seal 10.Ball bearing 15.Housing cover
6.Impeller 11.Bearing cover 16.Bolt
7.Oil seal 12.Socket bolt

- 82 -
4.1.3. Thermostat

• General descriptions and main data To radiator

The thermostat maintains a constant tem-
perature of coolant (90 ~ 95 ˚ C) and
improves thermal efficiency of the engine
by preventing heat loss.
Namely, when the temperature of coolant
is low, the thermostat valve is closed to Bypass
From cooling valve
make the coolant bypass to directly enter To bypass
water pump tube
the water pump; when the coolant temper-
EAMC002I
ature rises to open wide the thermostat
valve, the bypass circuit is closed and the
water passage to the radiator is opened so that the coolant is forced to flow into the radiator.

Item Specifications
Type Wax-pallet type
Open at 83 ˚C
Open wide at 95 ˚C
Valve lift 8 mm or more

• Inspecting
(1) Check the wax pallet and spring for
damage.
(2) Put the thermostat in a container of Bar
Temp. gauge
water, then heat the water slowly and
check temperature with a thermometer.
If the valve lift is 0.1 mm (starting to Wooden plate
open) at temperature of 83 ˚C and 8 mm
or more (opening wide) at temperature
of 95 ˚C, the thermostat is normal. EFM2055I

• Replacing thermostat and precautions for handling

(1) Precautions for handling
The wax pallet type thermostat does not react as quickly as bellows type one to a vari-
ation 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 start-
ing off.
(2) When draining out or replenishing coolant, do it slowly so that air is bled sufficiently
from the entire cooling system.
(3) Replacing thermostat
If the thermostat is detected defective, retrace with a new one.

- 83 -
4.1.4. Diagnostics and troubleshooting

Complaints Possible causes Corrections

1. Engine overheating • Lack of coolant • Replenish coolant
• Radiator cap pressure • Replace cap
valve spring weakened

• Fan belt loosened or • Adjust or replace fan belt

broken

• Fan belt fouled with oil • Replace fan belt

• Thermostat inoperative • Replace thermostat
• Water pump defective • Repair or replace
• Restrictions in water • Clean radiator and water
passages due to deposit passages
of scales

• Injection timing incorrect • Adjust injection timing cor

rectly

• Restriction in radiator • Clean exterior of radiator

core

• Gases leaking into water • Replace cylinder head

jacket due to broken cyli gasket
nder head gasket
2. Engine overcooling • Thermostat inoperative • Replace thermostat
• Ambient temperature • Install radiator curtain
too low
3. Lack of coolant • Radiator leaky • Correct or replace
• Radiator hoses loosely • Retighten clamps or
connected or damaged replace hoses

• Radiator cap valve spring • Replace cap

weakened

• Water pump leaky • Repair or replace

• Heater hoses loosely • Tighten or replace hoses
connected or broken

• Cylinder head gasket • Replace cylinder head

leaky gasket

• Cylinder head or cylinder • Replace cylinder head

block cracked block
4. Cooling system • Water pump bearing • Replace bearing
noisy defective

• Fan loosely fitted or bent • Retighten or replace fan

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

- 84 -
4.2. Lubricating system

4.2.1. General descriptions and main data

• General descriptions
All the engine oil pumped up from the oil pan by the gear type oil pump is filtrated through
the oil cooler and oil filter, and this filtrated oil is forced through the main oil gallery in the
cylinder block from where it is distributed to lubricate the various sliding parts, and fuel
injection pump in order to ensure normal engine performance.
• Specifications
Item Specifications Item Specifications
Lubricating system Forced pressure Oil filter type Full flow
circulation
Oil pump type Gear type Bypass for filter element
Relief valve opening pressure 10±1.5 kg•cm 2
Valve opening pressure 1.8 ± 2.3 kg•cm2
Bypass for oil cooler Bypass for entire oil filter
Opening pressure 5+1 kg•cm 2
Valve opening pressure 4.0 ~ 4.8 kg•cm2
Adjusting valve for spray nozzle
Opening pressure 1.5 ~ 1.8 kg•cm2

• 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 2bar

EQM4005I

- 85 -
4.2.2. 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 dri-

ven gear.

EQM4007I

• Inspection and correction

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

End play 0.025 ~ 0.089 mm

Steel plate

Feeler gauge

EQM4008I

(2) With a feeler gauge, measure the

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

Backlash 0.50 ~ 0.64 mm

EQM4009I

- 86 -
 (3) Measuring clearance between drive shaft and bushing
a. Measure the outside diameters of the drive shaft and driven shaft, and replace if the
measured values are less than the limit.

Standard 16.95 ~ 16.968 mm

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

Clearance 0.032 ~ 0.077 mm

• Reassembly

(1) For reassembly, reverse the disassembly sequence.

4.2.3. Oil filter

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

Oil filter (Cartridge)

Oil filter head

EQM4010I

- 87 -
4.2.4. Diagnostics and troubleshooting

Complaints Possible causes Corrections

1. Oil consumption • Poor oil • Use suggested oil

excessive • Oil seal or packing leaky • Replace
• Pistons or piston rings worn • Replace pistons and/or pis
ton rings

• Cylinder liner worn • Replace cylinder liner

• Piston rings sticking • Replace pistons and/or pis
ton rings

• Valve guide oil seals or valve • Replace

guides, or valve stem worn

2. Oil pressure too low • Poor oil • Use suggested oil

• Relief valve sticking • Replace
• Restrictions in oil pump • Clean strainer
strainer

• Oil pump gear worn • Replace

• Oil pump feed pipe cracked • Replace
• Oil pump defective • Correct or replace
• Oil pressure gauge defective • Correct or replace
• Various bearings worn • Replace
3. Oil deteriorates • Restriction in oil filter • Replace filter element
quickly • Gases leaking • Replace piston rings and
cylinder liner

• Wrong oil used • Use suggested oil

- 88 -
4.3. Fuel injection pump

4.3.1. General information of fuel system

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

1 2
4
3 7

8
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

- 89 -
4.3.2. Injection pump

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

1) DE12T

(1) Main data and specifications

Part No. : 65.11101-7222(106672-9920)
Model : NP-PE6P120/720RS3000(106061-7250)
Governor : NP-EP/RSV200-1200PD36C311(105407-4720)
Timer : without timer
Plunger : 12, right hand helix 30 lead
Delivery valve : 120 mm3/st( 8 x 2.4mm)
Fuel feed pump : NP-FP/K-P(105207-1400)
Pre-stroke : 4.7 mm
(2) Nozzle holder assembly : 65.10101-7300(105160-4351)
(3) Nozzle : 65.10102-6046(105029-1330)
(4) Injection pipe : 65.10301-7004B
(5) Injection order : 1-5-3-6-2-4
(6) Injection timing : BTDC 12˚C
(7) Calibration data

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

D - 100 193.5±10 -

Engine
Content Specification
Application
Adjusting Nozzle holder assembly 105780-8140 65.10101-7300
conditions Nozzle 105780-0000 65.10102-6046
Nozzle holder 105780-2080 -
Opening pressure 175 kg•cm 2
220 kg•cm2
Injection pipe 8x 3 - 600 mm 6x 2.2 - 650 mm
Fuel delivery pressure 1.6 kg•cm 2
-
Fuel temperature 35 ~ 45 ˚C 35 ~ 45 ˚C

- 90 -
(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

- 91 -
 2) P126TI
(1) Main data and specifications
Part No. : 65.11101 -7310 (106674-4130 ZEXEL)
Model : NP-PE6P120/700RS3S (106067-6020)
Governor : GAC electric (65.11501-7002A)
Plunger & barrel : 12, right hand double helix 30 lead
Delivery valve : 90mm2/st ( 7 x 2.35mm)
Fuel feed pump : NP-FP/KD-PS (105237-5470)
Pre-stroke : 3.9 ± 0.05 mm
(2) Nozzle holder assembly : 65.10101-7054 (10501-8520)
(3) Nozzle : 65.10102-6048 (105019-2450)
(4) Injection pipe : 65.10301-6042, 65.10301-6043
(5) Injection order : 1-5-3-6-2-4
(6) Injection timing : BTDC 12°

Nozzle & Holder Ass’y 105780-8130 Opening pressure : 175 kg•cm2

(A) Test condition
Injection pipe(ID ,OD ,L) - 3.0 x 8.0 - 600 mm
for injection pump
Test oil ISO4113 Temperature :40±5˚C
65.10101-7054 Nozzle (5 x 0.37)
Nozzle & holder Ass’y 1st pressure : 160 kg•cm2
(B) Engine standard 65.10102-6048
2nd pressure : 220 kg•cm2
parts
65.10301-6042
Injection pipe(ID, OD ,L) 2.2 x 6 - 600mm
65.10301-6043
Rack diagram and setting valve at each point

Injection Q’ty on RIG

Check Rack Pump (mm3 / 1,000 st) Press.
position speed
point (A) Test condition (B) Engine (mmHg)
(mm) (rpm)
Standby power for inj. pump standard parts
B 900 240±3 -
- - - - - -
- - - - - -
- - - - - -
- - - - - -

- 92 -
4.3.3. Governor system (P126TI)

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

(1) Integral Actuator

<Side View> <Top View>

- 93 -
Fig. No. Description Q’ty Remark

1 stop lever (emergency) 1

2 pump gasket 1

3 washer 4

4 allen screw 4 7 ~ 9 N.m

5 ball link 2 *

6 stop nut 2 3.5 ~ 4.0 N.m *

7 operating lever 1

8 oil seal 1

9 counter nut 1 4.5 ~ 6.0 N.m

10 stop screw 1

11 connector screw 4

12 mounting bar 1

13 flat washer 2

14 lock washer 2

15 nut 2 17 ~ 21 N.m

16 flat washer 2

17 lock washer 2

18 nut 2 7 ~ 9 N.m

19 threaded bolt (part of bearing kit) 2

20 actuator spring 1

21 gasket, lower cover 1

22 lower cover 1

23 washer 8

24 allen screw 6 2.0 ~ 3.0 N.m

25 receptacle 1

26 sealing screw 2 3.5 ~ 4.5 N.m

27 gasket, upper cover 1

28 flat washer 2
29 screw, ball link 2 *

30 connecting rod 1 *

31 nut 2 *

32 stop plate 1 *

33 top cover 1

34 manual stop device complete 1

* linkage complete 1

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

35 fixing screw 1 12.5 ~ 13.0 N.m

36 stop nut 1 12.5 ~ 13.0 N.m

- 94 -
(2) Speed control unit for governor system
The ESD5550 Series speed control unit is an all electronic device designed to control
engine speed with fast and precise response to transient load changes. This closed loop
control, when connected to a proportional electric actuator and supplied with a magnetic
speed sensor signal, will control a wide variety of engines in an isochronous or droop
mode. It is designed for high reliability and built ruggedly to withstand the engine environ-
ment.
Simplicity of installation and adjustment was foremost in the design. Non-interacting perfor-
mance controls allow near optimum response to be easily obtained.
The primary features of the ESD5550 Series speed control unit are the engine STARTING
FUEL and SPEED RAMPING adjustments. The use of these features will minimize engine
exhaust smoke experienced prior to attaining engine operating speed.
Other features include adjustable droop and idle operation, inputs for accessories used in
multi-engine or special applications, protection against reverse battery voltage, transient
voltages, accidental short circuit of the actuator and fail safe design in the event of loss of
speed sensor signal or battery supply.

Engine model P126TI

GAC governor model ACE 175A
Speed control unit model ESD5550

- 95 -
(A) Specification

PERFORMANCE
Isochronous Operation/steady State Stability ±0.25% or better
Speed Range/Governor ±1 K ~ 7.5 KHz continuous
Speed Drift with Temperature ±1% Maximum
Idle Adjust CW 60% of set speed
Idle Adjust CCW Less than 1,200 Hz.
Droop Range 1 ~ 5 % regulation*
Droop Adj. Max. (K-L Jumpered) 400 Hz ± 75 Hz per 1.0 A change
Droop Adj. Min. (K-L Jumpered) 15 Hz ± 6 Hz. per 1.0 A change
Speed Trim Range ± 200 HZ
Remote Variable Speed Range 500 ~ 7.5 Hz or any part thereof
Terminal Sensitivity
J 100 Hz ± 15 Hz/Volt @ 5.0 K Impedance
L 735 Hz ± 60 Hz/Volt @ 65 K Impedance
N 148 Hz ± 10 Hz/Vo1t @ 1 Meg. Impedance
P 10 VDC Supply @ 20 ma Max.
Speed switch adjustment range 1,000 ~ 10,000 Hz
ENVIRONMENTAL
Ambient Operating Temperature Range - 40 ˚F to 180˚F (- 40 ˚C to + 85 ˚C)
Relative Humidity up to 95 %
All Surface Finishes Fungus Proof and Corrosion Resistant
INPUT POWER
Supply 12 or 24 VDC Battery Systems
(Transient and Reverse Voltage Protected)**
Polarity Negative Ground (Case Isolated)
Power Consumption 50 ma continuous plus actuator current
Actuator Current Range Min.2.5 Amps/ Max. 10 Amps continuous ***
@ 77 ˚F (25 ˚C) -(Inductive Load)
Speed Sensor Signal 0.5 ~ 120 Volts RMS
Speed switch relay contacts (N.O. and N.C.) 10 Amps
RELIABILITY
Vibration 1G @ 20 ~ 100 Hz
Testing 100% Functionally Tested
PHYSICAL
Dimensions See Outline
Weight 1.8 lbs (820 grams)
Mounting Any Position, Vertical Preferred

Note :

* Droop is based on a speed sensor frequency of 4,000 Hz and an actuator current

change of 1 amp from no load to full load. Applications with higher speed sensor signals
will experience less percentage of droop. Applications with more actuator current
change will experience higher percentages of droop. See droop description for specific
details on operation of droop ranges.

** Protected against reverse voltage by a series diode. A 15 Amp. fuse must be Installed in
the positive battery lead,

*** Protected against short circuit to actuator (shuts off current to actuator), unit automati-
cally turns back on when shorts is removed.

- 96 -
 (B) Diagram

6.00 (152)
5.25 (133)
O 0.27 (7)

C1 OFF ON C2
LEAD CIRCUIT SOFT COUPLING
ON OFF

OVERSPEED
OVERNORS
GA MERICA 1 2 3 RESET TEST
C ORP
OVERSPEED
SPEED CONTROL UNIT

MODEL : ESD5550 SPEED

S/N
GAIN
MADE IN AGAWAM, MA U.S.A

STABILITY
6.05 (165)

6.00 (152)

STARTING SPEED
E2
FUEL RAMPING E1 E3
DEAD TIME
CAUTION
ENGINE SPEED CONTROL DROOP COMPENSATION
COMPONENT WHEN INSTALLING
OR SERVICING REFER TO
JUMPER
PRODUCT PUBLICATION

PICK-UP _ + IDLE
10V
ACTUATOR BATTERY
AUX OUTPUT
A B C D E F G H J K L M N P

OPTIONAL ACTUATOR ACCESSORY POWER 1.03 (26)

CABLE SHELDING TO SUPPLY
MEET CE DIRECIVE ACCESSORY INPUT
* ADD JUMPER FOR 12V
BATTERY OR ACTUATOR
ACTUATOR CURRENTS ABOVE 5A
CW GROUND REFERENCE
MAGNETIC
CLOSE FORDROOP
PICK-UP
SPED TRIM
_ CONTROL - 5K CLOSE FOR IDLE
+ S1
FUSE
BATTERY 15A MAX

SEE SPECIFIC ACTUATOR PUBLICATION FOR PROPER

* WIRING OF ACTUATOR BASED ON BATTERY VOLTAGE

EA6M4004

- 97 -
 Note :
* If wire leads are longer than 3 meters (10 ft), a shielded cable should be used. Ground
shield at ONE END ONLY.

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

Caution :

An overspeed shutdown device, independent of the governor system, should be provided

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

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

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

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

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

- 98 -
 (D) System Trouble shooting

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

Step Terminals Normal Reading Probable Cause Of Abnorma Reading

1 F(+) & E(-) Battery supply voltage 1. DC battery power not connected. Check
(12 or 24 VDC) for blown fuse
2. Low battery voltage.
3. Wiring error.
2 C&D 1.0 VAC RMS min., 1. Gap between speed sensor and gear teeth
while cranking too great. Check gap.
2. Improper or defective wiring to the speed
sensor. Resistance between terminals C
and D should be 30 to 1,200 ohms.
3. Defective speed sensor.
3 P(+) & G(-) 10 VDC, 1. Short on terminal P (This will cause a
Internal Supply defective unit.)
2. Defective Speed Control.
4 F(+) & A(-) 1.0~ 2.0 VDC 1. SPEED adjustment set too low
while cranking 2. Short/open in actuator wiring.
3. Defective speed control.
4. Defective actuator.

- 99 -
 • UNSATISFACTORY PERFORMANCE
If the governing system functions poorly, perform the following tests.

Symptom Test Probable Fault

Engine over- 1. Do not crank. Apply DC power to the 1. Actuator goes to full fuel. Then, dis-
speeds governor system connect speed sensor at Terminals C
& D.
If actuator still at full fuel speed control
unit defective. If actuator at minimum
fuel position - erroneous speed signal.
Check speed sensor data.
2. Manually hold the engine at the 1. If the voltage reading is 1.0 to 2.0 VDC.
desired running speed. Measure the a) SPEED adjustment set above
DC voltage between Terminals A(-) & desired speed.
F(+) on the speed control unit. b) Defective speed control unit.
2. If the voltage reading is above 2.0
VDC, a) Actuator or linkage binding.
3. If the voltage reading is below 1.0
VDC, a) Defective speed control unit.
4. Gain set too low.
Actuator does 1. Measure the voltage at the battery 1. If the voltage is less than 7V for a 12V
not energize while cranking. system, or14V for a 24V system,
fully. replace the battery if it is weak or
undersized.
2. Momentarily connect Terminals A and 1. Actuator or battery wiring in error.
F The actuator should move to the full 2. Actuator or linkage binding.
fuel position. 3. Defective actuator.
4. Fuse opens. Check for short in actua-
tor or actuator wiring harness.
1. Measure the actuator output. 1. If voltage measurement is within
Engine remains
Terminals A & B, while running under approximately 2 volts of the battery
below desired
governor control. supply voltage, then fuel control
governed speed.
restricted from reaching full fuel posi-
tion. Possibly due to interference from
the mechanical governor, carburetor
spring or linkage alignment.
2. Speed setting too low.

- 100 -
4.3.4. Fuel feed pump
1) General descriptions and construction

Priming pump

Check valve

Check valve

Outlet
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 compressed,
resulting in interrupting further delivery of fuel as shown in (C).

- 101 -
 (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 for-
eign 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 for-
eign substances possibly mixed in fuel.

- 102 -
2) disassembly

• Clamp the feed pump with a vise and disassemble the plugs (30, 32), strainer (31) and
gaskets (35, 36).
• Take off the priming pump (25), plug (16), both gaskets (18), spring (15), and check
valve (14).
• Take off the prig (7), gasket (8), spring (6), and piston (5) on the piston side.
• Pull out the snap ring (20) holding the tappet (10).
• Disassemble the snap ring, then take off the tappet (10) and push rod (1).

3) Inspection

• If the check valve is damaged or scored on its seat face, replace it with a new one.

• Inspect the piston and tappet for damage.

• Replace the push rod if excessively worn, and replace together with the pump housing if
required. The inspection for wear should be performed in the same procedure as for
suction pressure test described below.

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

- 103 -
5) Testing
(1) Suction capacity test
Connect one end of a hose to the inlet
side of the feed pump and immerse the Outlet hose

other end of it into the fuel tank as illus-

Feed pump
trated.
Hold the feed pump in position about 1
m above the level of fuel in the fuel
tank.
Inlet hose
Operate the tappet at the rate of 100
rpm and check to see if fuel is drawn in
and delivered for 40 seconds or so.

Fuel tank

EQM4022I

(2) Delivery test

Make a test with the feed pump mounted

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

EAMC016I

(3) Sealing test

Plug up the delivery port on the feed

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

- 104 -
4.3.5. Injection nozzle

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

(1) At valve closed (2) At valve opened

EQM4024I

2) 1-spring type
(1) Disassembly

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

- 105 -
(2) Reassembly

• After removing carbon deposit, sub-

merge the nozzle in diesel oil and clean
it.
• Replace all the gaskets with new ones.
• Assemble the parts and tighten them to
specified torque.

(3) Adjustment

• Remove the cap nut and assemble a

nozzle to a nozzle tester.
• With the adjusting screw loosened,
operate the nozzle 2 ~ 3 times to bleed
it.
• Operate the nozzle tester lever at the
specified rate.
• Adjust the injection pressure to the stan-
dard pressure using the adjusting
EA0M3003
screw.
• After adjusting the injection pressure,
tighten the cap nut to specified torque.
• Re-check the injection pressure and
see if the spray pattern is normal.

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

EAMC022I

- 106 -
3) 2-spring type
(1) Disassembly

31

30
2

7
1
6

10
11
3
12
13
15 14
16
A

17

EQM4029I

1. Nozzle holder body 13. Lift pin

2. Push rod 14. Pin
3. Primary spring 15. Spacer
4. Adjusting screw 16. Pin
6. Gasket 17. Retaining nut
7. Cap nut 30. Gasket
10. Adjusting shim 31. Eve bolt
11. Scondary spring A. Nozzle
12. Spring Seat

- 107 -
(2) Inspection and adjustment
Adjusting the primary opening pressure a.
Install the plate of plate assembly
(157944-9520) onto a vise.

NOTE : Use the plate assembly

(157944-9520) in fixing a nozzle
holder having a flange. A nozzle
holder without flange should be EQM4030I
directly installed onto a vise.

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

c. Install the nozzle holder body (1) onto

the plate with the cap nut side facing
downward.
1

EQM4031I

d. Assemble adjusting shim (10), secondary

12
spring (11), and spring seat (12) on the
11
nozzle holder body in the order as
10
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 nozzle holder body.
15
14
13

EQM4033I

- 108 -
f. Install the pin (16) and nozzle (A) onto the
spacer.

A
16

EQM4034I

g. After installing the gasket (157892-1500)

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

Note : While tightening the cap nut,

keep checking to see if the lock pin
comes all the way into the nozzle.

Note : Tighten the retaining nut until

it resists hand tightening, then fur-
ther tighten it using a torque
wrench.

h. Be sure to follow the specified torque rat-

ing when tightening the adjusting retaining
nut.

7
Torque 6.0 ~ 8.0 kg•m

EQM4036I

i. With the cap nut facing upward, install the

nozzle holder on the plate.

- 109 -
j. Assemble the push rod (2), primary spring
(3), and adjusting screw (4) on the nozzle
holder in the order described.

k. Install the gasket and cap nut onto the

adjusting screw.

l. Assemble the nozzle and nozzle holder

60

assembly to the nozzle tester (105785- 40

80
20

1010). 0
100

EQM4039I

m. Adjust the primary opening pressure to

the specified pressure using the adjusting
screw (4).

EQM4040I

n. With a monkey wrench, fix the nozzle hold-

er securely and tighten the cap nut (SW
19mm) to specified torque.

Torque 3.0 ~ 4.0 kg•m

EQM4041I

- 110 -
• Inspecting the needle valve for full lift
a. Install gasket (026508-1140) and plug
(157892-1600 : SW12mm) onto the
adjusting retaining nut (157892-1400).

EQM4042I

b. Install the nozzle holder on the plate

with the cap nut facing upward.

c. Install the holder into the cap nut.

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

on the holder.

e. Assemble the pin (157892-4200 or

157892-4300) to the dial gauge
(157954-3800).

Part No. L (mm)

157892-4200 160
157892-4300 110

Note : “L” means the length of the pin

except the threaded portion.

EQM4045I

- 111 -
f. Install the dial gauge on the holder assem-
bly so that the pin is brought into contact
with the upper end of the push rod, then fix
the pin with the nut.

Note 1 : Fix the dial gauge so that a

stroke of 2 mm or so can be mea-
sured.
Note 2 : Overtightening the nut may
cause a sticking of the dial gauge
seat.

g. Assemble the nozzle and nozzle holder

assembly to the nozzle tester and zero the
dial gauge.

h. Operate the nozzle tester, bleed the retain-

ing nut, and check for fuel leakage.

I. Operate the nozzle tester and increase the

L
tester pressure up to 350 ~ 450kgf•cm2 in
order that the needle valve can be fully lift-
ed. Then, record the full lift value “L”.

Note : This testing is to be made in order

to check the nozzle seat portion for
unusual wear or whether the nozzle
0
assembly is a standard item. EQM4048I

- 112 -
• Inspection of pre-lift
a. If the nozzle tester handle is released
200 300
with the needle valve engaged in a full lift
condition, the tester pressure drops,
100 400
being accompanied by decrease in the
needle valve lift value (indicated value on
500
0
the dial gauge). 2
kgf / cm

EQM4049I

Amount of lift 0
Tester pressure
EQM4050I

b. Take the indicated value on the dial

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

Measuring point for pre-lift

L
Take the indicated value on the dial gauge
at a point of primary opening pressure +
Amount of lift

approx. 1 0 kgf•cm2.

Note : Locate the point of primary

opening pressure + approx. 0
Primary opening pressure
10kgf•cm while dropping the pres-
2
Tester pressure EQM4052I
EQM4050I
sure.

- 113 -
 c. If the measured pre-lift value deviates
from the specified limit, replace the pin 13 14
15
(14, 16), lift piece (13), spacer (15), and 16
nozzle assembly (A) with a new “nozzle
service kit”. A

EQM4053I

• Inspection of secondary opening pressure L

a. After confirming the pre-lift, operate the
nozzle tester and increase the internal

Amount of lift
pressure up to 350 ~ 450 kgf/cm2 to fully
lift the needle valve. +0.05

b. Release the nozzle tester handle to

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

c. Take the indicated value on the pressure

gauge at the point of time when the nee-
60

dle of the dial gauge indicates the speci- 0

40

80
20

fied needle valve lift value. (In general, 100

0

pre-lift “ “ + 0.05mm. Refer to following

figure.)

EQM4055I

0
90 300
10 200

80
20 100 400

70
30
500
0
60
40
50

EQM4056I

- 114 -
• Adjusting secondary opening pressure
a. In the event that the measured value
deviates from the specified limit, readjust
the primary opening pressure if the
amount of deviation is small. (to the stan-
dard range of the primary opening pres-
sure)
- If the secondary opening pressure is
lower than the standard value: Adjust the
primary opening pressure up to the top EQM4040I
limit of the standard vague, and then
measure the secondary opening pres-
sure.
- If the secondary opening pressure is
higher than the standard value: In a
reverse manner, readjust the primary
opening pressure down to the bottom
limit of the standard value.

b. If the secondary opening pressure still

deviates from the specified limit in spite
10
of the readjusting the primary opening
pressure, take off the nozzle fixing por-
tion from the nozzle holder and remove
the adjusting shim (10).

c. If the secondary opening pressure is

higher than the standard value, fit a thin- EQM4058I
ner adjusting shim than the existing one.
d. After replacing the existing adjusting
shim, measure the secondary opening pressure and continue the adjustment until a value
satisfying the standard value.

- 115 -
 Adjusting shim for secondary opening pressure
(Out diameter = 9.5 , Inner diameter = 4.5)

Part No. Thickness(mm) Part No. Thickness(mm)

1505380-4900 0.40 1505380-5300 0.56
1505380-5000 0.50 1505380-5400 0.58
1505380-5100 0.52 1505380-5500 0.60
1505380-5200 0.54 1505380-5600 0.70

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

7
Torque 6.0 ~ 8.0 kg•m

EQM4036I

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

tester and check the primary opening 40

80
20

pressure, spray patterns, oil tightness of 0

100

seat portion, and oil leakage from each

part.

EQM4039I

b. When replacing the nozzle, replace it

13
with a new “nozzle service kit” integrated
with a nozzle, lift piece, and spacer as a 15
complete set.

Note : If only a nozzle is replaced, the

A
amount of pre-lift will deviate from
the specified value.

EQM4060I

- 116 -
4.3.6. 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 pumped (2) Feed pump valve defective Replace
out from feed pump (3) Feed pump piston or push rod sticking Disassemble, correct

2) Fuel not being injected (1) Fuel filter element restricted Clean
from injection pump (2) Air in fuel filter or injection pump Bleed
(3) Plunger and/or delivery valve sticking Disassemble, correct
or defective

3) Fuel injection timing (1) Injection pump not properly installed Check, correct
incorrect on pump bracket
(2) Injection pump tappet incorrectly Check, correct
adjusted
(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 Correct or replace
nozzle 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 Replace breather
of fuel tank air breather

3. Engine lacks power (1) Plunger worn excessively Replace

(2) Injection timing incorrect Adjust
(3) Delivery valves defective Replace
(4) Nozzle leaks excessively Correct or replace
(5) Nozzle not working normally Disassemble, correct

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 (1) Injection timing incorrect Adjust

seriously producing (2) Nozzle injection pressure too low Adjust
excessive exhaust (3) Nozzle spring broken Replace
smoke (4) Nozzles not working normally Replace
(5) Plungers worn excessively Adjust
(6) Delivery valves seat defective Replace
(7) Supply of fuel excessively Check feed pump

- 117 -
 Complaints Possible causes Corrections

6. Engine output (1) Supply of fuel insufficient Check feed pump

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

7. Engine does not reach (1) Nozzles not working normally Disassemble, correct
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
rod correctly

- 118 -
4.4. Turbocharger

4.4.1. Main data and specifications

1) Main data and specifications

Specification DE12T P126TI

Turbocharger Model T45 TV51

Air pressure at compressor outlet Approx. 1.257 kg/cm2 Approx.1.9 kg/cm2

At maximum output Air suction volume Approx. 19.0m3/min Approx. 26.0m3/min

Speed of turbine revolution Approx. 95,00 rpm Approx. 91,000rpm

Maximum allowable speed 110,000rpm 105,414rpm

Max. allowable temperature of exhaust gas at turbine inlet 750˚C 750˚C

Lubricating system External oil supply External oil supply

Weight 14kg 14kg

2) Operating principle

Turbine wheel and Oil inlet

shaft assembly
Turbine housing Compressor
housing
Exhaust pipe
Exhaust gas discharge Fresh
air inlet
Compressed
air folw
Compressor
Oil outle wheel
Intake pipe

EM0A8001

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

- 119 -
3) Construction

1. Turbine housing 15. Retainer ring 25. Bolt

2. Plug 16. Bearing 26. O-ring
5. Crank 17. Thrust collar 27. Compressor wheel
7. V-band 18. Screw 28. Nut
8. Wheel 19. Thrust bearing 29. Bolt
9. Piston ring 20. Thrust space 30. Clamp
10. Wheel shroud 21. Piston ring 31. Compressor housing
11. Center housing 22. Seal ring 32. Elbow
12. Retainer ring 23. Seal ring 38. Retainer
13. Bearing 24. Rear plate 45. Bolt
14. Retainer ring

- 120 -
4.4.2. General descriptions
The engine output is determined by the fuel delivery volume and engine efficiency.
To burn the supplied fuel completely to change into effective power for the engine, the volume
of air enough to burn the fuel completely should be supplied into the cylinders.
Therefore, the engine output is determined substantially by the cylinder capacity, and a
greater volume of compressed air is charged into cylinders of given capacity, the greater
engine output can be obtained as a greater volume of air charged into the cylinders burns so
much more fuel.
As explained, the compressing of air to supply into the cylinders is called “Supercharging” and
the making use of the energy of exhaust gas discharged from the combustion chamber to
charge the compressed air into the cylinders is called “Turbocharging”.

4.4.3. Functions
1) Turbine
Exhaust gas discharged from the combustion chamber distributes its own energy to the tur-
bine 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 operat-
ing 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.

- 121 -
 4.4.4. Precautions for operation
1) Precautions for operation of engine
The following precautions should be observed when starting, operating, or stopping the
n
engine:

Operations Precautions Reasons

When starting 1) Check oil level

the engine 2) Crank the engine with starter to 2) Abrupt starting of the engine
check the increase in oil pres- causes the engine to rotate with
sure(until the needle of pressure oil not being distributed not only
gauge starts to move or pressure to each part but also to the tur-
indicator lamp is actuated) before bocharger, resulting in abnormal
starting the engine. wear or seizure on the bearing
due to insufficient supply of oil.
3) When having replaced oil, oil filter 3) In the case of the engine stopped
element, or lubricating parts, or for extended time or in a cold
when having stopped the engine place, oil fluidity within the pipes
for extended period of time, or in a can be deteriorated.
cold place, loosen the oil pipe con-
nections and operate the starter
motor until oil is discharged. After
completing the operation, be sure
to retighten the oil pipe connections
portion before starting the engine.

Immediately 1) Run the engine at idle for 5 min- 1) Applying load abruptly If load is
after starting utes after 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.
Immediately 2) Check each part for leakage of 2) Leakage of oil, gas, and air (espe-
after starting oil, gas, and air, and take proper cially, oil leak) causes drop in oil
measure. pressure and loss of oil. resulting
in seizure of the bearing.

During Check the followings: 1) Excessively low oil pressure caus-

operation 1) Oil pressure es unusual wear or seizure of the
At idle: 0.8kg/cm2 or more bearing. Too high pressure caus-
At full load: 3.0~4.8kg/cm2 es oil leakage.
2) If unusual sound or vibration is 2) The engine is operated continu-
heard or felt, reduce engine revo- ously with unusual sound or vibra-
lutions slowly and locate the tion not corrected, it can be dam-
cause. aged beyond repair.

When stopping 1) Run the engine at idle for 5 min- 1) If the engine is put to a stop after
the engine utes before stopping. being operated at high load, heat
from the red-hot turbine blades is
transmitted to the bearing portion
and burns oil to cause seizure of
the bearing metal and rotating
shaft.

- 122 -
4.4.5. Walk-around check and servicing
As the condition of turbocharger depends greatly on how well the engine is serviced, it is very
important to maintain the engine in accordance with the specified maintenance procedure.

1) Intake system
Pay particular attention to the air cleaner when servicing the intake system.
In the case of wet-type air cleaner, if the level of oil surface is lower than specified, clean-
ing 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 vibra-
tion 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 sys-
tem because leakage of exhaust gas from discharge pipes, turbocharger fixing portions, etc.
lowers charging effect.
As such components as turbine chamber that becomes red-hot during operation use heat
resisting steel nuts, do not interchange these nuts with ordinary steel nuts. In addition, apply
anti-seizure coating to fixing nuts on the portions as designated.

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

4) Lubricating system
Pay particular attention to oil quality and oil filter change intervals when servicing the lubri-
cating system. Deteriorated engine oil affects adversely not only the engine but torso the
turbocharger. Suggested engine oils for the turbocharger-mounted engine are as follows:
• SAE 15W30
• API grade CD or CE

- 123 -
4.4.6. Periodical checking and servicing
Make it a rule to check the turbocharger assembly for condition and contamination periodically.

1) Guide for checking the rotor for rotating condition

The inspection of the rotor assembly for rotating condition should be performed by the
degree of unusual sound. If a sound detecting bar is used, install its tip on the turbocharg-
er housing and increase the engine revolutions slowly. If a high-pitch sound is heard con-
tinuously, 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 room
Magnet vise

Move the turbine

shaft to axial
direction
Dial gauge

Wear limit : 0.117~0.20mm

Limit of wear : 0.24mm EA8M4003

- 124 -
 (2) Rotor radial play

Dial gauge
Magnetic vise

Oil outlet

Radial play Move the turbine shaft

Limit of wear : 0.075~0.11mm in both directions
Limit of wear : 0.12mm simultaneously

Oil inlet

EA8M4004

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

3) Guide for disassembling/cleaning and checking the turbocharger

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

4) Precautions for reassembling the tarbocharger onto the engine

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

(1) Lubricating system

• Before reassembling the turbocharger onto the engine, inject new oil in the oil inlet port
and lubricate the journal and thrust bearings by rotating them with hand .
• Clean not only the pipes installed between the engine and oil inlet port but also the oil
outlet pipe and check them for damage or foreign matters.
• Assemble each joint on oil pipes securely to prevent oil leaks.

(2) Intake system

• Check the inside of the intake system for foreign matters.
• Assemble each joint on the intake duct and air cleaner securely to prevent air leaks.

- 125 -
 (3) Exhaust system

• Check the inside of the exhaust system for foreign matters.

• Be sure to use heat resisting steel bolts and nuts. Do not interchange them with ordi-
nary steel bolts and nuts when performing reassembly operation. Apply anti-seizure
coating to the bolts and nuts.
• Assemble each joint on the exhaust pipes securely to prevent gas leaks

4.4.7. Diagnostics and troubleshooting

Complaints Possible causes Corrections

1. Excessive black 1) Air cleaner element clogged Replace or clean
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 Disassemble/repair or replace
coming in contact with each other or
damaged
6) Exhaust piping deformed or clogged Check and correct
2. Excessive white 1) Oil leak into turbine and compressor Disassemble/repair or replace
smoke 2) Worn or damaged seal ring due to Disassemble/repair or replace
excessive 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 Check and correct
compressor side
4. Unusual sound 1) Rotor assembly coming in contact Disassemble/repair or replace
or vibration 2) Unbalanced rotation of rotor Disassemble/repair or replace
3) Seized up Disassemble/repair or replace
4) Each joint loosened Check and correct

- 126 -
5. Special tool list

No. Description Part No. Illustration

1 Nozzle tube Insert ass’y DPN-5337

2 Valve stern oil seal installer EF.123-082

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

4 Oil seal insert ass’y(FR) EF.123-127

5 Oil seal insert ass’y(RR) EF.123-053

6 Oil seal puller ass’y(FR) EF.123-052

EA8M5001

- 127 -
No. Description Part No. Illustration

7 Oil seal puller ass’y(RR) EF.123-048

8 Cylinder pressure tester EU.2-0531

adapter

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

10 Valve stem seal punch EF.123-066

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

12 Valve spring press EF.123-065

EA8M5001

- 128 -
No. Description Part No. Illustration

13 Crankshaft gear punch EU.2-0647

14 Feeler gauge 60.99901-0027

15 Snap ring plier T7610001E

16 Piston ring plier T7621010E

- 129 -
Appendix

•Tightening torque for major parts

Screw Strength
Major Parts Tightening torque Remarks
(diameter x pitch) (Grade)

6 kg•m+180˚+150˚
Cylinder head bolt M14 x 1.5 12.9T
Angle

Connecting rod bearing cap bolt M14 x 1.5 12.9T 28.0 kg•m

Crankshaft main bearing cap bolt M16 x 1.5 12.9T 30.0 kg•m

Balance weight fixing bolt M14 x 1.5 10.9T 9.0 kg•m

Flywheel fixing bolt M14 x 1.5 10.9T 18.0 kg•m

Crankshaft gear fixing bolt M12 x 1.5 10.9T 13.4 kg•m

•Tightening torque for injection pump system

Parts Tightening Torque

Injection pump delivery valve holder 2.0 ~ 3.0 kg•m

Nozzle holder fixing cap nut 7.0 kg•m

Nozzle fixing cap nut 6.0 ~ 8.0 kg•m

High pressure injection pipe fixing cap nut Max. 3.0 ~ 5.0 kg•m

- 130 -
•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
Diameter
x (4A) (4D) (4S) (5D) (5S) (6D) (6S) (6G) (8G) (10K) (12K)

pitch Limit value for elasticity (kg/mm2)

(mm)
20 24 32 30 40 36 48 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 0.50 0.75 0.90

M6 0.28 0.30 0.45 0.40 0.55 0.47 0.77 0.85 0.90 1.25 0.5

M7 0.43 0.46 0.70 0.63 0.83 0.78 1.20 1.30 1.40 1.95 2.35

M8 0.70 0.75 1.10 1.00 1.40 1.25 1.90 2.10 2.20 3.10 3.80

M8x1 0.73 0.80 1.20 1.10 1.50 1.34 2.10 2.30 2.40 3.35 4.10

M10 1.35 1.40 2.20 1.90 2.70 2.35 3.70 4.20 4.40 6.20 7.40

M10x1 1.50 1.60 2.50 2.10 3.10 2.80 4.30 4.90 5.00 7.00 8.40

M12 2.40 2.50 3.70 3.30 4.70 4.20 6.30 7.20 7.50 10.50 12.50

M12x1.5 2.55 2.70 4.00 3.50 5.00 4.60 6.80 7.70 8.00 11.20 13.40

M14 3.70 3.90 6.00 5.20 7.50 7.00 10.00 11.50 12.00 17.00 20.00

M14x1.5 4.10 4.30 6.60 5.70 8.30 7.50 11.10 12.50 13.00 18.50 22.00

M16 5.60 6.00 9.00 8.00 11.50 10.50 17.90 18.50 18.00 26.00 31.00

M6x1.5 6.20 6.50 9.70 8.60 12.50 11.30 17.00 19.50 20.00 28.00 33.00

M18 7.80 8.30 12.50 11.00 16.00 14.50 21.00 24.20 25.00 36.00 43.00

M18x1.5 9.10 9.50 14.50 12.50 18.50 16.70 24.50 27.50 28.00 41.00 49.00

M20 11.50 12.00 18.00 16.00 22.00 19.00 31.50 35.00 36.00 51.00 60.00

M20x1.5 12.80 13.50 20.50 18.00 25.00 22.50 35.00 39.50 41.00 58.00 68.00

M22 15.50 16.00 24.50 21.00 30.00 26.00 42.00 46.00 49.00 67.00 75.00

M22x1.5 17.00 18.50 28.00 24.00 34.00 29.00 47.00 52.00 56.00 75.00 85.00

M24 20.50 21.50 33.00 27.00 40.00 34.00 55.00 58.00 63.00 82.00 92.00

M24x1.5 23.00 25.00 37.00 31.00 45.00 38.00 61.00 67.00 74.00 93.00 103.00

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

- 131 -
 •Maintenance specification table
Standard value Limit for
Group Part Check Correction Remarks
for assembly use
Measure unworn portion beneath
Inside diameter of Cylinder. liner for wear 123~ 123.023 123.223 Replace liner the rim of upper side
Cylinder Projected portion of liner 0.03~0.08 -
block &
The upper surface of cylinder block for distortion 0.05 - Correct with a surface grinder Per distortion length for 200mm
liner
Engine Hydraulic test for 1 minute (kg/cm2) 4 -
body
Intake 0~0.3 0.55 In case of new valve and seat
Valve seat depression
Cylinder Exhaust 0~0.3 0.55
head &
valve Height 114.95~115 113.9 Replace cyl. head

Hydraulic test for 1 minute (kg/cm2) 4 - Replace if leaky Water temp : 70˚C

Piston diameter (18mm from the lower side) 122.854~ 122.886 -

Clearance between piston and liner 0.114~0.169 -

- 132 -
Piston Tor ring 3.5 -
Width of piston ring Replace piston if groove width
2nd ring 3.060~3.080 -
grooves is beyond specified value
Oil ring 4.040~4.060 -
Measure unworn portion beneath
Major Piston projection from cylinder block upper surface 0~0.12 - the rim of upper side
moving Permissible weight difference of each piston ± 15g 96g
parts Top ring 0.30~0.45 1.5
Standard gauge inside
Piston ring gap 2nd ring 0.35~0.50 1.5
diameter : 123
Oil ring 0.30~0.50 1.5

Piston Top ring - -

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

Direction of ring gap - - Install ring by 120°

 Standard value Limit for
Group Part Check Correction Remarks
for assembly use

Axial run-out of journal and pin 0.05 0.1 Correct with a grinder In horizontal and vertical directions

Outside diameter of journal 95.966~ 95.988 94.966 Replace crank shaft 96 g6

Outside diameter of pin 82.966~ 82.988 81.966 Replace crank shaft 83 g6

Out of round of journal & pin 0.008 0.025

Permissible radial run-out of journal & pin 0.01 0.03

Permissible taper of journal & pin 0.01 0.03

Crank
shaft Clearance between crank shaft & bearing 0.072~0.142 0.25 Replace bearing Measure in the position of crown

End play of crank shaft 0.15~0.325 0.5 Replace thrust bearing

Run-out of crank shaft 0.05 0.1 or less Adjust by a press if bent No.4 bearing(holding Nos. 1 & 7)

Balance of crank shaft 60 60 or less Check dynamic balance Measure at 400 rpm

Major Tightening torque of journal bearing cap bolt(kg.m) 30 - Apply oil to bolt No foreign matters on bearing
cap installing surface
moving Measure by tightening metal cap
Journal bearing crush 0.15~0.25 -
parts and then loosening one stud bolt

- 133 -
Oil seal for wear - - Replace oil seal if oil leaking Replace with new one, use shim

Clearance between conn. bearing & crank pin 0.049~0.119 0.20 Replace bearing

End play of con. rod crush 0.22~0.319 0.5 Replace conn. rod

Conn. Clearance between small end bush & piston pin 0.050~0.080 0.12

rod Conn. rod bearing crush height 0.086~0.116 - After completing installation of bearing,
loosen one stud bolt and measure
Permissible weight difference of each conn. rodrod ± 18g -

Tightening torque of con-rod bearing cap bolt (kg•m) 28 - Apply oil to bolt

Outside diameter of cam shaft 59.860~ 59.880 59.52 60

Cam
Clearance between cam shaft and bush 0.050~0.128 0.20
shaft
Axial play of camshaft 0.13~0.27 0.3 Replace thrust plate

Timing Clearance between idle gear shaft and inserting hole 0.025~0.091 0.15
gear End play of idle gear shaft 0.043~0.167 0.3 Replace thrust collar
 Standard value Limit for
Group Part Check Correction Remarks
for assembly use
Timing Between crank gear & idle gear 0.10~0.20 -
Replace gear
gear Between idle gear & cam shaft gear 0.10~0.20 -
Outside diameter of intake valve stem 10.950~ 10.970 10.87 Replace valve guide together
Replace valve & valve guide
Outside diameter of exhaust valve stem 10.935~ 10.955 10.84 when replacing valve

Clearance between valve Intake 0.030~0.065 0.15 Replace & valve guide
stem and valve guide Exhaust 0.045~0.080 0.18 Replace
Intake 1.5 1 or more
Thickness of valve Replace
Exhaust 1.5 0.9 or more
Perm. radial run-out between valve Intake 0.04~0.07 0.2
Replace
stem & valve head Exhaust 0.06~0.09 0.25
Clearance between valve guide & cyl. head installing hole 0.01~0.39 - Apply oil to valve guide and press in
Intake 22 -
Valve Clearance between valve
Valve guide & valve spring seat Exhaust 22 -

- 134 -
system Free length 75.5 72
Intake
Spring tension(set length : 37mm) kg 61.8~68.3 61.8
Spring
Straightness(against free length) 1.0 2.0
Free length 65 61.75
Inner Spring tension(set length: 34mm) kg 36.1~39.9 36.1 Replace valve spring
Exhaust Straightness(against free length) 1.0 2.0
Spring Free length 75.5 72
Outer Spring tension(set length:37mm) kg 61.8~68.3 61.8 Replace valve spring
Straightness(against free length) 1.0 2.0
Valve clearance Intake 0.3 -
Adjust
(at cold) Exhaust 0.3 -

Correct or replace if severely

Contacting face of valve stem & rocker arm - - pitted on tip of arm and stem
 Standard value Limit for
Group Part Check Correction Remarks
for assembly use

Clearance between rocker arm shaft & rocker arm bush 0.020~0.093 0.2 Replace bush or shaft

Rocker arm shaft for wear 23.978~ 23.959 23.75 Replace

Valve Permissible taper of push rod 0.3 - Replace

System Clearance between tappet & cyl. block 0.035~0.077 0.15 Replace tappet

Tappet Outside diameter of tappet 19.944~ 19.965 - Replace tappet

Contacting face of tappet & cam - - Replace if excessively worn or deformed

Oil pressure(nominal speed) kg/cm2 4.5 or less 3.5 Correct oil leakage and clearance between each part
Oil
Pressure Oil pressure(idling) kg/cm2 0.8~1.4 0.6 Use suggested oil

Oil Max. permissible oil temperature ˚C - 105 Temperature above this

temp Permissible oil temperature in short time ˚C - 120 not allowable

Axial play of oil pump gear 0.055~0.105 -

Replace gear or cover
Clearance between gear shaft & oil pump over hole 0.032~0.068 -

Clearance between drive gear bushing & cover hole 0.040~0.082 - Replace bushing or cover

- 135 -
Oil Outside diameter of gear shaft 16.950~ 16.968 - Replace gear 17e7
Lubricating
pump
System Outside diameter of drive gear bushing 27.939~ 27.960 - Replace bushing 28e7
Between crank gear & oil pump drive gear 0.15~0.25 0.8
Backlash Adjust backlash
Between oil pump drive gear and intermediate gear 0.15~0.25 0.8

Oil pressure control valve (kg/cm2) 4.3~4.7 -

By-pass valve for filter element (kg/cm2) 1.8~2.3 - Replace valve

Valve By-pass valve for full oil filter (kg/cm2) 4.0~4.8 -
opening
By-pass valve for oil cooler (kg/cm2) 5~6 -
pressure
Relief valve for oil pump (kg/cm2) 8.5~11.5 -

Control valve for spray nozzle (kg/cm2) 1.5~1.8 -

Oil filter Oil filter element for damage - - Clean or replace

 Standard value Limit for
Group Part Check Correction Remarks
for assembly use

Radiator & water pump for corrosion, damage & improper connecting - - Correct or replace

Test for leakage(air pressure) kg/cm2 1.0 - Submerge in water and replace if air bubbles found
Radiator
Pressure valve for opening pressure kg/cm 2 0.5 -

Negative pressure valve for opening pressure (kg/cm2) 0.2 -

Engine speed 1,800rpm

Cooling Water Delivery volume l/min Water temp 24˚C Approx. 270 -

system pump Back pressure:1kg/cm2

Clearance between pump impeller & pump body 0.3~0.6 - Replace if contacted impeller and pump body

Cooling Operating temperature(permissible temp.) ˚C 90~95 95 Temperature above this not

water
temp Permissible temperature in a short time ˚C 103 103 allowable

Thermostat opening temp.

Thermostat 83 - Replace if defective
(under atmospheric pressure) ˚C

Full opening temp. ˚C 95 or lower - Stroke : minimum 8mm

- 136 -
Piping Fuel pipe, injection pipe & Nozzle holder for - - Correct or replace
and the damage, cracks, looseness, bad packing
other
Fuel filter element for damage - - Clean or replace
Fuel Injection pressure of injection nozzle (kg/cm2) 220 - Adjust by shim 1st : 160, 2nd : 220
System Opening pressure of overflow valve (kg/cm2) 1.6 - Replace valve

Height of projected nozzle on the cyl. head (mm) 4.3 - Replace cyl. head and nozzle

Clearance between injection pump coupling and coupling (mm) 0.2~0.4 -

Running-in the engine - - Refer to supplement “running-in” Retighten head bolt after running in

Cylinder compression 24 or
Inspection 24~28 Overhaul the engine
at Cylinder Pressure of cylinder(kg/cm2) more
completion
pressure Compression pressure ± 10% or less
- Correct at 200rpm or more (20˚C)
difference of each cylinder against average
 INÍCIO

DAEWOO HEAVY INDUSTRIES &

MACHINERY LTD. AROUND THE WORLD

FRAMERIES
(Belgium)
CARDIFF
(U.K.)
XINJIANG
DUSSELDORF (China) SEATTLE CLEVELAND
(Germany) TAIANJIN SEOUL(Korea) (U.S.A) (U.S.A)
(China)
TOKYO ATLANTA NEW JERSEY
YANTAI (U.S.A) (U.S.A)
(China) (Japan)
TRAPPES
(France)
TAIPEI
(Taiwan R.O.C)
BOGOTA
(Colombia)

SAO PAULO
(Brazil)
JOHANNESBURG SYDNEY
(South Africa) (Australia)

Head Office Daewoo Heavy Industries America Cleveland Office

Hwasu-Dong 7-11, Dong-Gu, Incheon, Korea. 4530 Renaissance Parkway, Warrensville Heights, OH 44128,
Tel : 82-32-760-1114 Fax : 82-32-762-1546 U.S.A
Tel : 1-216-595-1212 Fax : 1-216-595-1214
Seoul Office
8th floor Daewoo Heavy Industries & Machinery Bidg, 14-34, Daewoo Rep. C/O Boeing Co.
Youido-Dong, Youngdungpo-Gu, Seoul, Korea P.O.Box 3707 M/S 39-AH, Seattle, WA 98124-2207, U.S.A
Tel : 82-2-2167-3114 Fax : 82-2-785-2677 Tel : 1-425-266-0478 Fax : 1-425-266-0518
ASIA & OCEANIA EUROPE
Daewoo Heavy Industries Australia Pty. Ltd Euro Daewoo U,K Ltd
Suite 5, Level 4,20 Charles St., Parramatta NSW 2150, Australia
Tel : 61-2-9633-4544 Fax : 61-2-9633-5266 Daewoo House, Unit 6.3 Nantgarw Park, Cardiff
CF47QU, U.K. / Tel : 44-1443-84-2273 Fax : 44-1443-84-1933
Daewoo Machinery Co., Ltd
No.83 WenHwa 1st. Road, Kueishan Hsiang, Taoyuan Hsien, Daewoo Maschinen Vertriebs GmbH
Taiwan R.0.C Hans-Bockler strasse 29, D-40764, Langenfeld-Fuhrkamp,
Tel : 886-3-327-5576 Fax : 886-3-327-3013 Germany / Tel : 49-2173-8509-20 Fax : 49-2173-8509-60

Xinjiang Daewoo Machinery Co., Ltd Euro Daewoo S. A

No, 178, Hetanbei Road, Wurumuqi, Xinjiang, China 1A Rue Achille Degrace 7080 Frameries Belgium
Tel : 86-991-463-2217 Fax : 86-991-461-8641 Tel : 32-65-61-3231 Fax : 32-65-61-3238

Dajian(Tianjin) Mechanical Construction Co., Ltd Euro Daewoo S. A France

No.87 Gongxing Road, Tanggu, Tianjin, china 2Eme Etage, 1/3 Avenue Pavlov, Z.A.I. Des Bruyeres 78190
Tel : 86-222-521-0540 Fax : 86-222-521-0714 Trappes France
Tel : 33-1-3016-2140
Daewoo Heavy Industries Yantai Co., Ltd Fax : 33-1-3016-2144
#28, Wuzhishan Road, Eco. & Tech, Development Zone,
Yantai, Shandong, China SOUTH AMERICA
Tel : 86-535-638-2000 Fax : 86-535-638-2004
Daewoo Maquinas I Equipamentos Ltda
Daewoo Construction Machinery Co., Ltd AV Tres Andradas 519- Jd. Piratininga - CEP
3rd Floor, k-1 Bld.,19-4, Nishi-shinbashi 2-Chome,
06230-050- Osasco - SP - Brazil
Minato-Ku, Tokyo, Japan
Phone : 81-3-3433-8400 Fax : 81-3-3433-8648 Phone : 55-11-3686-0177 Fax : 55-11-3686-0970

NORTH AMERICA DHIAC Colombia Liaison Office

Diagonal127 A No. 17-34 Oficina 302
Daewoo Heavy Industries America Corp. Bogota, Colombia
2905 Shawnee Industrial Way, Suwanee,
Georgia 30024, U. S. A AFRICA
Tel : 1-770-831-2200 Fax : 1-770-831-0480
Daewoo Heavy Industries America N.J. Office Daewoo Heavy Industries South Africa Pty. Ltd
8 York Avenue, West Caldwell, N.J. 07006, U.S.A 60C Electron Road Isando 1600, Johannesburg, South Africa
Tel : 1-973-618-2500 Fax : 1-973-618-2501 Phone : 27-11-974-2095 Fax : 27-11 -974-2778

FECHAR