Daewoo DE12, Shop Manual

Page 1: ...hat consumers periodically contact their distributors for recent documentation on purchased equipment This documentation may include attachments and optional equipment that is not available in your machine s package Please call your distributor for additional items that you may require Illustrations used throughout this manual are used only as a representation of the actual piece of equipment and ...

Page 2: ...in 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 You are requested to thoroughly read this manual from cover to cover and to acquaint yourself with all the information contained in this manual All information illustration and specifications continued in this literature are based on the lates...

Page 3: ...ly and reassembly of major components 37 3 1 Disassembly 3 3 Reassembly 3 2 Inspection 3 4 Breaking in 4 Maintenance of major components 79 4 1 Cooling system 4 3 Fuel system 4 2 Lubricating system 4 4 Turbocharger 5 Scan pole diagnosis for DE12TIS 142 5 1 Wire harness connection 5 4 Sensor data 5 2 System Vehicle selection 5 5 Actuator test 5 3 Self diagnosis current 5 6 Flight record 6 Maintenan...

Page 4: ...tion bowl strong swirl is produced in the combustion bowl and strong squish flow makes the fuel be mixed more sufficiently with air Due to the application of OMEGA combustion system and optimal ultilization of intake and exhaust port configuration within the cylinder head the DE12 series engines discharge a very low level of hazardous exhaust gases such as smoke nitrogen oxide hydrocarbon or carbo...

Page 5: ...st gas is present at low speed On the other hand if higher charging pressure is produced than what is present at high speed fuel consumption increases To correct this part of exhaust gas is forced to be discharged into the exhaust manifold through the waste gate not through the turbine The waste gate is controlled by the ACTUATOR mounted in the turbocharger and if the pressure in the turbocharger ...

Page 6: ...TDC Firing order 1 5 3 6 2 4 Injection pump type S3000 S3000 S3S HD TICS Governor type RFD C RLD RFD C RFD D RLD J Timer type SP SP SPG Electronically control Nozzle type Multi hole type 5 N0 29 Multi hole type 5 N0 31 Multi hole type 5 N0 33 Multi hole type 5 N0 29 Feed pump type K P K P K PS Valve Timing Intake valve open at BTDC 18 BTDC 18 Intake valve close at ABDC 34 ABDC 32 Exhaust valve ope...

Page 7: ...ower ps rpm 228 2 200 280 2 100 310 2 100 340 2 100 Max torque kg m rpm 80 1 400 115 1 260 125 1 260 140 1 260 Firing order 1 5 3 6 2 4 Engine dimension LxWxH 1 317x747x1 015 1 317x847x1 064 Dry weight kg 872 909 910 Cycle 4 Piston Material AL Comp ring 2 Oil ring 1 Open BTDC 18 BTDC 18 Close ABDC 34 ABDC 32 Open BBDC 46 BBDC 70 Close ATDC 14 ATDC 30 Intake 0 3 Exhaust 0 3 Engine speed at no load ...

Page 8: ...njection type Mechanical Electronic control Type Inline Timing BTDC 8 BTDC 12 BTDC 1 0 Plunger Dia 12 Cam lift mm 11 12 14 Nozzle mounting Flange Nozzle type Multi hole Orifice No 5 Dia mm 0 29 0 33 0 29 Inj pressure kg cm2 220 130 220 163 224 Voltage V 24V Type Electric Voltage V Amp A 22 120 Output V A Regulator Type Reduction Output kW 24V 6 0kW Type Air compression Cooling system Engine Fuel s...

Page 9: ... 1000 1200 1400 1600 1800 2000 2200 2400 85 80 75 170 160 165 70 Performance criteria ISO 1585 SAE J1349 Output Max 235 ps 2 200 rpm Torque Max 81 5 kg m 1 400 rpm Fuel consumption ratio min 160 g ps h EQM1004I Revolution rpm Output ps Torque kg m Fuel consumption g ps h ...

Page 10: ...00 1200 1400 1600 1800 2000 2200 2400 80 75 70 165 160 155 Performance ISO 1585 SAE J1349 Output Max 228 ps 2 200 rpm Torque Max 80 kg m 1 400 rpm Fuel consumption ratio min 155 g ps h EQM1005I Revolution rpm Output ps Torque kg m Fuel consumption g ps h ...

Page 11: ...0 1400 1600 1800 2000 2200 2400 120 150 180 210 240 270 300 Performance ISO 1585 SAE J1349 Output Max 300 ps 2 200 rpm Torque Max 110 kg m 1 300 rpm Fuel consumption ratio min 155 g ps h EQM1006I Revolution rpm Output ps Torque kg m Fuel consumption g ps h ...

Page 12: ... 1400 1600 1800 2000 2200 2400 160 190 220 250 280 310 340 Performance ISO 1585 SAE J1349 Output Max 340 ps 2 100 rpm Torque Max 135 kg m 1 260 rpm Fuel consumption ratio min 147 g ps h EQM1007I Revolution rpm Output ps Torque kg m Fuel consumption g ps h ...

Page 13: ... 1600 1800 2000 2200 2400 145 150 155 115 105 95 1400 140 260 Performance ISO 1585 SAE J1349 Output Max 280 ps 2 100 rpm Torque Max 115 kg m 1 260 rpm Fuel consumption ratio min 145 g ps h EQM1008I Revolution rpm Output ps Torque kg m Fuel consumption g ps h ...

Page 14: ... 145 280 240 200 160 1000 1200 1400 1600 1800 2000 2200 2400 Performance ISO 1585 SAE J1349 Output Max 310 ps 2 100 rpm Torque Max 125 kg m 1 260 rpm Fuel consumption ratio min 145 g ps h EQM1009I Revolution rpm Output ps Torque kg m Fuel consumption g ps h ...

Page 15: ...h ISO 1585 kg m 140 1000 200 190 210 160 150 140 220 100 1000 EA2M1002 2000 2200 1800 1600 1400 1200 Revolution rpm Power output ps Fuel consumption g ps h Torque kg m Performance ISO 1585 SAE J1349 Output Max 340 ps 2 100 rpm Torque Max 140 kg m 1 260 rpm Fuel consumption ratio min 143 g ps h ...

Page 16: ...5 Vibration damper 6 Flywheel 7 V pulley 8 Cylinder head 9 Oil filter 10 Oil cooler 11 Oil pan 12 Oil dipstick 13 Cooling water pipe 14 Water pump 15 Exhaust manifold 16 Heat shield 17 Intake manifold 18 Intake stake 19 Injection pipe 20 Injection pump 21 Injection pump bracket 22 Fuel filter 23 Starter 24 Air heater 25 Air compressor 26 Mounting bracket 27 Power steering pump EQM1010I ...

Page 17: ...ulley 8 Cylinder head 9 Cylinder head cover 10 Oil filter 11 Oil cooler 12 Oil pan 13 Oil dipstick 14 Cooling water pipe 15 Water pump 16 Cooling fan 17 Exhaust manifold 18 Intake manifold 19 Intake stake 20 Injection pipe 21 Injection pump 22 Injection pump bracket 23 Fuel filter 24 Alternator 25 Starter 26 Air heater 27 Air conditioning compressor 28 Engine mounting bracket 29 Power steering pum...

Page 18: ...6 Flywheel 7 V pulley 8 Cylinder head 9 Oil filter 10 Oil cooler 11 Oil pan 12 Oil dipstick 13 Cooling water pipe 14 Water pump 15 Exhaust manifold 16 Intake manifold 17 Heat shield 18 Intake stake 19 Turbocharger 20 Injection pipe 21 Injection pump 22 Injection pump bracket 23 Fuel filter 24 Starter 25 Air heater 26 Air compressor 27 Mounting bracket 28 Power steering pump EQM1011I ...

Page 19: ... 8 Cylinder head 9 Oil filter 10 Oil cooler 11 Oil pan 12 Oil dipstick 13 Cooling water pipe 14 Water pump 15 Exhaust manifold 16 Intake manifold 17 Intake stake 18 Turbocharger 19 Air pipe T C A P 20 Air pipe A P I C 21 Air pipe A P I C 22 Injection pipe 23 Injection pump 24 Injection pump bracket 25 Fuel filter 26 Starter 27 Air heater 28 Air compressor 29 Alternator 30 Mounting bracket 28 Power...

Page 20: ...l 7 V pulley 8 Cylinder head 9 Oil filter 10 Oil cooler 11 Oil pan 12 Oil dipstick 13 Cooling water pipe 14 Water pump 15 Exhaust manifold 16 Intake manifold 17 Intake stake 18 Turbocharger 19 Air pipe T C A P 20 Air pipe A P I C 21 Injection pipe 22 Injection pump 23 Injection pump bracket 24 Fuel filter 25 Starter 26 Air heater 27 Air compressor 28 Alternator 29 Mounting bracket 30 Power steerin...

Page 21: ...lley 8 Cylinder head 9 Oil filter 10 Oil cooler 11 Oil pan 12 Oil dipstick 13 Cooling water pipe 14 Water pump 15 Exhaust manifold 16 Intake manifold 17 Intake stake 18 Turbocharger 19 Air pipe T C A P 20 Air pipe A P I C 21 Air pipe A P I C 22 Injection pipe 23 Injection pump 24 Injection pump bracket 25 Fuel filter 26 Starter 27 Air heater 28 Air compressor 29 Alternator 30 Mounting bracket 31 P...

Page 22: ...nder head cover 10 Oil filter 11 Oil cooler 12 Oil pan 13 Oil dipstick 14 Cooling water pipe 15 Water pump 16 Cooling fan 17 Exhaust manifold 18 Heat screen 19 Intake manifold 20 Intake stake 21 Turbocharger 22 Air pipe A C T C 23 Air pipe T C I C 24 Injection pipe 25 Injection pump 26 Injection pump bracket 27 Fuel filter 28 Alternator 29 Starter 30 Air heater 31 Air conditioning compressor 32 En...

Page 23: ...head cover 10 Oil filter 11 Oil cooler 12 Oil pan 13 Oil dipstick 14 Cooling water pipe 15 Water pump 16 Exhaust manifold 17 Heat screen 18 Intake manifold 19 Intake stake 20 Turbocharger 21 Air pipe A C T C 22 Air pipe T C A P 23 Air pipe A P I C 24 Injection pipe 25 Injection pump 26 Pick up sensor 27 Prestroke actuator sensor 28 Rack sensor 29 Injection pump bracket 30 Fuel filter 31 Starter 32...

Page 24: ...ter 11 Oil cooler 12 Oil pan 13 Oil dipstick 14 Cooling water pipe 15 Water pump 16 Cooling fan 17 Exhaust manifold 18 Heat screen 19 Intake manifold 20 Intake stake 21 Turbocharger 22 Air pipe A C T C 23 Air pipe T C I C 24 Injection pipe 25 Injection pump 26 Pick up sensor 27 Prestroke actuator sensor 28 Rack sensor 29 Injection pump bracket 30 Fuel filter 31 Alternator 32 Starter 33 Air heater ...

Page 25: ...the mixture decreases new coolant should be added to make up for the loss in old coolant resulting from engine operation check the mix ratio with every replenishment of coolant and top up as necessary 7 To prevent corrosion or air bubbles in the coolant path be sure to add a specific additive i e corrosion inhibitor to the coolant Type DAC65L Mix ratio 1 5M of inhibitor to 50M of coolant Namely ad...

Page 26: ...k 3 Engine oil should be changed at the specified intervals Oil in the oil filter also should be changed simultaneously First oil change 1 000km running Suggested engines oils 2 1 4 Oil filter 1 Check for oil pressure and oil leaks and repair or replace the oil filter if necessary 2 Change the oil filter element simultaneously at every replacement of engine oil 2 1 5 Fuel filter 1 Drain water in c...

Page 27: ...nder compression pressure 1 Stop the engine after warming up then remove the nozzle holder assembly 2 Install a special tool gauge adapter in nozzle holder hole and mount the compression gauge in position of the nozzle holder 3 Cut off fuel circulation rotate the starter then measure compression pressure in each cylin der 6 Testing conditions Coolant temperature 20C Engine speed 200 rpm 10 turns 2...

Page 28: ...ave not been removed 2 1 11 Battery 1 Check the battery for damage or leaking of battery fluid electrolyte from cracks on the bat tery Replace the battery if damaged 2 Check battery fluid level and add distilled water if necessary 3 Measure the specific gravity of the electrolyte in the battery Recharge the battery if the hydrometer readings are lower than the specified limit 1 12 1 28 25 ...

Page 29: ...liner piston etc Check fuel feed pump for function Check feed pump valve and strainer Air in the fuel Retighten the joint and or replace gasket Air bleeding Continuous entry of air in fuel system Disassemble and check feed pump Dirty element and or overflow valve faulty Check fuel filter Replace Normal Too low Retighten or replace Check valve clearance Normal No fuel Replenish Check fuel injection...

Page 30: ...e Normal Replace Normal Damaged Repair or replace Normal Check fan belt for tension wear or breaks Clean or replace with the specified fuel Check radiator cap Replenish Check thermostat Check radiator Repair or replace Normal Check water pump Check water pump Internal External Overhaul engine Retighten or repair Clean coolant path Abnormal Repair or replace Normal Check injection nozzles Excessive...

Page 31: ...t and overflow valve Check injection piping Check injection nozzle injection pres sure nozzle spray patterns etc Normal Clean or replace Normal Clean or replace Normal Check valve clearance Check cylinder head gasket for break Overhaul engine valve assembly Adjust Normal Adjust Normal Replace Normal Replace Normal Repair or replace Normal Adjust or replace Normal Adjust Check injection timing Over...

Page 32: ...e indicates exactly Check cooling water temperature Too low Refill with recommanded oil Check oil quality Refer to Engine overheating Check oil pressure relief valve Water fuel etc mixed in oil Overhaul engine or injection pump Inadequate Replace with suggested lub oil Overhaul the engine Check oil level ...

Page 33: ...linder liner etc Check injection nozzle injection pressure spray patterns etc Causes according to operating conditions 1 Overload 2 Frequent use of low gear position at high speed 3 Frequent use of high gear position at low speed 4 Clutch slip 5 Too low tire inflation pressure Oil leakage Retighten or replace Check fuel leakage Adjust Check valve clearance Repair or replace Cylinder liner Piston r...

Page 34: ...ressure Retighten or replace Overhaul engine piston cyl liner 31 6 Excessive oil consumption Normal Check oil quality Replace with suggested lub oil Causes according to operating conditions 1 Too high lub oil level 2 Continuous driving at low speed or with excessive cold engine Check oil leakage Check air cleaner ...

Page 35: ...ion pressure Check injection timing Check fuel quality Use suggested fuel Normal Too low Check valve clearance cyl head gasket for damage Normal Adjust Normal Replace or adjust Overhaul engine Check fuel and oil burning Check carbon deposit from exhaust gas Not identified ...

Page 36: ...k wiring connections for short etc Repair or replace Battery Normal Replenish Replace Recharge Check battery fluid specs Damaged battery case Normal Check charging condition Discharged Disassemble alternator and regulator Abnormal Adjust or replace Battery discharged Battery overcharged Check alternator and voltage regulator ...

Page 37: ...sion pressure insufficient Injection timing incorrect Volume of fuel delivery insufficient Injection pump timer faulty Nozzle injection pressure or spray angle incorrect Feed pump faulty Volume of intake air insufficient Lack of engine oil or poor oil Lack of coolant Fan belts slipping worn or damaged Water pump faulty Thermostat inoperative Valve clearance incorrect Back pressure in exhaust line ...

Page 38: ...zed up Piston poorly seated Piston rings damaged Crankshaft and or thrust bearing worn Camshaft end play excessive Idle gear end play excessive Timing gear backlash excessive Valve clearance excessive Tappets and cams worn Injection timing incorrect Volume of fuel injection excessive Tire under inflated Gear selection inadequate frequent use of low gears 4 3 2 1 6 5 4 3 2 1 5 4 3 2 1 5 4 3 2 1 4 3...

Page 39: ...ly Oil return holes in oil control ring restricted Oil ring seated incorrectly Breather piping restricted Valve stems and valve guide loose excessively Valve stem seals worn Leaky cylinder head gasket Applicable parts loosened Applicable packings worn Oil seals worn 3 2 1 3 2 1 8 7 6 5 4 3 2 1 Replace Replace pistons and piston rings Replace piston rings Correct Replace pistons Replace piston ring...

Page 40: ...y damage to them 3 1 2 Engine oil 1 Take out the oil dipstick 2 Remove the drain plug from the oil pan and drain out the engine oil into a con tainer 3 Reassemble the drain plug with the oil pan after draining out the engine oil 37 EQM3001I 3 1 3 Cooling water 1 Remove the drain plug from the cylinder block and drain out the cooling water into a container EQM3002I 3 1 4 Fan belt 1 Remove the fan g...

Page 41: ...e tube EQM3005I 3 1 7 Alternator 1 Loosen the alternator fixing bolts to dis assemble the alternator then remove the tension adjusting bolt and bracket EQM3006I 3 1 8 Air conditioning compressor 1 Remove the compressor fixing bolts and disassemble the A C compressor 2 Disassemble the A C compressor ten sion adjusting bolt and alternator fixing bracket 3 Disassemble the A C compressor fixing bracke...

Page 42: ...e fuel return pipe 2 Remove the nuts installed on the fuel injection pump and nozzles then disas semble the injection pipe EQM3009I 3 1 12 Air heater 1 Remove the electrical wiring for the air heater 2 Disassemble the intake pipes by loos ening the nuts installed thereon 3 Disassemble the air heater and gasket EQM3010I 3 1 13 Intake manifold 1 Remove the air hose connected to the fuel injection pu...

Page 43: ...st manifold fixing bolts disassemble the exhaust mani fold then remove the heat shield and gasket Note Make sure to release the nuts one after another because the exhaust manifold will be removed if you unscrew the two nuts simultane ously 3 1 16 Starter 1 Unscrew the starter fixing bolts then disassemble the starter 40 EQM3012S EQM3013S EQM3014I EQM3015I 3 1 17 Thermostat 1 Remove the by pass pip...

Page 44: ...jection pump 3 Release the pump fixing bracket bolts to disassemble the bracket from the cylinder block Note Do not interchange the shims as they must be installed in their original positions at reassembly 3 1 19 Oil filter 1 Using a filter remover remove the filter element 2 Remove the pipe connected to the oil cooler 3 Loosen the oil filter fixing bolts and dis assemble the oil filter head from ...

Page 45: ...water pump fixing bolts and remove the water pump EQM3021S 3 1 23 Air compressor 1 Remove the oil hose water pipe air pipe connected to the air compressor remove the air cooler fixing bolts then disassemble the air compressor from the timing gear case EQM3022S 3 1 24 Vibration damper 1 Unscrew the pulley fixing bolts and dis assemble the pulley vibration damper assembly 2 Unscrew the vibration dam...

Page 46: ...o prevent damage to them EQM3025S 3 1 27 Fuel injection pump drive assembly 1 Remove the dowel pin for the steering pump 2 Unscrew the injection pump drive shaft bearing housing fixing bolts and remove the injection pump drive assembly in which the shaft gear bearings and housing are put together EQM3026I 3 1 28 Cylinder head cover 1 Unscrew the cover fixing bolts and dis assemble the cover 2 Keep...

Page 47: ...e the nozzle tube using nozzle tube removing jig Do not perform disassembly opera tion unless coolant gas etc leak out EQM3029I 3 1 31 Cylinder head 1 Unscrew the cylinder head fixing bolts and take off the cylinder head 2 Remove the cylinder head gasket EQM3030I 3 1 32 Valve and valve stem seal 1 Compress the valve spring retainer using a jig and take off the valve cotter pin 2 Disassemble the va...

Page 48: ...flywheel housing facing toward the bottom 2 Release the oil pan fixing bolts remove the stiffeners then disassemble the oil pan 45 EQM3031I EQM3032I 3 1 35 Oil pump and oil pipe 1 Unscrew the oil inlet pipe bracket bolts releasing the pipe fixing bolts then dis assemble the oil suction pipe assembly 2 Disassemble the oil pipe feeding oil from the oil pump to the cylinder block 3 Unscrew the oil pu...

Page 49: ...he direction of piston 46 EQM3035I 3 Remove the piston pin snap rings take off the piston pin then disconnect the conn rod from the piston EQM3036S 4 Disassemble the piston rings using ring pliers 5 Take care not to interchange the disas sembled parts and keep them in the sequence of cylinder No EQM3037S 3 1 38 Cylinder liner 1 Take off the cylinder liner EQM3038I Piston ring jig ...

Page 50: ...al 1 Take off the rear oil seal using an oil seal disassembling jig 2 If only the inside guide ring is removed use a general tool to take off the outside seal 47 EQM3039I EQM3040I 3 1 41 Flywheel housing 1 Loosen the housing fixing bolts and dis assemble the flywheel housing EQM3041I 3 1 42 Cam shaft and tappet 1 Remove the cam shaft gear 2 Take off the cam shaft gear thrust washer 3 Take out the ...

Page 51: ...shaft gear 48 EQM3043S 3 1 44 Timing gear case 1 Unscrew the case fixing bolts and dis assemble the timing gear case EQM3044I 3 1 45 Crankshaft 1 Unscrew the main bearing cap fixing bolts and remove the bearing cap 2 Take off the crankshaft 3 Take off the main bearing EQM3045S 3 1 46 Oil spray nozzle 1 Remove the oil spray nozzles EQM3046S Puller ...

Page 52: ... nonmetallic mate rial to prevent scratching of the valve seat faces 2 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 Check the lower face of the cylinder head for distortion 1 Measure the amount of distortion using a straight edge and a feeler gauge at six positions as shown in the figure right 2 If ...

Page 53: ...ve if the mea sured value is 1mm or less a Dimensions Standard Limit Descriptions Intake valve N10 950 10 970 10 87 stem mm Exhaust valve N10 935 10 955 10 84 stem mm 2 Inspection and measurement of valve guide 1 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 g...

Page 54: ...tor 4 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 5 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 com pound 51 EQM3049I 4 Inspection and correction of valve spr...

Page 55: ...rable amount of step wear should be replaced 2 Measure the inside diameter of the rocker arm bushing with an inside micrometer or vernier calipers and compare the measured values with the rocker arm shaft diameter If the clearance exceeds the limit replace either bushing or shaft whichever worn more 52 EDM2037I Figure 3 5 Measuring run out of rocker arm shaft 3 Inspection of tappet and push rod 1 ...

Page 56: ...ator and compare the measured value with the camshaft outside diameter to determine the clearance 3 Replace the bushing if the measured value is beyond the specified limit 4 Support the cam shaft on two V blocks and check for run out using a dial indicator Correct or replace the cam shaft if the amount of run out is beyond the value indicating need for servicing EAOM4063 Figure 3 9 Measuring insid...

Page 57: ...g paper of fine grain size Be sure to use grinding paper which has been immersed in oil Undersize bearings available 1 Standard 2 0 25 Inside diameter is 0 25mm lesser than the standard size 3 0 50 Inside diameter is 0 50mm lesser than the standard size 4 0 75 Inside diameter is 0 75mm lesser than the standard size 5 1 00 Inside diameter is 1 00mm lesser than the standard size Undersize bearings a...

Page 58: ...nd connecting rod bearing 1 Visually check the crank shaft bearing and connecting rod bearing for scores uneven wear or damage 2 Check oil clearance between crankshaft and bearing 1 Install the main bearing in the cylin der block tighten the bearing cap to specified torque then measure the inside diameter 2 Install the connecting rod bearing in the conn rod bearing cap tighten the connecting rod c...

Page 59: ...gure 3 17 Measuring conn rod bearing inside diameter 3 Inspection of bearing spread and crush 1 Check to see that the bearing requires a considerable amount of finger pressure at reassembly opera tion 2 With a bearing crush aligner mea sure bearing crush Standard bearing crush Crank shaft bearing crush mm 0 15 0 25 Conn rod bearing crush mm 0 3 0 5 EDM2046S Figure 3 18 Checking bearing tension Fig...

Page 60: ...istons for cracks scuff or wear paying particular attention to the ring groove 2 Measurement of the clearance between the piston and cylinder liner 1 With an outside micrometer mea sure the piston outside diameter at a point 18mm away from the lower end of piston skirt in a direction at a right angle to the piston pin hole EQM3051S Figure 3 23 Measuring piston outside diameter Figure 3 24 Measurin...

Page 61: ...ld at a right angle to the cylinder liner wall 2 Measure the piston ring gap with a feeler gauge 3 Replace piston rings with new ones if the gap is beyond the limit 3 Measure piston ring side clearance 1 Fit the compression ring and oil ring in the piston ring groove 2 With a feeler gauge measure side clearance of each ring and replace either the ring or piston if the mea sured value is beyond the...

Page 62: ...e clearance between the piston pin and conn rod bushing and replace either of them which ever damaged more if the mea sured value is beyond the limit 0 011mm 2 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 replacing the piston be sure to replace the piston pin together Dimensions Stan...

Page 63: ...on of the amount of wear on the conn rod big end and small end 1 Assemble the conn rod to the crank shaft and measure conn rod big end side clearance using a feeler gauge 2 Assemble the conn rod to the piston and measure conn rod small end side clearance 3 If the measured values are beyond the limit 0 5mm replace the con necting rod 60 EJM2087I Figure 3 27 Measuring alignment of conn rod 3 2 12 Ta...

Page 64: ...ictions 2 Arrange the general and special tools for engine assembly operation 3 To wet each sliding part prepare clean engine oil 4 Prepare service materials such as sealant etc 5 Discard used gaskets seal rings and consumable parts and replace with new ones 6 Apply only the specified torque for bolts in the specified tightening order and avoid over tightening 7 Be sure to check that all the engin...

Page 65: ...the key is aligned with the key groove then apply oil to the bearing surface 2 Apply sealant in the inside wall of the crank shaft gear evenly before placing over the shaft 3 Semi tighten a bolt at both sides of the crank shaft apply engine oil to journals and pins then assemble the crank shaft with the cylinder block by tightening the fixing bolts 4 Install the oiled thrust washers with the oil g...

Page 66: ...nally to about 15kg m for the first stage and 25kg m for the second stage respectively then tighten them completely to the specified torque using a torque wrench 9 Tighten the bearing cap in the sequence of 4 3 5 2 6 1 7 10 Check to see that the assembled crank shaft turns smoothly 3 4 5 6 7 2 1 EQM3058I EQM3059I 3 3 6 Flywheel housing 1 Temporarily install the guide bar on the cylinder block 2 Ap...

Page 67: ... fly wheel for temporary assembly operation 2 Install bolts in the remaining holes with no guide bar installed take out the guide bar then install a bolt in the hole where the guide bar had been inserted 3 Tighten the fixing bolts using a torque wrench in a diagonal sequence to speci fied torque 18kg m EQM3062I 2 6 4 8 1 5 7 3 EQM3063I 3 3 9 Timing gear case 1 Mount gasket using dowel pin 2 Instal...

Page 68: ...the idle gear by coinciding the marks impressioned on the crank gear cam gear fuel injection pump drive gear and idle gear 5 Install a thrust washer on the idle gear and tighten to specified torque 6 2kg m 6 Check and adjust the amount of back lash between gears using a feeler gauge backlash 0 1 0 2 EQM3066I Fuel injection pump drive gear Idle gear Cam gear Crank gear EDM2075I 3 3 12 Timing gear c...

Page 69: ... inside diameter with engine oil EQM3069I 3 3 15 Piston and connecting rod 1 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 conn rod with the piston 2 Noting the direction of the piston make the longer side machined with key groove on the bearing of the conn rod big end and the mark of impres sione...

Page 70: ...ton 120 120 120 EFM2069I 8 Position the valve seating surface toward the tappet hole and insert the piston with hand Take care not to damage the cylinder liner and piston and slightly lift and insert the piston into the cylinder so that the ring may not be damaged by the fillet of the liner EDM2080I 9 Install the bearing in the conn rod cap and apply oil 10 Make sure that the manufacture num bers ...

Page 71: ...ng bolts in the described order EQM3074I 3 3 17 Oil pump and oil pipe 1 Install a dowel pin in the No 7 bearing cap mount gasket then assemble the oil pump 2 Install the fixing bolts and bend the fixing washers to prevent looseness of bolts 3 Assemble the oil suction pipe with the delivery pipe then install the bracket on the ladder frame EQM3075I 3 3 18 Oil pan 1 Mount gasket and put the oil pan ...

Page 72: ...alve is assembled correctly EJM2027S 3 3 20 Nozzle tube 1 Apply sealant LOCTITE 620 to the nozzle tube and place the O ring over the cylinder head fitting face on the nozzle tube then install the nozzle tube in the cylinder head 2 Install a nozzle tube pressing tool into the cylinder head then tighten the noz zle fixing nuts 3 Apply engine oil to an expander and install it onto the special tool 4 ...

Page 73: ...d bolts 2 Clean the head bolt holes on the cylin der block with compressed air to remove foreign substances and thor oughly clean the gasket fitting face of the cylinder block 3 Install head gasket with TOP mark facing upward on the cylinder block by aligning the holes with dowels 4 Check the inside of combustion cham ber for foreign substances and careful ly mount the cylinder head assembly in th...

Page 74: ...f the cylinders and intake exhaust valves beginning with the flywheel housing size Intake valve clearance 0 3mm Exhaust valve clearance 0 3mm 9 Adjust valve clearance with a feeler gauge and tighten the fixing nuts to specified torque 4 4kg m 71 EQM3082I 6 5 4 3 2 1 EA2O2001 EDM1003S EQM3083I Tightening sequence of cylinder head fixing bolts ENGINE TOP VIEW Cylinder No Cylinder No 1 2 3 4 5 6 IN E...

Page 75: ...and oil cooler EQM3018S 3 3 26 Oil filter 1 With the hollow screw assemble the oil pipe connected between the oil cooler and cylinder block 2 Install a connection pipe between the oil cooler and oil filter 3 Install the oil cooler connecting pipe 4 Install packing and assemble the oil fil ter using a filter assembling wrench EQM3018S 3 3 27 Injection pump 1 Install the fuel injection pump bracket ...

Page 76: ...to the fuel injection pump is aligned with the notch mark of the timer 73 EQM3088I EQM3089S 7 Tighten the coupling fixing bolts and nuts to specified torque 6 0kg m 8 Tighten the drive shaft connecting flange fixing bolts to specified torque 7 5 8 5kg m 9 Install the oil delivery pipe and return pipe 10 At the same time install the oil delivery pipe which feeds oil to the air compressor EQM3090I 3...

Page 77: ...31 Air compressor 1 Mount gasket and assemble the air compressor assembly with care to pre vent damage 2 Using hollow screw assemble the oil delivery pipe with the adaptor 3 Install water hoses to the water pump 4 Connect the air hoses and pipes to the air compressor EQM3094S 3 3 32 Water pump 1 Mount a new gasket 2 Install the water pump drive pinion over the air compressor spline 3 Connect water...

Page 78: ... 3 34 Turbocharger 1 Fit a new gasket over the stud bolts of the exhaust manifold before tightening those turbocharger fixing bolts 2 Install the oil supply pipe and return pipe 3 Fit a gasket on the exhaust side of the turbocharger to assemble the exhaust elbow then install the bracket onto the cylinder block 4 Semi assemble the bracket to the intake pipe connect a rubber hose between the turboch...

Page 79: ...a nut at both ends of the fuel high pressure pipe and tighten them up one by one to specified torque 2 Tighten hollow screws to assemble the fuel return pipe 3 Assemble the fuel return hose with the fuel injection pump EQM3101I 3 3 38 Fuel filter 1 Assemble the fuel filter at bracket 2 Assemble the fuel hose EQM3102I 3 3 39 Cylinder head cover 1 Assemble the cover packing with the cover install th...

Page 80: ...ixing bolt onto the cylinder head 2 Install the alternator in position EQM3105S 3 3 42 Cooling fan 1 Install the cooling fan and flange onto the fan coupling 2 Install the flange onto the crank pulley EQM3106I 3 3 43 V belt 1 Install the V belt on the crank pulley idle pulley and alternator pulley 2 Adjust the V belt tension using the A C compressor tension adjusting bolt 3 Install another V belt ...

Page 81: ...radiator or surge tank check the air bleeding of the fuel system 4 Connect the electrical systems such as starter air heater etc with power source 3 4 2 Breaking in 1 Idle the engine for about 30 minutes 2 Run the engine at 1 200 1 600 rpm for about 2 hours 3 Run the engine at the maximum speed for about 10 minutes when the temperature of cool ing water reaches 80 95 4 Keep checking the oil pressu...

Page 82: ... 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 tem perature 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 79 Water p...

Page 83: ...ical seal 4 Remove the shaft and bearing assembly from the housing 5 With a press remove the spline shaft and bearing 6 Reverse the disassembly sequence for reassembly operation 7 Replace the oil seal 6 with a new one at reassembly 8 To reassemble the impeller maintain a constant gap 0 3 0 6mm between the impeller and pump housing using a feeler gauge 80 ...

Page 84: ...Thickness 0 3 0 6 Par latex coating 2 Bead 1 Water pump housing 2 Pipe 3 Shaft 4 Mechanical seal 5 Impeller 6 Oil seal 7 Ball bearing 8 Spacer 9 Ang contact ball 10 Stop ring 11 Spline shaft 13 Cover water pump housing 14 Bolt ass y 15 Pipe for surge tank EQM4003I ...

Page 85: ...iner of water then heat the water slowly and check temperature with a thermometer If the valve lift is 0 1mm starting to open at temperature of 83C and 8mm or more opening wide at temperature of 95C the thermostat is normal 3 Replacing thermostat and precautions for handling 1 Precautions for handling The wax pallet type thermostat does not react as quickly as bellows type one to a variation of te...

Page 86: ...er jacket 10 Replace cylinder head gasket due to broken cylinder head gasket 2 Engine 1 Thermostat inoperative 1 Replace thermostat overcooling 2 Ambient temperature too low 2 Install radiator curtain 3 Lack of 1 Radiator leaky 1 Correct or replace coolant 2 Radiator hoses loosely connected 2 Retighten clamps or replace hoses or damaged 3 Radiator cap valve spring weakened 3 Replace cap 4 Water pu...

Page 87: ...tem 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 10L1 5 Valve opening pressure kg cm2 1 8 2 3 kg cm2 Bypass for entire oil filter Bypass for oil cooler Valve opening pressure kg cm2 4 0 4 8 Opening pressure kg cm2 5 1 Adjusting valve for spray nozzle O...

Page 88: ...sassemble the drive gear and dri ven gear 85 EQM4006I Figure 4 6 Disassembling drive gear EQM4007I Figure 4 7 Disassembling pump cover 2 Inspection and correction 1 With steel rule and feeler gauge measure the axial end play of the oil pump gear Replace if the measured value is beyond the limit EQM4008I Figure 4 8 Measuring end play 2 With a feeler gauge measure the amount of back lash between the...

Page 89: ...ermine 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 077mm 3 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 86 Oil filter Car...

Page 90: ...l seals or valve 6 Replace guides or valve stem worn Oil pressure 1 Poor oil 1 Use suggested oil too low 2 Relief valve sticking 2 Replace 3 Restrictions in oil pump strainer 3 Clean strainer 4 Oil pump gear worn 4 Replace 5 Oil pump feed pipe cracked 5 Replace 6 Oil pump defective 6 Correct or replace 7 Oil pressure gauge defective 7 Correct or replace 8 Various bearings worn 8 Replace Oil deteri...

Page 91: ...ry pipe 8 Fuel pipe manual pump filter 9 Fuel tank 10 Fuel return pipe 11 Suction pipe 12 Feed pump 13 Injection pump EQM4011I 4 3 2 Injection pump The components related 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 dete rioration of the engine Make sure that servicing should be perfor...

Page 92: ...C 12 b Calibration data 89 Adjusting Rack position Pump speed Injection volume Variation Basic Fixing Ref point mm rpm mm3 1 000st rate point point A 9 4 700 123L2 L2 0 B 9 4 1 100 117L3 L3 C 8 9 500 110L2 L3 D 5 2 250 14 5L1 5 L15 E 100 100 or more Contents Specifications Engine application Nozzle holder assembly 105780 8140 65 10101 7070 Nozzle 105780 0000 65 10102 6032 Nozzle holder 105780 2080...

Page 93: ... c Adjusting governor 90 9 4 8 9 8 4 6 7 5 2 3 9 1170 1150 20 680 20 500 15 390 10 1205 5 380 250 D B A E RACK LIMIT CR 9 5 Rack position mm Injection pump speed rpm or more 0 05 EQM4012I ...

Page 94: ...g BTDC 8 b Calibration data Adjusting Rack position Pump speed Injection volume Variation Basic Fixing Ref point mm rpm mm3 1 000st rate point point A 12 700 99 L2 0 B 12 3 1 100 95L3 C 11 3 500 81 D 8 5 250 14 5 L15 E 100 95L3 Contents Specifications Engine application Nozzle holder assembly 105780 8140 65 10101 7070 Nozzle 105780 0000 65 10102 6032 Nozzle holder 105780 2080 Opening pressure 175 ...

Page 95: ...2 c Adjusting governor A B C RACK LIMIT D 12 1 12 0 11 3 8 5 10 5 or more 8 1 0 0 1 0 1 6 5 250 290 380 500 700 1100 1120 1210 15 12 3 Rack position mm Injection pump speed rpm Damper spring set EQM4013I ...

Page 96: ...TDC 9 b Calibration data Adjusting Rack position Pump speed Injection volume Variation Basic Fixing Ref point mm rpm mm3 1 000st rate point point A 10 9 700 161 5L2 L2 0 B 10 9 1 100 152L3 L3 C 500 97 D 5 2 250 14 5L1 5 L15 E 100 165L5 Contents Specifications Engine application Nozzle holder assembly 105780 8140 65 10101 7071 Nozzle 105780 0000 65 10102 6033 Nozzle holder 105780 2080 Opening press...

Page 97: ...94 c Adjusting governor 9 4 8 9 8 4 6 7 5 2 5 2 3 9 1170 1150 20 680 20 500 15 390 10 1205 5 380 250 D B A E RACK LIMIT CR 9 5I0 05 EQM4014I Rack position mm Pump speed rpm Rack limit CR 9 510 05 or more ...

Page 98: ...b Calibration data Adjusting Rack position Pump speed Injection volume Variation Basic Fixing Ref point mm rpm mm3 1 000st rate point point A 8 2 1 050 135L2 L2 0 B 5 1 250 16L1 5 L15 C 100 90 or More D 8 7 500 150L3 E 7 1 500 115 L3 Contents Specifications Engine application Nozzle holder assembly 105780 8140 65 10101 7072 Nozzle 105780 0000 65 10102 6034 Nozzle holder 105780 2080 Opening pressur...

Page 99: ...ing governor 8 7 7 1 8 2 R1 R2 1 5 4 0 R4 5 1 R2 R2 3 6 0 5 250 25 450 15 720 15 1100 10 0 5 0 1 850 1185 250 B D A C E BOOST COMPENSATOR STROKE 1 6 0 1 mm Rack position mm Injection pump speed rpm or more EQM4016I ...

Page 100: ... Calibration data Adjusting Rack position Pump speed Injection volume Variation Basic Fixing Ref point mm rpm mm3 1 000st rate point point A 9 2 1 050 154L2 L2 0 B 5 1 250 16L1 5 L15 C 100 100 D 9 7 500 170L3 E 7 1 500 115L3 Contents Specifications Engine application Nozzle holder assembly 105780 8140 65 10101 7072 Nozzle 105780 0000 65 10102 6034 Nozzle holder 105780 2080 Opening pressure 175 kg ...

Page 101: ...justing governor 9 7 7 1 9 2 R1 R2 1 5 3 0 R4 5 1 R2 R2 3 6 0 5 250 25 450 15 740 15 1100 10 0 5 0 1 870 1185 250 B D A C E BOOST COMPENSATOR STROKE 2 6 0 1 mm Rack position mm Injection pump speed rpm EQM4017I ...

Page 102: ... b Calibration data Adjusting Rack position Pump speed Injection volume Variation Basic Fixing Ref point mm rpm mm3 1 000st rate point point A R1 1 050 171L2 L2 0 B R2 250 14 5L1 5 L15 C 100 115 D R1L0 5 500 186 5 L3 E R1L2 5 500 122 L3 Contents Specifications Engine application Nozzle holder assembly 105101 7971 65 10101 7294 Nozzle 105029 1320 65 10102 6043 Nozzle holder 105030 4711 Opening pres...

Page 103: ...ting governor R1 R2 1 5 R4 R2 R2 3 6 0 5 250 25 450 15 720 15 1100 10 0 5 0 1 850 1185 250 B D A C E BOOST COMPENSATOR STROKE 2 5 0 1 mm EQM4017I Rack position mm Pump speed rpm Boost compensator stroke 2 5 L 0 1mm ...

Page 104: ... Calibration data Adjusting Rack position Pump speed Injection volume Variation Basic Fixing Ref point mm rpm mm3 1 000st rate point point A R1 1 050 158 0L2 L2 0 B R1 1 5 630 162 3L3 L15 C R1 1 85 500 173 8L3 I R2L2 0 100 45 8 H R2 300 2 3 Contents Specifications Engine application Nozzle holder assembly 105780 8250 65 10101 7298 Nozzle 105780 0120 Nozzle holder 105780 0120 Opening pressure 220 k...

Page 105: ...c Adjusting governor Rack position mm Injection pump speed rpm A B C I H BOOST COMPENSATOR STROKE 3 8 0 1 mm R1 0 55 R1 0 9 R1 1 5 R1 1 85 R2 2 0 R2 R1 420 10 540 10 1100 10 500 790 850 950 1185 250 EA2M4001 ...

Page 106: ...njection pump and performs recipro cating 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 compresse...

Page 107: ...ration air must be bled from the fuel lines When using the priming pump fix it securely to prevent the possible entry of moisture or other foreign substances inside of feed pump In addition a gauge filter is fitted into joint bolt on the inlet side of the fuel feed pump to filtrate any foreign substances possibly mixed in fuel 104 EQM4020I A Inlet side B Outlet side C Interruption ...

Page 108: ...on and tappet for damage 3 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 NOTICE Check the item no 3...

Page 109: ... Outlet hose Feed pump Inlet hose EQM4022I 2 Delivery test Make a test with the the feed pump mounted on a pump tester as illus trated Operate the the pump at the rate of 1 000 rpm and check to see if the pump delivery is more than 405cc 15 seconds EQM4022I Figure 4 16 Delivery test 3 Sealing test Plug up the delivery port on the feed pump and apply compressed air of 2kg cm2 into the inlet side Su...

Page 110: ...eral descriptions Pressurized fuel delivered from the fuel injection pump is sprayed into the combustion cham ber 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 EQM4025S Figure 4 18 Spray patterns 1 2 3 5 9 7 8 6 4 Figure 4 19 Exploded view of 1 spring ...

Page 111: ... nozzle tester lever at the specified rate d Adjust the injection pressure to the standard pressure using the adjusting screw e After adjusting the injection pressure tighten the cap nut to specified torque f 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 200 210 bar applied check the nozzle for fuel lea...

Page 112: ... 17 1 1 Nozzle holder body 2 Push rod 3 Primary spring 4 Adjusting screw 6 Gasket 7 Cap nut 10 Adjusting shim 11 Secondary spring 12 Spring seat 13 Lift pin 14 Pin 15 Spacer 16 Pin 17 Retaining seat 30 Gasket 31 Eye bolt A Nozzle EQM4029I Fig 4 23 Exploded view of 2 spring ...

Page 113: ...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 110 EQM4030I Figure 4 24 Installing plate 1 EQM4031I Figure 4 25 Installing nozzle holder d Assemble adjusting shim 10 secondary spring 11 and spring seat 12 on the nozzle holder body in the order as described Figure 4 26 Note The secondary spring is the same one as the pri...

Page 114: ...g After installing the gasket 157892 1500 on the nozzle use the retain ing nut 157892 4000 SW22mm to fix the nozzle onto the nozzle hold er Figures 4 28 and 4 29 Note While tightening the retain ing 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 tighten ing then further tighten it using a torque wrench EQM4035I Figure...

Page 115: ...ozzle holder on the plate Figure 4 31 EQM4037I Figure 4 30 Fixing the nozzle Figure 4 31 Installing nozzle holder j Assemble the push rod 2 primary spring 3 and adjusting screw 4 on the nozzle holder in the order described Figure 4 32 k Install the gasket 6 and cap nut 7 onto the adjusting screw 4 EQM4038I Figure 4 32 Assembling secondary push rod primary spring and adjusting screw 4 2 3 ...

Page 116: ...ssembly m Adjust the primary opening pres sure to the specified pressure using the adjusting screw 4 Figure 4 34 EQM4040I Figure 4 34 Adjusting the primary opening pressure n With a monkey wrench fix the nozzle holder securely and tighten the cap nut SW19mm to speci fied torque Figure 4 35 Cap nut tightening torque 29 39N m 3 0 4 0kg m EQM4041I Figure 4 35 Tightening cap nut ...

Page 117: ...ure 4 36 114 EQM4042I Figure 4 36 Installing gasket and plug b Install the nozzle holder on the plate with the cap nut facing upward c Install the holder into the cap nut Figure 4 37 EQM4043I Figure 4 37 Installing nozzle holder d Install a nut 157892 1000 17mm on the holder EQM4044I Figure 4 38 Installing the nut ...

Page 118: ...dial gauge on the holder assembly so that the pin is brought into contact with the upper end of the push rod then fix the pin with the nut Figure 4 40 Note 1 Fix the dial gauge so that a stroke of 2mm or so can be measured Note 2 Overtightening the nut may cause a sticking of the dial gauge seat 115 EQM4045I Figure 4 39 Installing pin EQM4046S Figure 4 40 Installing dial gauge Dial gauge Threaded ...

Page 119: ...ease the tester pressure up to 350 450 kgf cm2 in order that the needle valve can be fully lifted Then record the full lift value L Figure 4 42 Note This testing is to be made in order to check the nozzle seat portion for unusual wear or whether the nozzle assembly is a standard item 116 EQM4047I L 0 EQM4048I Tester pressure Amount of lift Figure 4 41 Air in the retaining nut Figure 4 42 Checking ...

Page 120: ...lue on the dial gauge at the point of time when the secondary spring completes its opera tion and the needle valve puts an end to descent the position of needle valve lift value l as shown in the figures 4 44 and 4 45 and check that the value is within the specified limit 117 200 100 400 500 0 300 kgf cm2 EQM4049I Figure 4 43 Drop of tester pressure L 0 EQM4050I Figure 4 44 Descent of needle valve...

Page 121: ...6 lift piece 13 spacer 15 and nozzle assembly A with a new nozzle service kit Figure 4 47 13 14 15 16 A EQM4053I Figure 4 47 Nozzle service kit Inspection of secondary opening pressure a After confirming the pre lift operate the nozzle tester and increase the internal pressure up to 350 450kgf cm2 to fully lift the needle valve Figure 4 48 b Release the nozzle tester handle to decrease the tester ...

Page 122: ...ified needle valve lift value in general pre lift M 0 05mm Figure 4 50 119 0 20 40 60 80 100 0 EQM4055I Figure 4 49 Checking the secondary opening pressure by means of cover method 90 80 70 60 50 40 30 20 10 0 200 100 0 500 400 300 EQM4056I Figure 4 50 Taking needle valve lift value and measuring secondary opening pressure ...

Page 123: ...ressure still deviates from the specified limit in spite of the readjusting the primary opening pressure take off the nozzle fixing por tion from the nozzle holder and remove the adjusting shim 10 Figure 4 52 c If the secondary opening pressure is higher than the standard value fit a thinner adjusting shim than the existing one d After replacing the existing adjusting shim measure the secondary op...

Page 124: ...tances are shown below Also check that the resistance between the terminals and the hous ing is Terminal Resistance Ω 1 2 2 45 2 95 3 4 5 5 6 1 5 6 5 5 6 1 EA2M4003 2 Check the conductance between each of the pre stroke acuator termi nals and connectors using a circuit tester COUTION The connector ter minal layouts and shapes differ with maker and engine Con Act Harness term term Remarks no no col...

Page 125: ...s snown in the table below Note The above apply to speed sen sors with the following part numbers 479748 6201 479748 6600 479748 6800 Also check that the resistance between the terminals and the housing is Wire color Resistance kΩ Yellow SIGNAL 2 1 2 5 Black GND 3 Pre stroke actuator installation 1 Insert the ball on the end of the actu ator s shaft into the top of the U shaped link s opening Temp...

Page 126: ... smooth ly when moved with a finger as shown at left 123 EA2M4008 3 Install the actuator cover on the actu ator and tighten the bolts to the spec ified torque Specified torque 4 9 6 9 N m 0 5 0 7 kgf m EA2M4009 4 Connect the fuel hose to the rear of the actuator EA2M4010 ...

Page 127: ...nel switch dial and ter minal 124 EA2M4011 Key no Name Remarks 1 Power switch Used to turn the checker s power ON add Off 2 Pilot lamp 3 Target dial Used to set the pre stroke actuator s output voltage 4 Actuator operation switch Switch to Normal when operating the actuator and Act OFF when not operating the actuator 5 Rack sensor output terminals Used to connect the racd sensor to the digital vol...

Page 128: ... the pre stroke actuator from over heating EA2M4013 3 Reinstall the measuring device 105782 4371 on the No 1 cylinder as described in Injection timing adjustment 4 Adjust the pump test stand s fuel oil supply pressure to as low a pressure as possible eg 20 kPa 0 2 kgf cm2 5 Turn the pump test stand s flywheel and adjust the No 1 cylinder s lift to 4L0 05mm refer to pages 50 and 51 EA2M4014 ...

Page 129: ...ch OFF to cut the power to the actuator 2 Turn the pump test stand s flywheel and confirm that the pre stroke is 6 4L0 03mm refer to pages 51 and 52 3 Turn the checker s power switch on and then turn the Normal Act OFF switch to Act OFF At this time confirm that the pre stroke sensor output is 1 2L0 2 V 4 Set the control unit s Normal Act OFF switch to Normal and position each switch etc as shown ...

Page 130: ...e holder Then tighten the delivery valve holder to the specified torque 2 Attach the measuring device 105782 6370 to the end of the control rod 127 EA2M4018 EA2M4019 3 Lock the control lever near the idling position 4 Fully tighten the governor shaft to loosen the governor spring Then loosen the idling spring s plate plug to loosen the idling spring 5 Increase the pump speed to 1 000 1 200 r min a...

Page 131: ...4017 3 If not as specified loosen the injec tion pipe loosen the two nuts fixing the plunger barrel s flange and then turn the flange right or left to adjust the injection quantity Note When the sleeve flange is turned as shown in the figure at left right helix plunger the injection quantity increases EA2M4021 4 Idling fuel quantity confirmation Rotate the target dial to set the sen sor output to ...

Page 132: ...ll the block and measure the dis tance X EA2M4024 3 Install the joint and measure the dis tance Y EA2M4025 4 Install the core and adjust the dimen sion X using shims until it equals Y After adjusting the distance Y install the joint and check the fuel injection quantity Note If not as specified add or remove shims until it is as specified EA2M4026 ...

Page 133: ... 3 Read the pump speed that corre sponds to the specified rack position from the governor graph of the fuel injection quantity adjustment table page 1 of the data sheet and set the pump speed to the speed specified EA2M4028 4 Then adjust the depth that the bob bin is screwed in so that the rack sen sor output voltage is 2 00L0 01 V COUTION The values at left vary with the pump Refer to the data sh...

Page 134: ...19 20 1 6 7 VEHICLE EA2M4031 1 Prest ACT 5 TW sensor 6 Prest sensor OSC 7 Prest sensor MDL 8 Rack sensor OSC 9 Rack sensor MDL 10 Ne sensor SIG 12 Pre heater relay 14 Prest ACT 19 Prest sensor GND 20 Prest sensor SHLD 21 Prest sensor GND 23 Ne sensor GND 27 Prest power VB 29 Diag SW 31 Tacho SIG 32 K line 33 DDS 3 data 34 DDS 3 clock 35 DDS 3 stb 36 Prest shut off relay 37 VB 38 Prest Power GND 39...

Page 135: ...emble the nozzle holder to a nozzle tester and check the primary opening pressure spray patterns oil tightness of seat portion and oil leakage from each part Figure 4 54 0 20 40 60 80 100 EQM4059I Figure 4 54 Inspection at completion b When replacing the nozzle replace it with a new nozzle service kit integrat ed with a nozzle lift piece and spacer as a complete set Figure 4 55 Note If only a nozz...

Page 136: ...zle and needle valve 3 Injection pressure incorrect Adjust 2 Engine starts but 1 Pipe from feed pump to injection pump Clean stalls immediately clogged or filter clogged 2 Air in fuel Bleed 3 Feed pump delivery insufficient Disassemble correct 4 Fuel delivery insufficient due to clogging Replace breather of fuel tank air breather 3 Engine lacks power 1 Plunger worn excessively Replace 2 Injection ...

Page 137: ...es 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 uns...

Page 138: ... Model Specifications Air pressure at compressor outlet About 1 257kg cm2 Gauge At maximum output Air suction volume About 19 0m3 min Speed of turbine revolution About 95 000rpm Maximum allowable speed 110 000rpm Max allowable temperature of exhaust gas at turbine inlet 750C Lubricating system External oil supply Weight 14kg 135 Exhaust pipe Turbine wheel and shaft assembly Turbine housing Oil inl...

Page 139: ...st space 35 Piston 6 Retaining ring 21 Piston ring 36 Bracket body 7 V band 22 Seal ring 37 Cove 8 Wheel 23 Seal ring 38 Retainer 9 Piston ring 24 Rear plate 39 Gimble 10 Wheel shroud 25 Bolt 40 Diaphragm 11 Center housing 26 O ring 41 Spring 12 Retaining ring 27 Compressor wheel 42 Nut 13 Bearing 28 Nut 43 End rod 14 Retaining ring 29 Bolt 44 Retaining ring 15 Retaining ring 30 Clamp 45 Bolt ...

Page 140: ... that the turbine shaft can get rotating force This is the working 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 rotat ing body takes in and compresses ambient air with rotating force transmitted from the turbine...

Page 141: ...3 0 4 8kg cm2 2 If unusual sound or vibration is heard or felt reduce engine revo lutions slowly and locate the cause 1 Run the engine at idle for 5 min utes before stopping 2 Abrupt starting of the engine causes the engine to rotate with oil not being distributed not only to each part but also to the tur bocharger resulting in abnormal wear or seizure on the bearing due to insufficient supply of ...

Page 142: ... ers charging effect As such components as turbine chamber that becomes red hot during operation use heat resisting steel nuts do not interchange these nuts with ordinary steel nuts In addition apply anti seizure coating to fixing nuts on the portions as designated 3 Fuel system If the full load stopper regulating the maximum injection volume and the maximum speed stop per regulating the maximum s...

Page 143: ...g 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 tape etc 1 Rotor axial play 140 Turbine wheel chamber Magnetic vise Dial gauge Move...

Page 144: ...b Be sure to use heat resisting steel bolts and nuts Do not interchange them with ordinary steel bolts and nuts when performing reassembly operation Apply anti seizure coating to the bolts and nuts c Assemble each joint on the exhaust pipes securely to prevent gas leaks 4 4 7 Diagnostics and troubleshooting 141 Complaints Possible causes Corrections 1 Excessive black 1 Air cleaner element clogged ...

Page 145: ... displayed to the system check and memory check items of the scan pole screen 5 2 2 Select function Follow screen is the main menu screen in here user can select a test item Selecting method is two ways Move to the test item by means of using up down key and press the key If user selects the then following screen will be displayed ELECTONIC VEHICLETEST ENTER ON OFF ON OFF 142 EA2M5001 Diagnosis po...

Page 146: ...t of unit check In here press the key to go on next screen Now user can test concerned with elec troic control engine ENTER Engine Control Unit DAEWOO BUS 143 COMMUNICATION CHECK ENGINE MODEL DE12TIS DHI ECU NO 65 12201 7001 DHI ROM NO 65 99901 0001 ZEXEL ECU NO 2860 ZEXEL ROM NO 1320 PART NO EF 123 157 COMMUNICATION ERROR Communication falt Check on connection and do it again Line and unit checki...

Page 147: ... F2 function key at self diagnosis screen then display as shown on the right In here press the key for erase or press the key for cancel Then you can see the screen with Self diagnosis result is normal as shown onthe right 5 3 4 Printing User can print the self diagnosis result or help message and repair hint to press the F6 function key Before printing Scan Pole must be connected with printer via...

Page 148: ...can select a sensor to press the F1 function key And then left Selection indication bar display mark at the same time sensor data displayed on top of the screen Selected data is used to graph function or to see concerned sensor s value If user wants to deselect it then press the F1 function key again SELECT SELECT SELECT PRINT MULTI GRAPH FULL SELECT SENSOR DATA DIAGNOSIS ITEM SELECT SENSOR DATA 1...

Page 149: ...IR HINT or refer to D12TIS DIAGNOSIS REAIR HINT Press the F4 function key then the screen for sensor data multimeter will be displayed as shown on the right F1 Testing value displayed on screen is frozen to allow analysis during pressing the F1 key F2 Voltage meter F3 Frequency meter F4 Duty meter Tested value of each meter is displayed at each 1 µs sampling term DUTY FREQ VOLT FIX MULTI MULTI FIX...

Page 150: ...D data output 5 F5 RECORD data graph output 6 F6 RECORD data printing User can adjust interval of recording time using F3 key Time Interval 0 1 10 0 sec TIME PRINT GRAPH OUTPUT TIME RECORD SELECT FLIGHT RECORD DIAGNOSIS ITEM FLIGHT RECORD ESC Now it is not engine running Please starting engine STOP ACTUATOR TEST 147 ACTUATOR TEST 1 PRESTROKE ACTUATOR TEST 2 TACHO METER TEST 3 AIR HEATER LAMP TEST ...

Page 151: ...press the key Then diagnosis code will be read before recording And diagnosis fault numbers are dis played as shown on the right And then press the key to start recording User can finish the recording to press the F3 key STOP ENTER YES ENTER RECORD RECORD RECORD SELECT SELECT SELECT FLIGHT RECORD 148 FLIGHT RECORD 01 ENGINE RPM RECORD 05 WATER TEMP SENSOR RECORD 06 RACK SENSOR OFFSET RECORD 07 PRE...

Page 152: ...a each one step by means of using up down keys for increase one step or using left right keys for move 10 steps There will be no output when total step is 0 5 6 6 function F5 key is used to see graph view for the items recorded RAPH GRAPH OUTPUT OUTPUT OUTPUT TIME TIME 149 FLIGHT RECORD 01 ENGINE RPM RECORD 05 WATER TEMP SENSOR RECORD 06 RACK SENSOR OFFSET RECORD 07 PRESTROKE OFFSET RECORD IME INT...

Page 153: ...OR circuit or water NO 5 pinand NO 24ofECU as follow temperature sensor TEMP RESISTANCE 20 2500 40 1170 60 594 80 310 2 Check the water temperature sensor 3 Check if cable is short or open 4 Check the contacts of connector C22 FUEL RACK Error is fuel rack CHECKING CONDITION Key on Running SENSOR ERROR sensor or circuit REGULAR VALUE Running below 0 2V IDLE below 3 49V 1 Check the voltage between p...

Page 154: ...le is short or open 4 Check the contacts of connector C13 PRESTROKE Error in prestroke CHECKING CONDITION Key on SENSOR ERROR sensor REGULAR VALUE f 18 2kHz 1 Check the resistance of prestroke actuator sensor as follow pin No 6 pin and pin No 7 of ECU pin No 6 pin and pin No 19 of ECU pin No 7 pin and pin No 29 of ECU 2 Check the prestroke sensor 3 Check if cable is short or open 4 Check the conta...

Page 155: ... Nozzle tube Insert ass y DPN 5337 2 Nozzle tube Extracter ass y EF 123 082 EF 123 015 DE12 T TI 3 Inj pump setting ass y EF 123 156 DE12TIS 4 Oil seal insert ass y FR EF 123 126 5 Oil seal insert ass y RR EF 123 053 6 Oil seal puller ass y FR EF 123 052 EA2M5003 ...

Page 156: ...l 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 Stem seal insert EF 123 066 11 Valve clearance adjust ass y EU 2 0131 12 Valve cottor extracter ass y EF 123 065 03 EA2M5003 ...

Page 157: ...m 3 Nozzle fixing cap nut 6 8kg m 4 High pressure injection pipe fixing cap nut Max 3 5kg m 154 Part Dia Bpitch mm Grade Tightening torque Cylinder head bolt M14B1 5 12 9T 24 5 Conn rod bearing cap bolt M16B1 5 12 9T 28 Crankshaft main bearing cap bolt M16B1 5 12 9T 30 Balance weight fixing bolt M14B1 5 10 9T 9 Flywheel fixing bolt M14B1 5 10 9T 18 Crankshaft gear fixing bolt M12B1 5 10 9T 13 4 ...

Page 158: ...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 15 50 17 90 18 50 26 00 31 00 M6B1 5 6 20 6 50 9 70 8 60 12 50 11 30 17 00 19 50 20 00 28 00 33 50 M18 7 80 8 30 12 50 11 00 16 00 14 50 21 00 24 20 25 00 36 00 43 00 M18B1 5 9 10 9 50 14 50 12 50 18 50 16 70 24 50 27 50 28 50 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 M20B1 5 12...

Page 159: ...ston diameter 18mm from the lower side 122 433 122 863 Clearance between piston and liner 0 123 0 162 Piston Tor ring 3 5 Width of piston ring 2nd ring 3 060 3 080 Replace piston if groove width grooves Oil ring 4 040 4 060 is beyond specified value Major Piston projection from cylinder block upper surface 0 0 12 moving Top ring 0 30 0 45 1 5 parts Piston ring gap 2nd ring 0 35 0 50 1 5 Standard g...

Page 160: ...ng torque of journal bearing cap bolt 30 Apply oil to bolt moving Journal bearing crush 0 15 0 25 parts Oil seal for wear Replace oil seal if oil leaking Replace with new one use shim Clearance between conn bearing crank pin 0 032 0 102 0 20 Replace bearing End play of conn rod 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 cr...

Page 161: ...or more Replace Perm radial run out between valve stem valve head Clearance between valve guide cyl head installing hole 0 01 0 39 Apply oil to valve guide and press in Clearance between valve Intake 22 Valve Valve guide valve spring seat Exhaust 22 Free length 75 5 72 85 9 Intake Spring tension set length 37mm kg 65 61 8 68 3 61 8 Spring 57 1L3 51 Straightness against free length 10 Free length 6...

Page 162: ...0 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 0 077 Replace gear or cover Clearance between drive gear bushing cover hole 0 040 0 089 Replace bushing or cover Oil Outside diameter of gear shaft N 17e7 16 950 16 968 Replace gear pump Outside diameter of drive gear bushing N 28e7 27 939 27 960 Replace bushing Betwe...

Page 163: ...stat opening temp Thermostat under atmospheric pressure C 83 Replace if defective Full opening temp C 95 or lower Stroke minimum 8mm Compression pressure Cylinder compression pressure kg cm2 28 or higher 24 28 or higher 24 or higher Overhaul the engine at 200 rpm or more Piping Fuel pipe injection pipe Nozzle holder for and the damage cracks looseness bad packing Correct or replace other Fuel filt...

Page 164: ... 8 12 or less Correct if damaged Bolt tightening for loose Correct Electric Run out of shaft N14 0 1 or less Correct device Front bearing N14 0 1 Armature Gap between shaft Center bearing N20 4 0 1 Replace bush or shaft brush Pinion bearing N14 0 2 Diameter of commutator N48 N45 Replace Out of round of commutator 0 05 or less 0 4 or less Correct Starter Commutator Depth of under cut insulator from...

Page 165: ...at 20C after recharging 1240 1260 10 8 or more Adjust specific gravity Capacity 20 hrs rate 24 65B2 Terminal voltage 12 6 or more 0 8 or more Recharge Height of electrolyte level Specified level Replenish distilled water if low Running in the engine Refer to SUPPLEMENT Running in Retighten head bolt after running in Compression pressure of cylinder kg cm2 28 or more 24 28 24 or more Correct At 20C...