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DOOSAN Generator diesel engine DE12T, P126TI, P126TI-1, P126TI-II, PU126TI. Operation and Maintenance Manual - page 2

5.5. Fuel System

5.5.1. Fuel filter

● After every

200 hour of operation,

drain the water and sediment from

1

the fuel-water separator.

3

● Shut off the engine. Use your hand to

5

4

open the drain valve (6).

● Turn the valve counter clockwise

2

approximately 2 ~ 3 turns until draining

occurs. Drain the filter sump of water

6

until close fuel is visible.

EA2O4009

● Turn the valve clockwise to close the

drain valve. Do not over tighten the

valve, overtightening can damage the

threads.

5.5.2. Replacement of fuel filter

● Clean the area around the fuel filter

head (3).

● Remove the fuel filter

(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.

NOTE :

Mechanical over tightening of the

filter can distort the thread or

damage the filter element seal.

Maintenance and Care

-

37 -

5.5.5. Priming pump strainer cleaning

Clean the priming pump strainer every

200

operation hours.

The strainer is incorporated in the priming

pump inlet side joint bolt.

Clean the strainer with the compressed

air and rinse it in the fuel oil.

Strainer(Inner)

EA7O5009

5.5.6. Bleeding the fuel system

Whenever fuel filter is changed or the

engine is stopped by cause of the fuel

lack, the air of fuel line must be removed

as follows.

Bleed the fuel by manually operating the

priming pump with fuel filter outlet joint

Priming pump

bolt and injection pump bleeder screw

loosened.

● Press the feed pump cap repetitively

EA9O4005

until the fuel without bubbles overflows

from the bleeding plug screw.

● After the whole air is pulled out, close

the plug screws of the filter and the

pump.

● Confirm the resistance of fuel delivery

by

repetition pressing of the feed

pump cap, Pressure and turn the prim-

ing 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.

Maintenance and Care

-

39 -

5.6. Injection Nozzle Maintenance (by authorized specialist personnel)

The injectors are designed to spray the

fuel delivered by the injection pump directly

into the spherical combustion chamber in

the piston crown. The injector consists of

the nozzle and the nozzle holder.

A copper seal fitted to the injector ensures

gas-tight seating and good heat dissipation.

The opening pressure of the nozzle is

adjusted by means of shims at the com-

EA0M3003

pression spring.

EFM1006I

● Install a nozzle to a nozzle tester.

● Check injection pressure, and adjust the nozzle using the adjusting shim if the pressure does

not meet the specified limit.

● Check nozzle spray patterns and replace if damaged.

DE12T

P126TI / P126TI-1 / P126TI-II / PU126TI

1st : 160kg/cm2

Opening pressure

220kg/cm2

2nd : 220kg/cm2

NOTE :

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

reacts chemically with the zinc coating to form powdery flakes which can quickly clog

the fuel filters and damage the fuel pump and injection nozzles.

● When mounting the pipes to the engine take care of good fitness.

● Do not bend pipes to permanent deformation (not for replacing the nozzles either).

● Do not mount any heavily bent pipes.

● Avoid bending the pipes at the ends by more than 2 to 3 degrees.

In case of faults in the injection system which might have resulted in excessive operating pres-

sures, not only the failed part but also the injection line has to be replaced.

-

40 -

Maintenance and Care

5.7. Turbocharger

5.7.1. Maintenance (by authorized specialist personnel)

The turbochargers do not call for any specific maintenance.

The only points to be observed are the oil pipes which should be checked at every oil change for leak-

age 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 soak in a ves-

sel 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

Turbine wheel chamber

clearances of the rotor be checked after

Magnetic vise

every 3,000 hours operation.

This precaution will enable any wear of the

Measuring of axial clearance bearings to be

Move the turbine

detected in good time before serious damage

shaft to axial

direction

is caused to the rotor and bearings.

Dial gauge

<Measuring rotor axial clearance>

Wear limit : 0.20mm

(m m )

EA4M2017

Axial clearance

0.2

<Measuring radial clearance>

(m m )

Radial clearance

0.65

Dial gauge

Magnetic vise

Radial play

Move the turbine shaft

Limit of wear : 0.57mm

in both directions

simultaneously

Oil inlet

EA4M2018

Maintenance and Care

-

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.

6.1.2. Adjusting order of the valve clearance

● Cylinder No. 1 begins from the rear side where the flywheel is mounted but cylinder No. 6

begins from the front side of the engine on the contrary.

Flywheel

Intake Valve

Exhaust Valve

Cylinder No.

Crank pulley

ED5OM005

Step 1 :

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

the valves corresponding to " " of following figure. At this time cylinder No. 1 should be at

the ignition TDC position (O.T).

Step 2 :

● After adjusting upper valves turn the crank pulley

360° to adjust the other valve clearance

until the cylinder No. 1 comes to overlap TDC position.

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

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

After reconfirming the valve clearances, retighten it if necessary.

-

42 -

Checking and Setting

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

and adjust the valve clearance with adjusting screw respectively.

(mm)

Model

Intake Valve

Exhaust Valve

DE12T / P126TI / P126TI-1 /

0.3

0.3

P126TI-II / PU126TI

6.1.3. Method of adjusting the valve clearance

1) Loosen the lock-nuts

(1) using a ring

spanner.

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

3

screw driver until the gauge can be

2

pulled out with some restriction.

4) After the adjustment fix the adjusting

EAOO4014

bolt not to rotate and tighten the lock-

nut at the same time.

5) Measure the clearance one more time

and if necessary adjust again.

Checking and Setting

-

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

Timing

Check hole

marks on the flywheel, and then turn

again the flywheel clockwise until

showing the notch mark of the right

figure corresponding to the injection

timing is aligned with the pointer

(↓)

on the flywheel housing.

DE12T /

P126TI /

PU126TI

P126TI-1

P126TI-II

Fuel injection

timing

12°

16°

14°

Injection timing

Flywheel

(B.T.D.C

notch mark

ring gear

static)

EA8O6002

● Turn the timer until the notch mark of

the indicator plate attached to the fuel

Notch

injection pump is aligned with the

mark

notch mark of the timer.

EA9O5002

-

44 -

Checking and Setting

● 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.

6.3. Cylinder Compression Pressure

1) Stop the engine after warming it up,

then remove the nozzle assemblies.

EA9O5003

2) Install a special tool

(gauge adapter) in

nozzle holder hole and connect the

compression

pressure gauge to the

adapter.

3) Cut off fuel circulation, rotate the starter,

then measure compression pressure of

each cylinder.

Standard value

25 ~ 28 kg/cm2

EA9O5004

Limit

24 kg/cm2 or less

Difference between

Within ± 10%

each cylinder

- Testing conditions : at water tempera-

ture of

20C and speed of

200 rpm

(10 turns)

Checking and Setting

-

45 -

6.4. V-belts

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

1)

Change the V-belts if necessary

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

complete set of belts.

2)

Checking condition

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

3)

Testing by hand

The tension is correct if the V-belts can

Press here

be pressed in by about the thickness of

15mm

the V-belt.

(no more midway between

Alternator

Fan

the belt pulleys)

Pulley

Pulley

A more precise check of the V-belt ten-

sion is possible only by using a V-belt

V-belt

tension tester.

Crank Pulley

EA8O3005

4)

Measuring tension

(1)

Lower indicator arm

(1) into the

scale.

(1)

● Apply tester to belt at a point mid-

way between two pulleys so that

edge of 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

EA6O6011

upwards.

If pressure is maintained after the

spring has disengaged a false

reading will be obtained!

(2)

Reading of tension

● Read of the tensioning force of

(3)

the belt at the point where the top

surface of the indicator arm

(1)

intersects with the scale.

● Before taking readings make

ensure that the indicator arm

remains in its position.

(2)

EA6O6012

-

46 -

Checking and Setting

Tensioning forces on the tester

new installation

Type

Drive belt width

When servicing after

After 10 min.

Installation

long running time

running time

A

11.8 mm

55 kg

50 kg

45 kg

* V-belt of raw edge cogged type

When servicing after

Type

new installation

long running time

3V

45 kgf

41 kg

3V 2 - 0000

3V 4 - 0000

Belt length

Belt length

No. of belt rib

No. of belt rib

Belt type

Belt type

EF8OM084

5) Tensioning and changing V-belt

● Remove fixing bolts. (1)

● Remove lock nut. (2)

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

(2)

rect tensions.

(3)

● Retighten lock nut and fixing bolts.

(1)

EA8O6004

Checking and Setting

-

47 -

7. Operation Tip

7.1. Periodic Inspection Cycle

{

: Check & adjust z

: Replace

Every

Every

Every

Every

Every

Inspection

Daily

Remark

50hrs

200hrs

400hrs

800hrs

1,200hrs

Check for leakage (hoses, clamp)

{

Check the water level

{

Cooling

Change the coolant water

z

System

Every

Adjust the V-belt tension

{

2,000hrs

Clean the radiator

{

Check for leakage

{

Check the oil level gauge

{

Lubrication

z

Change the lubricating oil

z

System

1st

z

Replace the oil filter cartridge

z

1st

Check the leakage for

{

intercooler (hoses, clamp)

Intake &

Clean and change

{

z

Exhaust

the air cleaner element

clean

System

Clean the inter-cooler air fins

{

Every

Clean the turbo-charger

2,000hrs

Check the leakage fuel line

{

Clean the fuel strainer

{

of fuel feed pump

Remove sediment from fuel tank

{

Fuel

Drain the water in separator

{

System

Drain the water in separator

z

When

Check fuel Injection timing

{

necessary

When

Check the injection nozzles

{

necessary

Check the state of exhaust gas

{

Check the battery charging

{

When

Engine

Check the compression pressure

{

necessary

Adjust

Adjust Intake/Exhaust valve

{

When

clearance

1st

necessary

- 48 -

Operation Tip

7.2.2. Engine overheated

2. Engine Overheated

Operating state

1. Overload

2. Radiator core clogged

Cooling unit

Fuel unit

3. Continuous over-run

Check coolant

Inspect fuel quality

Fuel excessive supply

Normal

Too low

Poor

Check fan belt

Repair

Clean and replace

Check injection nozzle

tension wear

Replace

with specilied fuel

or damage etc.

Inspect cooling

Replenish

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

Replace

injection

pump

Inspect heat

Repair

Damage

exchanger

Replace

Check cooling

Repair

Normal

water pump

Replace

Clean cooling

Normal

water passage

Engine

disassembly

- 50 -

Operation Tip

7.2.3. Output insufficient

3. Output Insufficient

Engine

Installation improper

Check for coupling

Fuel unit

Others

alignemnt

Check for air mixing

Inspect air cleaner

Adjust or replace

in fuel

coupling

Normal

Clean Relpace

Inspect fuel supply pump

Inspect air leakage

Inspect engine control

Normal

Clean Replace

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

of Intercooler

Normal

Adjust

Normal

Repair Replace

Inspect cylinder head

gasket for damage

Inspect injection nozzle

injection pressure

atomizing state

Normal

Replace

Normal

Adjust Replace

Engine disassembly

(valve assembly)

Check injection timing

Normal

Adjustment

Disassemble engine or

Check Turbocharger

injection pump

Normal

Repair

Replace

Disassemble injection

pump or engine

Operation Tip

- 51 -

7.2.4. Oil pressure lowered

4. Oil pressure lowered

Check if oil pressure

gauge indicates wrongly

Check oil amount

Too low

Normal

Use recommended oil

Check cooling

(replenish)

temperature

Too high

Normal

Refer to engine overhea

Inspect oil quality

Normal

Check oil relief

Water & fuel mixed

Improper

valve

in oil

Replace with

Retighten

Disassemble engine

Normal

recommended oil

Replace

or injection pump

Disassemble

engine

- 52 -

Operation Tip

7.2.5. Fuel consumption

5. Fuel Consumption Excessive

Causes according to Use Conditions

1. Overload

2. Govemor's Arbitrary Adjustment

3. Full Speed Operation for Long time

4. Sudden Speed Change from Low to

Inspect fuel leakage

High Speed

Normal

Oil leakage

Inspect injection nozzle

(injection pressure

Adjust Replace

atomizing state etc.)

Retighten Replace

Normal

Check injection timing

Adjust

Normal

Repair Replace

Inspect compressed

Check valve

Cylinder liner

pressure

clearance

Piston ring Piston

Normal

Disassemble

Adjust

injection pump

Normal

Inspect head gasket

Replace

Normal

Disassemble engine

(valve assembly piston

cylinder liner etc.)

Operation Tip

- 53 -

7.2.6. Oil consumption excessive

6. Oil Consumption Excessive

Cause according to use conditions

1. Excessive oil infusing

2. Continuous operation in low or

extremely cold state

Inspect oil leakage

Inspect air cleaner

Clean Replace

Normal

Oil leakage

External

Internal

Check oil quality

Retighten

Check compressed

Replace with

Replace

pressure

specified oil

Engine disassembly

Normal

(piston cylinder liner)

Disassemble

cylinderhead

(valve stem seal)

7.2.7. Engine knocking

7. Engine Knocking

Inspect combustion of fuel & oil

(carbon residue exhaust gas)

Unconfirmed

Confirm

Inspect compressed

Disassemble

pressure

engine

Too low

Normal

Check valve clearance and

Inspect injection

cylinderhead gasket for damage

pump

Normal

Adjust

Replace

Normal

Adjust

Check fuel quality

Disassemble

engine

Use specified fuel

- 54 -

Operation Tip

7.2.8. Battery discharge

8. Battery Discharge

Generator

Battery

Wiring Switch

Inspect cut wire

Check fan belt

Check electrolytic

shorts and loose

tension & damage

liquid amount

connections

Repair Replace

Normal

Battery self

Battery over

Electrolytic

Battery room

discharge

charging

liquid's

damage

standard

Inspect generator

Replace

Charging

Voltage regulator

Replenish

Abnormal

Normal

Adjust

Check charged stated

Replace

Discharging

Disassemble

generator Voltage

regulator

Operation Tip

- 55 -

7.3. Causes and Remedies

Condition

Causes

Remedies

1) Starting difficult

● Valveís poor shut, stem distortion

Repair or replace

(1) Compression pressure

● Valve spring damage

Replace valve spring

● Cylinder head gasket’s leak

Replace gasket

● Wear of piston, piston ring or liner

Adjust

2) Idle operation abnormal

● Injection timing incorrect

Adjust

● Air mixing at injection pump

Remove air

Adjust

3) Engine output insufficient

● Valve clearance incorrect

Repair

(1) Continuous output insuffi-

● Valve tightness poor

Replace gasket

cient

● Cylinder head gasket’s leak

Replace piston ring

● Wear, stick, damage of piston ring

Adjust

● Injection timing incorrect

Adjust injection pump

● Fuel injection amount insufficient

Adjust or replace

● Nozzle injection pressure improper or stuck

Repair or replace

● Supply pump’s function lowered

Repair

● Fuel pipe system clogged

Clean or replace air

● Air suction amount insufficient

cleaner

● Supercharger poor

Repair or replace

(2) Output insufficient when in

● Compression pressure insufficient

Disassemble engine

acceleration

● Injection timing incorrect

Adjust

● Fuel injection amount insufficient

Adjust injection pump

● Injection pump timer’s function insufficient

Repair or replace

● Nozzle infection pressure, infection angle

Repair, replace

improper

● Supply pump’s function lowered

Repair or replace

● Air intake amount insufficient cleaner

Clean or replace air

4) Overheating

● Engine oil insufficient or poor

Replenish or replace

● Cooking water insufficient

Replenish or replace

● Fan belt loosened, worn, damaged

Adjust or replace

● Cooling water pump’s function lowered

Repair or replace

● Water temp. regulator’s operation poor

Replace

● Valve clearance incorrect

Adjust

● Exhaust system’s resistance increased

Clean or replace

5) Engine noisy

For noises arise compositely such asrota ting

parts, lapping parts etc., there is nec essity to

search the cause of noises accurately.

(1) Crankshaft

● As the wear of bearing or crankshaft

Replace bearing & grind

progress, the oil clearances increase.

crankshaft

● Lopsided wear of crankshaft

Grind or replace

● Oil supply insufficient due to oil passage

Clean oil passage

clogging

● Stuck bearing

Replace bearing & Grind

- 56 -

Operation Tip

Condition

Causes

Remedies

(2) Con rod and Con rod

● Lopsided wear of con rod bearing

Replace bearing

bearing

● Lopsided wear of crank pin

Grind crankshaft

● Connecting rod distortion

Repair or replace

● Stuck bearing

Replace & grind crank-

● Oil supply insufficiency as clogging at oil

shaft

passage progresses

Clean oil passage

(3) Piston, piston pin &

● Piston clearance increase as the wear of

Replace piston & piston

piston ring

piston and piston ring progresses

ring

● Wear of piston or piston pin

Replace

● Piston stuck

Replace piston

● Piston insertion poor

Replace piston

● Piston ring damaged

Replace piston

(4) Others

● Wear of crankshaft, thrust bearing bearing

Replace thrust

● Camshaft end play increased

Replace thrust plate

● Idle gear end play increased

Replace thrust washer

● Timing gear backlash excessive

Repair or replace

● Vale clearance excessive

Adjust valve clearance

● Abnormal wear of tappet, cam

Replace tappet, cam

● Supercharger inner part damaged

Repair or replace

● Injection timing incorrect

Adjust

6) Fuel Consumption Exttive

● Fuel injection amount excessive

Adjust injection pump

7) Oil Consumption Excessive

(1) Oil level elevated

● Clearance between cylinder iner & piston

Replace

● Wear of piston ring, ring groove

Replace piston, piston ring

● Piston ring’s damage, stick, wear

Replace piston ring

● Piston ring opening’s disposition improper

Correct position

● Piston skirt part damaged or abnormal wear

Replace piston

● Oil ring’s oil return hole clogged

Replace piston ring

● Oil ring’s contact poor

Replace piston ring

(2) Oil level lowered

● Looseness of valve stem & guide

Replace in set

● Wear of valve stem seal

Replace seal

● Cylinder head gasket’s leak

Replace gasket

(3) Oil leak

● Looseness of connection parts

Replace gasket, repair

● Various part’s packing poor

Replace packing

● Oil seal poor

Replace oil seal

Operation Tip

- 57 -

8.2. Engine Characteristics

8.2.1. OMEGA combustion bowl

The OMEGA combustion bowl is a unit

designed to perform high efficiency, low

emission combustion. As the rim around

the combustion bowl port of the upper of

the piston has been machined in a

smaller size than the interior of the com-

bustion bowl, strong swirl is produced in

the combustion bowl and strong squish

flow makes the fuel be mixed more suffi-

ciently with air.

Due to the application of OMEGA com-

bustion system and optimal utilization of

intake and exhaust port configuration

within the cylinder head, the P126TI

series, DE12T and PU126TI engines dis-

charge very low level of hazardous

exhaust gases such as smoke, nitrogen

oxide, hydrocarbon, or carbon monoxide

and thus ensure high performance and

low fuel consumption.

EA8M1001

8.2.2. Oil gallery cooling type piston (P126TI / PU126TI)

Oil gallery cooling is used for the piston

of P126TI series and PU126TI engine.

When thermal loading is high, piston 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 spray nozzle and the

quantity of oil flowing in the gallery are

critical in order to achieve the desired

temperature reduction.

The cross section shape of the gallery

should be designed to achieve sufficient

oil movement to maximize cooling effi-

ciency.

General Information

-

59 -

9. Disassembly and Reassembly of Major Components

9.1. Disassembly

9.1.1. General precautions

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

● Before disassembly, provide parts racks for storage of various tools and disassembled parts.

● Arrange the disassembled parts in the disassembly sequence and use care to prevent any

damage to them.

9.1.2. Cooling water

● Remove the radiator cap. Open the

drain plug at the radiator lower part to

drain the coolant as the right figure.

CAUTION :

When removing radiator filler cap

while the engine is still hot, cover

the cap with a rag, then turn it

slowly to release the internal steam

pressure This will prevent a person

from scalding with hot steam

spouted out from the filler port.

Drain Valve

EA5O4002

● Remove the drain plug from the cylin-

der block and drain out the cooling

water into a container.

EI7OM003

D

-

60 -

isassembly and Reassembly of Major Components

9.1.3. Engine oil

● Take out the oil dipstick.

● Remove the oil drain valve of oil pan

and drain out the engine oil into a pre-

pared container.

Drain valve

EA8O5001

9.1.4. Alternator belt

● Loosen the tension adjusting nut

installed on the alternator bracket, and

take off the alternator belt.

EA8M3001

9.1.5. Cooling fan

● Remove the flange fixing bolts, then

take off the flange and cooling fan.

EQM3004I

9.1.6. Alternator

● Remove the alternator fixing bolt and

disassemble the alternator.

● Remove the tension adjusting bolt and

bracket.

Disassembly and Reassembly of Major Components

-

61 -

9.1.7. Guide tube of oil level gauge

● Loosen the flange nut installed on the

oil pan to remove the guide tube.

EQM3005I

9.1.8. Fuel filter

● Remove fuel hoses connected to the

fuel injection pump, take off the

bracket fixing bolts, then disassemble

the fuel filter.

EI6OM016

9.1.9. Breather

● Loosen the clamp screw to remove the

rubber hose.

9.1.10. Intercooler

● Tear down the various hoses and air

pipes from the inter cooler.

● Remove the intercooler fixing bolts

and tear it down.

EA6M2001

D

-

62 -

isassembly and Reassembly of Major Components

9.1.11. Injection pipe

● Unscrew the hollow screws to disas-

semble the fuel return pipe.

● Remove the nuts installed on the fuel

injection pump and nozzles, then dis-

assemble the injection pipe.

EQM3009I

9.1.12. Intake manifold

● Remove the air hose connected to

the fuel injection pump.

● Loosen the intake manifold fixing

bolts, then disassemble the intake

manifold.

EQM3011I

9.1.13. Turbo charger

● Release the clamp screw of the rub-

ber hose connected to the intake

manifold, and take off the intake

pipes both simultaneously.

● Unscrew the exhaust pip5e bracket

fixing bolts, release the nuts installed

on the turbocharger, then disassem-

ble the exhaust pipe.

● Remove the turbocharger after remov-

ing the oil supply pipe and return

pipe and releasing the fixing nuts.

Disassembly and Reassembly of Major Components

-

63 -

9.1.14. Exhaust manifold

● Release the exhaust manifold fixing

bolts, disassemble the exhaust mani-

fold, then remove the heat shield and

gasket.

NOTE :

Make sure to release the nuts one

after another because the exhaust

manifold will be removed if you

unscrew two nuts simultaneously.

9.1.15. Thermostat

● Remove the by-pass pipe connected to

the water pump, unscrew the thermostat

fixing bolts, then disassemble the ther-

mostat housing.

● Disassemble the thermostat housing

and remove the thermostat.

● Disassemble the water pipe by

unscrewing the bolts and nuts

installed on the cylinder head.

EAMD014I

9.1.16. Starter

● Unscrew the starter fixing bolts, then

disassemble the starter.

ED5OM009

9.1.17. Water pump

● Remove the water pipe connected to

the expansion tank.

● Remove the water pipe and hoses

connected to the water pump.

● Unscrew the water pump fixing bolts

and remove the water pump.

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D

64 -

isassembly and Reassembly of Major Components

9.1.18. Injection pump

● Remove the oil supply pipe and return

pipe connected to the fuel injection pump.

● Unscrew the bolts connecting the

coupling and drive shaft, disassemble

the injection pump mounting bolts,

then detach theinjection pump.

NOTE :

After letting No.1 cylinder to the 'OT'

EAMD021I

position by turning the crankshaft,

disassemble the injection pump.

● Release the pump fixing bracket bolts

to disassemble the bracket from the

cylinder block.

NOTE :

Do not mix the disassembled shims.

These should be reassembled to the

original position.

EAMD022I

9.1.19. Oil filter

● Using a filter remover wrench, remove

the oil filter cartridge.

● Remove the pipe connected to the oil

cooler.

● Loosen the oil filter fixing bolts and dis-

assemble the oil filter head from the

cylinder block.

9.1.20. Fan drive pulley

● Remove the bolts and disassemble

the fan drive pulley.

Disassembly and Reassembly of Major Components

-

65 -

9.1.21. Vibration damper

● Unscrew the pulley fixing bolts and

disassemble

the

pulley-vibration

damper assembly.

● Unscrew the vibration damper fixing

bolts and disassemble the damper

from the pulley.

9.1.22. Timing gear case cover

● Disassemble the oil seal using an oil

seal removing jig.

● Remove the cover fixing bolts and

disassemble the cover from the timing

gear case.

EAMD025I

9.1.23. Idle gear

● Unscrew the idle gear fixing bolts and

disassemble the thrust washer and

idle gear.

● Disassemble the idle gear pin using a

rubber hammer to prevent damage to

them.

9.1.24. Fuel injection pump drive assembly

● Unscrew the injection pump drive

shaft bearing housing fixing bolts and

remove the injection pump drive

assembly which the shaft, gear, bear-

ings, and housing are put together.

EAMD027I

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66 -

isassembly and Reassembly of Major Components

9.1.25. Cylinder head cover

● Unscrew the cover fixing bolts and

disassemble the cover.

● Keep the bolts in an assembly state

so that the packings and washers

may not be lost, and keep the cover

packing as assembled with the cover.

EI7OM005

9.1.26. Rocker arm assembly

● Unscrew the rocker arm bracket bolts

and remove the rocker arm assembly.

● Take off the snap rings to remove

the washers and rocker arm, then

unscrew the bracket fixing bolts to

take off the bracket and springs.

● Take out the push rods.

EAMD029I

9.1.27. Injection nozzle

● Take off the injection pipes between

the injection pump and injection noz-

zles.

● Remove the nozzle tube using nozzle

tube removing jig.

Do not disassemble injection nozzle

unless coolant or gas come out.

EAMD030I

9.1.28. Cylinder head

● Unscrew the cylinder head fixing bolts

and take off the cylinder head.

● Remove the cylinder head gasket.

EAMD031I

Disassembly and Reassembly of Major Components

-

67 -

9.1.29. Valve & valve stem seal

● Compress the valve spring retainer

using a jig and take off the valve cot-

ter pins.

● Disassemble the valve springs and

retainers.

● Take off the valves.

Valve spring

● Remove using a general tool and dis-

compressor

card the valve stem seals in order

not to be re-used.

EA0M4007

9.1.30. Oil cooler

● Remove the water pipe connected to

the water pump.

● Remove the oil pipe connected to the

cylinder block.

● Unscrew the oil cooler cover fixing

bolts and disassemble the oil cooler

assembly from the cylinder block.

● Unscrew the oil cooler fixing bolts

and remove the oil cooler from the oil

EAMD033I

cooler cover.

9.1.31. Oil pan

● Stand the engine with the flywheel

housing facing the bottom.

● Release the oil pan fixing bolts,

remove the stiffeners then disassem-

ble the oil pan.

EAMD034I

9.1.32. Oil pump & oil pipe

● Unscrew the oil suction pipe bracket

bolts, releasing the pipe fixing bolts,

then disassemble the oil suction pipe

assembly.

● Disassemble the oil pipe feeding oil

from the oil pump to the cylinder

block.

● Unscrew the oil pump fixing bolts and

disassemble the oil pump.

EAMD035I

D

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68 -

isassembly and Reassembly of Major Components

9.1.33. Relief valve

● Disassemble the relief valve.

EAMD036I

9.1.34. Piston & 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

● Remove the piston pin snap rings,

take off the piston pin, then discon-

nect the connecting rod from the pis-

ton.

● Disassemble the piston rings using

ring pliers.

● Use care not to interchange the dis-

assembled parts and keep them in

the sequence of cylinder No.

Disassembly and Reassembly of Major Components

-

69 -

9.1.35. Cylinder liner

● Disassemble the cylinder liner using a

liner puller.

EAMD040I

9.1.36. Flywheel

● Position the engine so that the head

installing surface of the cylinder block

faces down.

● Unscrew the flywheel fixing bolts and

fit a dowel pin.

● Install flywheel disassembling bolts in

the bolt holes machined on the fly-

wheel, and disassemble the flywheel.

EAMD041I

9.1.37. Oil seal

● Take off the rear oil seal using an oil

seal disassembling jig.

● If only the inside guide ring is

removed, use a special tool to take

off the outside seal.

9.1.38. Flywheel housing

● Loosen the housing fixing bolts disas-

semble the flywheel housing.

EAMD043I

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70 -

isassembly and Reassembly of Major Components

9.1.39. Cam shaft & tappet

● Remove the cam shaft gear.

● Take off the cam shaft gear thrust

washer.

● Take out the cam shaft using care

not to damage the cam shaft.

● Slide out the tappets by hand.

EAMD044I

9.1.40. Crankshaft gear & oil pump idle gear

● Loosen the socket head bolts and

take out the oil pump idle gear.

● Use a puller to remove the crankshaft

gear.

9.1.41. Timing gear case

● Unscrew the case fixing bolts and

disassemble the timing gear case.

EAMD046I

Disassembly and Reassembly of Major Components

-

71 -

9.1.42. Crankshaft

● Remove the bolts from bearing caps.

● Remove the main bearing cap fixing

bolts in the order of assembling.

● (Remove them in the same way of

the cylinder head bolts.)

● Maintain the removed bearing caps in

the order of cylinders.

● Temporarily install the bolts at the

both side of crankshaft, and lift the

shaft with a rope.

NOTE :

Do not mingle with the metal

bearings and bearing caps randomly.

To prevent mixing, temporarily

assemble the metal bearings to the

corresponding bearing caps in turn.

9.1.43. Oil spray nozzle

● Unscrew the fixing bolt and remove

the oil spray nozzles.

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72 -

isassembly and Reassembly of Major Components

9.2. Inspection

9.2.1. Cylinder block

1) Clean the cylinder block thoroughly and make a visual inspection for cracks or damage.

2) Replace if cracked or severely damaged, and correct if slightly damaged.

3) Check oil and water flow lines for restriction or corrosion.

4) Make a hydraulic test to check for any cracks or air leaks. (Hydraulic test) :

5) Stop up each outlet port of water/oil passages in the cylinder block, apply air pressure of

about 4 kg/cm2 against the inlet ports, then immerse the cylinder block in water for about 1

minute to check any leaks. (Water temperature: 70C)

9.2.2. Cylinder head

1)

Inspection

● Carefully remove carbon from the lower face of the cylinder head using nonmetallic mate-

rial to

prevent scratching of the valve seat faces.

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

using a hydraulic tester or a magnetic flaw detector.

2)

Distortion at the lower face

● Measure the amount of distortion

(t)

using a straight edge and a feeler

gauge at six positions

(A

~ F) as

B

shown in the right figure.

A

● If the measured value exceeds the

C

D

standard value, retrace the head

with grinding paper of fine grain

E

size to correct such defect.

F

● If the measured value exceeds the

EA3M2031

maximum allowable limit, replace

the cylinder head.

<Lower face warpage and height>

(mm)

Standard

Limit

Warpage

0.2 or less

0.3

Thickness : t

114.95 ~ 115.0

113.9

(reference)

EA6M2002

Disassembly and Reassembly of Major Components

-

73 -

3) flatness

Measure flatness of the intake/

exhaust manifolds fitting surfaces on

the cylinder head using a straight

edge and a feeler gauge.

(mm)

Standard

Limit

0.05

0.2

4) Hydraulic test

Hydraulic test method for the cylinder

head is same as that for cylinder block.

9.2.3. Valve and valve guide

1)

Valve

Clean the valves with clean diesel oil,

then inspect them as follows:

● Valve stem outer diameter

Measure the valve stem outer diam-

eter at 3 positions. (top, middle, and

bottom) If the amount of wear is

beyond the limit, replace the valve.

End of stem

(mm)

Dimension

Standard

Limit

Description

EFM2036I

Intake valve

Ø10.950 ~

Ø10.87

stem

Ø10.970

Exhaust valve

Ø10.935 ~

Ø10.84

stem

Ø10.955

● 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.

D

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74 -

isassembly and Reassembly of Major Components

● Valve head thickness

Measure the valve head thickness,

and replace the valve if the mea-

sured value is beyond the limit.

(mm)

Dimension

Standard

Limit

Description

Intake valve

1.5

1 or less

EFM2037I

Exhaust valve

1.5

0.9 or less

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

Measuring

or the valve guide, whichever worn

position

more.

<Valve stem end play>

EA0M4052

Standard

Limit

Intake valve

0.04 ~ 0.07

0.2

Exhaust valve

0.06 ~ 0.09

0.25

● Install the valve into the cylinder

head valve guide, then check and

see if it is centered with the valve

seat using a special tool.

3)

Valve seat

● Contacting face amount

Measure the contacting

face

between intake valve and exhaust

valve seat for valve seat wear, and

replace if the measured value

exceeds the specified limit.

Contact width

<Valve contact width>

(mm)

EA0M4047

Standard

Limit

0 ~ 0.03

0.55

Disassembly and Reassembly of Major Components

-

75 -

● 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 cylin-

der head using a dial gauge.

EDM2032P

<Valve depression>

(mm)

Standard

Limit

Intake &

0 ~ 0.3

0.55

Exhaust

Depression

If the amount of depression is beyond

the specified limit, replace the valve seat.

EA0M4046

● 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 with inner extractor.

● For assembling of a new valve seat,

Cylinder head

by putting it among the dry ices of

an ice box previously for about

2

hours for the cold shrinkage, and

Welding bead

press it in the cylinder head by a

EA3M2032

special tool. (bench press)

● Apply the valve lapping compound

on the valve head seating face and

lap the valve seat by turning it until

it is seated in its position, then wipe

out the lapping compound.

NOTE :

Clean the valve and cylinder head

with light oil or equivalent after the

valve seat finishing is completed,

and make sure that there are no

grinding materials remained.

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76 -

isassembly and Reassembly of Major Components

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