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DOOSAN Generator diesel engine DE12T, P126TI, P126TI-1, P126TI-II, PU126TI. Operation and Maintenance Manual - page 4

10.1.4. Diagnostics and troubleshooting

Complaints

Possible causes

Corrections

1. Engine overheating

● Lack of coolant

● Replenish coolant

● Radiator cap pressure valve

● Replace cap

spring weakened

● Fan belt loosened or broken

● Adjust or replace fan belt

● Fan belt fouled with oil

● Replace fan belt

● Thermostat inoperative

● Replace thermostat

● Water pump defective

● Repair or replace

● Restrictions in water passages

● Clean radiator and water pas-

due to deposit of scales

sages

● Injection timing incorrect rectly

● Adjust injection timing cor

● Restriction in radiator core

● Clean exterior of radiator

● Gases leaking into water jacket

● Replace cylinder head gasket

due to broken cylinder head gas-

ket

2. Engine overcooling

● Thermostat inoperative

● Replace thermostat

● Ambient temperature too low

● Install radiator curtain

3. Lack of coolant

● Radiator leaky

● Correct or replace

● Radiator hoses loosely con-

● Retighten clamps or replace

nected or damaged

hoses

● Radiator cap valve spring weak-

● Replace cap

ened

● Water pump leaky

● Repair or replace

● Heater hoses loosely connected

● Tighten or replace hoses

or broken

● Cylinder head gasket leaky

● Replace cylinder head gasket

● Cylinder head or cylinder block

● Replace cylinder head block

cracked

4. Cooling system noisy

● Water pump bearing defective

● Replace bearing

● Fan loosely fitted or bent

● Retighten or replace fan

● Fan out of balance

● Replace fan

● Fan belt defective

● Replace fan belt

Maintenance of Major Components

-

117 -

10.2. Lubricating System

10.2.1. General descriptions and main data

● General descriptions

All the engine oil pumped up from the oil pan by the gear type oil pump is filtrated through

the oil cooler and oil filter, and this filtrated oil is forced through the main oil gallery in the

cylinder block from where it is distributed to lubricate the various sliding parts, and fuel injec-

tion pump in order to ensure normal engine performance.

● Specifications

Item

Specifications

Item

Specifications

Lubricating system

Forced pressure

Oil filter type

Full flow

circulation

Oil pump type

Gear type

Bypass for filter element

Relief valve opening pressure

10 ± 1.5 kg/cm2

Valve opening pressure

1.8 ± 2.3 kg/cm2

Bypass for oil cooler

Bypass for entire oil filter

Opening pressure

5 + 1 kg/cm2

Valve opening pressure

4.0 ~ 4.8 kg/cm2

Adjusting valve for spray nozzle

Opening pressure

1.5 ± 1.8 kg/cm2

● Diagram of lubricating system

Rocker arm

WAter pump

bearing

Fuel injection

pump

Turbocharger

Conn. rod bearing

Main bearing

Oil spray nozzle

1.3bar

Main oil gallery

Oil cooler

Oil filter

Oil pump

Relief valve

4.4bar

Valve

Valve

Valve

10bar

5bar

3bar

ED5OM008

-

118 -

Maintenance of Major Components

10.2.2. Oil pump

● Disassembly

1) Disassembly of oil pump drive

gear

a) Unscrew the screw and disas-

semble the oil relief valve.

b) Unfold the washer for the oil

pump drive gear fixing nut and

remove the nut.

c) Disassemble the drive gear.

EQM4006I

2) Remove the oil pump cover fixing

nuts and disassemble the oil

pump cover.

The oil pump cover is fixed with

the two dowel pins.

3) Disassemble the drive gear and

driven gear.

EQM4007I

● Inspection and correction

1) With steel rule and feeler gauge,

measure the axial end play of the

oil pump gear. Replace if the

measured value is beyond the

limit.

Steel plate

(mm)

Feeler gauge

End play

0.025 ~ 0.089

EQM4008I

2) With a feeler gauge, measure the

amount of backlash between the

oil pump drive gear and driven

gear. Replace if the measured

value is beyond the limit.

(mm)

Backlash

0.50 ~ 0.64

EQM4009I

Maintenance of Major Components

-

119 -

3) Measuring

clearance

between

drive shaft and bushing

a) Measure the outside diameters

of the drive shaft and driven

shaft, and replace if the mea-

sured values are less than the

limit.

(mm)

Limit

൵16.95

b) Measure the inside diameter of

the pump body bushing to deter-

mine the clearance between the

bushing and shaft, and compare

the measured value with the

standard value to determine

whether to replace or not.

(mm)

Clearance

0.032 ~ 0.077

● Reassembly

1) For reassembly, reverse the disas-

sembly sequence.

10.2.3. Oil filter

The oil filter mounted in this engine is of

cartridge type, so it is necessary to

replace it with a new one at the speci-

Oil filter (Cartridge)

fied intervals.

Oil filter head

EQM4010I

-

120 -

Maintenance of Major Components

10.2.4. Diagnostics and troubleshooting

Complaints

Possible causes

Corrections

1. Oil consumption

● Poor oil

● Use suggested oil

excessive

● Oil seal or packing leaky

● Replace

● Pistons or piston rings worn

● Replace pistons and/or piston

● Cylinder liner worn

rings

● Piston rings sticking

● Replace cylinder liner

● Valve guide oil seals or valve

● Replace pistons and/or piston

guides, or valve stem worn

rings

● Replace

2. Oil pressure too low

● Poor oil

● Use suggested oil

● Relief valve sticking

● Replace

● Restrictions in oil pump

● Clean strainer

strainer

● Replace

● Oil pump gear worn

● Replace

● Oil pump feed pipe cracked

● Correct or replace

● Oil pump defective

● Correct or replace

● Oil pressure gauge defective

● Replace

● Various bearings worn

3. Oil deteriorates quickly

● Restriction in oil filter

● Replace filter element

● Gases leaking

● Replace piston rings and cylinder

● Wrong oil used

liner

● Use suggested oil

Maintenance of Major Components

-

121 -

10.3. Fuel Injection Pump

10.3.1. General information of fuel system

The fuel system consists of the fuel tank, injection pump, injection nozzle, fuel filter, and fuel

lines such as pipes and hoses necessary to connect those components.

5

1

2

4

1a

3

7

6

13

8

12

10

9

11

EA8O3004

1. Fuel filter

7. Delivery pipe

1a. Fuel water drain plug

8. Fuel pipe (manual pump → filter)

2. Air bleeding screw (for fuel filter)

9. Fuel tank

3. Injection nozzle

10. Fuel return pipe

4. Overflow tube

11. Suction pipe

Fuel pipe (filter → injection

5.

12. Feed pump

pump)

6. Overflow valve

13. Injection pump

-

122 -

Maintenance of Major Components

10.3.2. Injection pump

The components relating to the injection pump should be serviced at regular intervals as the

plunger and delivery valve may be worn after a given length of time for use and cause the

deterioration of the engine.

Make sure that servicing should be performed at the professional maintenance shop as autho-

rized by Bosch or Zexel Company.

For adjustment of fuel injection volume, refer to the 'Specifications of fuel injection pump’

described on the following pages.

1)

DE12T

(1) Main data and specifications

Part No.

:

65.11101-7222 (106672 - 9920)

Model

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

Governor

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

Timer

: without timer

Plunger

:൵12, right hand helix 30 lead

Delivery valve

:120 mm³/st (൵8 x 2.4 mm)

Fuel feed pump

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

Pre-stroke

:

4.7 mm

(2) Nozzle holder assembly

:

65.10101 - 7300 (105160 - 4351)

(3) Nozzle

:

65.10102 - 6046 (105029 - 1330)

(4) Injection pipe

:

65.10301 - 7004B

(5) Injection order

:

1 - 5 - 3 - 6 - 2 - 4

(6) Injection timing

: BTDC 12C

(7) Calibration data

Pump

Adjusting

Rack position

Injection volume

Variation

Basic

Fixing

speed

Ref.

point

(rpm)

(mm3 / 1,000 st)

rate (%)

point

point

(rpm)

A

10.8

900

129 ± 2

± 2

B

11

875

(135) ± 3

C

Approx. 6.4

250

14.5 ± 1.5

± 15

D

-

10

193.5 ± 10

Adjusting

Content

Specification

Engine Application

point

Nozzle holder assembly

105780 - 8140

65.10101 - 7300

Nozzle

105780 - 0000

65.10102 - 6046

Nozzle holder

105780 - 2080

-

Adjusting

Opening pressure

175 kg/cm2

220 kg/cm2

conditions

Injection pipe

൵8 x ൵3 - 600 mm

൵6 x ൵2.2 - 650 mm

Fuel delivery pressure

1.6 kg/cm2

-

Fuel temperature

35 ~ 45 C

35 ~ 45 C

Maintenance of Major Components

-

123 -

(8) Governor adjustment

Rack limit

over 14

D

11.0

B

10.8

A

Idle spring

Set : 6.5-0.5 mm

6.5

6.4

C

45 -1

0

0

250 400+20

900^±5

PUMP SPEED (rpm)

EA8M4001

-

124 -

Maintenance of Major Components

2)

P126TI / P126TI-1 / P126TI-II

(1) Main data and specifications

Part No.

:

65.11101 - 7310 (106674-4130 ZEXEL)

Model

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

Governor

: Ghana Control (DWA-2000)

Plunger & barrel

:

൵12, right hand double helix 30 lead

Delivery valve

:

90 mm³/st (൵7 x 2.35 mm)

Fuel feed pump

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

Pre-stroke

:

3.9 ± 0.05 mm

(2) Nozzle holder assembly

:

65.10101 - 7101 (105101 - 852A)

(3) Nozzle

:

65.10102 - 6073 (105025 - 285A)

(4) Injection pipe

:

65.10301 - 6042A, 65.10301 - 6043A

(5) Injection order

:

1 - 5 - 3 - 6 - 2 - 4

(6) Injection timing

: P126TI (BTDC 16°) / P126TI-1 (BTDC 12°)

Nozzle & Holder Ass’y

105101-852A

Opening pressure : 175 kg/cm2

(A) Test condition

for injection

Injection pipe (ID ,OD ,L)

-

൵3.0 x ൵8.0 - 600 mm

pump

Test oil

ISO4113

Temperature :40 ± 5 C

65.10101-7101

Nozzle (5 x൵ 0.37)

(B) Engine

Nozzle & holder Ass’y

1st pressure : 160 kg/cm2

65.10102-6073

standard

2nd pressure : 220 kg/cm2

parts

65.10301-6042A

Injection pipe (ID, OD ,L)

൵2.2 x ൵6.35 - 650mm

65.10301-6043A

Rack diagram and setting valve at each point

Injection Q’ty on RIG

Rack

Pump

Check

(mm3 / 1,000 st)

Press.

position

speed

point

(A) Test condition

(B) Engine

(mmHg)

(mm)

(rpm)

for inj. pump

standard parts

B

900

260 ± 2

-

Standby power

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

Maintenance of Major Components

-

125 -

3)

P126TI (EDIOE)

(1) Main data and specifications

Part No.

:

65.11101 - 7310 (106674 - 4130 ZEXEL)

Model

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

Governor

: Ghana Control (DWA-2000)

Plunger & barrel

:

൵12, right hand double helix 30 lead

Delivery valve

:

90 mm³/st (൵7 x 2.35 mm)

Fuel feed pump

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

Pre-stroke

:

3.9 ± 0.05 mm

(2) Nozzle holder assembly

:

65.10101 - 7104 (105101 - 853A)

(3) Nozzle

:

105025 - 291A

(4) Injection pipe

:

65.10301 - 6042A, 65.10301 - 6043A

(5) Injection order

:

1 - 5 - 3 - 6 - 2 - 4

(6) Injection timing

: BTDC 16°

Nozzle & Holder Ass’y

105101-853A

Opening pressure : 175 kg/cm2

(A) Test condition

for injection

Injection pipe (ID ,OD ,L)

-

൵3.0 x ൵8.0 - 600 mm

pump

Test oil

ISO4113

Temperature :40ٻC ± 5 C

65.10101-7104

Nozzle (5 x൵ 0.35)

Nozzle & holder Ass’y

1st pressure : 160 kg/cm2

(B) Engine

-

2nd pressure : 220 kg/cm2

standard parts

65.10301-6042A

Injection pipe (ID, OD ,L)

൵2.2 x ൵6.35 - 650mm

65.10301-6043A

Rack diagram and setting valve at each point

Injection Q’ty on RIG

Rack

Pump

Check

(mm3 / 1,000 st)

Press.

position

speed

point

(A) Test condition

(B) Engine

(mmHg)

(mm)

(rpm)

for inj. pump

standard parts

B

900

260 ± 2

-

Standby power

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

126 -

Maintenance of Major Components

4) PU126TI

(1) Main data and specifications

Injection pump

:

65.11101 - 7310 (106674 - 4130 ZEXEL)

Model

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

Governor

: Ghana Control (DWA-2000)

Fuel feed pump

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

Cam Lift

:

12 mm

Injection timing

: BTDC 14° ± 1

Injection order

:

1 - 5 - 3 - 6 - 2 - 4

Rotating Direction

: Clockwise (Viewed at driving gear side)

Pre-stroke

:

3.9 ± 0.05 mm

(2) Calibration data

Nozzle & Holder Ass’y

105101-8530

Opening pressure : 175 kg/cm2

(A) Test condition for

Injection pipe (ID ,OD ,L)

-

൵3.0 x ൵8.0 - 600 mm

injection pump

Test oil

ISO4113

Temperature :40 ± 5 C

65.10101-7057

Nozzle (5 x൵ 0.40)

Nozzle & holder Ass’y

1st pressure : 160 kg/cm2

(B) Engine standard

65.10102-6050

2nd pressure : 220 kg/cm2

parts

65.10301-6043A

Injection pipe (ID, OD ,L)

൵2.2 x ൵6.35 - 650 mm

65.10301-6042A

Rack diagram and setting valve at each point

Injection Q’ty on RIG

Rack

Pump

Check

(mm3 / 1,000 st)

Press.

position

speed

point

(A) Test condition

(B) Engine

(mmHg)

(mm)

(rpm)

for inj. pump

standard parts

Refer to (3)

A

12.5

1,000

187 ± 2

-

≤ 675

Rack Diagram

B

6.1

350

10 ± 1.5

-

-

C

12.5

500

-

≤ 675

D

11.9

500

-

-

E

7.5

1,100

-

-

250

-

Boost pressure dependent full-load stop (boost compensator spring operation point)

Injection Q’ty on RIG

Rack

Pump

Check

(mm3 / 1,000 st)

Press.

position

speed

point

(A) Test condition

(B) Engine

(mmHg)

Refer to (4)

(mm)

(rpm)

for inj. pump

standard parts

Boost Pressure

P1

11.9

500

-

525

P2

12.5

500

-

675

-

-

-

-

-

Min. speed 1:1.2

Weight

Weight = 740 g

Lever ratio (min/max)

Max.speed 1:1.2

Governor spring

k = 70.6 mpa

Plunger

൵12, 30 lead

Idle sub spring

k = 11.8 mpa

Delivery valve retraction volume

2.45 mpa

Start spring

k = 0.098 mpa

Delivery valve opening pressure

k = 8.53 mpa

Boost compensator

k = 8.24 mpa

Delivery valve spring

105237-5470

Adapter spring

k = 63.7 mpa

Feed pump

Maintenance of Major Components

-

127 -

(3) Rack Diagram

16 above

BSC Stroke : 0.6 0 .1 mm

C

A

12.5

Governor Spring Se

11.9

D

7.5

E

6.1

B

0

350

1000

1100

Injection Pump Speed (mm)

EI6OM013

(4) Boost Compensator Pressure

13.1

P2

12.5

12.0

11.9

P1

11.5

11.0

0

100

200

300

400

500

600

700

525

675

Boost Pressure (mmHg)

EI6OM014

-

128 -

Maintenance of Major Components

10.3.3. Governor system

10.3.3.1. Actuator

● Actuator Component Parts Function

1. Emergency stop lever: The manual engine stop lever

Side view

when emergency.

Emergency

2. Upper control chamber: The cover is install for inside

stop lever

control.

Upper control chamber

3. Electronic control chamber: The electronic signal oper-

(oil lubrication)

ates the operation lever. It is sealed and can not

control.

4. Adjusting screw: Adjusting screw is the controlled

Fuel

max. fuel capacity. If the length of the nut is long, the

Electronic control

injection

chamber

Pump

torque is decrease. if the length of the nut is short,

the torque is increase.

5. Fuel stop plate: The plate controls the increasing fuel

Ghana Actuator

as the preventing movement of adjusting screw.

6. Operation lever: It is the connecting lever to operate

DV2213103B

the fuel rack.

Top view

7. Fuel rack: It controls the fuel capacity of the fuel injec-

Fuel rack stop position adjustment

tion pump connected link lever.

Linkage length(L)

Fuel rack stop position

Caution: Adjusting fuel injection pump is critical part for

the enfine performance and durability. Only certi-

fied professional technicians should repair and

maintain engines.

Operating lever

Fuel rack

Lock nut

Lock nut

Stop Screw

Adjusting Screw

DV2213104B

Maintenance of Major Components

- 129 -

14, 15

17

18

16

13

2, 3

10

6

4, 5

11

1

12

Fuel rack

6

7

8

9

DV2213210

No

Title

Amount

Remarks

No

Title

Amount

Remarks

16

Operating Lever

1

1

Ball link ASS"Y

1

M5xL15

17

Stop Lever

1

2

Screw, Ball link

2

M5xL15

Manual Stop Device

Φ5.5x

18

1

3

Plain Washer

2

ASS'Y

Φ14xT1.2

4

Stop Screw

1

M6xL25

5

Lock Nut

1

M6xP1.0

6

Allen Screw (SEMS)

6

M6x22L

M6x30L or

7

Allen Screw (SEMS)

2

18L

8

Mounting Bar

1

Φ6.5x

9

Spacer

2

Φ16xT7.4

10

Pump Gasket

1

T 0.5

11

Front Cover

1

T 3.2

12

Front Gasket

1

T0.5

Allen Screw

8

13

Seal Screw

4

14

Top Cover

1

T 3.2

15

Top Gasket

1

T 0.5

- 130 -

Maintenance of Major Components

10.3.3.2. Controller system

(DGC-2013 Governor Controller System)

9

8

7

6

5

4

3

2

1

±

Crank

°

Run

¯

Over speed

Power Pick-up Crank

Run Over speed

Starting

¦

Fuel

Test

Speed

§

Ramping

­

¬

«

Idle

¨

Droop

£

¤ ¥

Speed Gain Stability

ON

D1

D2

OFF

Battery

Speed Trim

Droop

Idle

ª

Frame

Actuator

Pick-up

-

+

AUX

10V

GND

A B

C D E

F G H J K L

M

N

P

®

DV2213203B

Maintenance of Major Components

- 131 -

● Adjustments

1. The ranges of resistance indicated on the case are

applicable only to DI engines.

Starting

4

2. For potentiometer adjustment, use a small sized (-)

Fuel

screw driver. (Be cautious of potentiometers being

damaged)

3. Check that all electrical connections are correctly

Speed

5

made and terminal screws tightened.

Ramping

4. Engine Startup

Connect terminals G and M (with idle switch ON).

1)

(4) Starting Fuel

Idle

6

Note) Reason for adjustment: To maximize the fuel effi-

ciency of the engine

DV2213193B

* Purpose of adjustment:

Note) Recommended position: Between the 1 and 5

o’clock positions

Note) Possible problems: Between the 7 and 1 o’clock

positions

→ starting problems due to a lack of fuel

Droop

7

supply; The 5 o’clock position or above

→

decreasing fuel efficiency and increasing exhaust

ON

emissions at engine start up

D1

D2

2) Turn ⑤ Speed Ramping to between the 9 and 12

OFF

o'clock position.

Note) The time to reach the rated speed (run speed)

8

AUX

10V

prolongs as turning ⑤ Speed Ramping clockwise

(max. over 10 sec)

DV2213193C

Note) With ⑤ Speed Ramping biased to counterclock-

wise direction, a symptom of overshoot or hunting

can occur.

3) Start cranking the engine.

5. Rated speed & Idle speed

1) Rated speed adjustment.

Note) After engine startup, remove the connection

between terminals G and M (with idle switch OFF)

Note) Under no load condition, adjust Speed. Clockwise):

RPM increase/counterclockwise RPM decrease

2) Idle speed adjustment

Note) With idle switch ON again, set the engine speed

at 800 rpm by ⑥ Idle potentiometer.

Note) Reason for adjustment: To adjust pre-heat levels

after engine start up or the initial fuel amount at

engine start up

Note) Recommended position: Between the 12 and 3

o'clock positions. Though varying by engine model

or rated RPM, it is recommended to set the RPM

as 800RPM.

Note) Possible problems: Decreasing cold start perfor-

mance and the excessive use of fuel during the

warm-up phase.

Maintenance of Major Components

- 133 -

Caution: Idle speed is one of the important factors to

determine the characteristics of engine startup. Therefore,

it is necessary to adjust the idle speed after rated speed

adjustment regardless of the use of "idle mode."

6. Governor performance adjustment

1

2

3

1) Remove the connection between terminals G and M

(with idle switch OFF). Once the engine reaches run

Speed

Gain

Stability

speed, adjust the performance of governor.

2) Gain adjustment.

Note) Turn ② Gain clockwise until instability develops at

no load.

Note) Gradually move ② Gain counterclockwise until

stability returns.

DV2213196B

Note) Move ② Gain counterclockwise further by around

20 minutes (10°) to ensure stable performance.

7. Stability adjustment.

1) Turn ③ Stability clockwise at no load until instability

Crank

Run

Over speed

develops.

2) Gradually move ③ Stability counterclockwise until

stability returns.

3) Move ③ Stability counterclockwise further by around

20 minutes (10°) to ensure stable performance.

8. Accessory adjustment

11

10

9

1) Run Lamp ON

Note) At the rated speed, turn ⑩ Run counterclockwise

until the Run Lamp is on.

DV2213196C

Note) Move ⑩ Run counterclockwise further by 90° to

prevent the Run Lamp from flickering.

2) Crank Lamp ON

Note) At the idle speed, turn ⑩ Crank counterclockwise

until the Crank Lamp is on.

Note) Move ⑩ Crank counterclockwise further by 90° to

prevent the Crank Lamp from flickering.

3) Overspeed Lamp ON

Note) At the rated speed, as pressing the Test button,

gradually turn ⑨ Over Speed counterclockwise

until the Overspeed Lamp is on and the engine is

shut off simultaneously.

Note) With the adjustment above, the overspeed function

is triggered at around 115% of the rated speed.

Caution: On completion of all the adjustments, start up

the engine again to ensure the stable operation

at engine startup, at no load, and at load oper-

ation, respectively.

- 134 -

Maintenance of Major Components

● External Wiring

Idle

Droop

Speed

ON

D1

D2

OFF

Battery

Speed Trim

Droop

Idle

Frame

Actuator

Pick-up

-

+

AUX

10V

GND

A B C D E F G H J

K L

M

N

P

9

10

10V POWER

8

Actuator

Jumper

Load sharing

5

unit

Auto

synchronizer

<Auxiliary unit>

1

1.5߮

2C

2

3

1

4

5ࠗ

Magnetic

7

Pick-up

2

1.5߮

2C shield

Droop switch

shield cable(cover with insulation tube)

3

1.5߮

2C

6

BATTERY

Idle switch

24V

-

Power switch Fuse(10A)

DV2213211A

•

Wiring to the speed control unit should be as shown in DV2213211A.

•

All the cables should be 1.5mm2 or larger and shielded cables should be used for all external connections.

•

Other shielded cables not described in DV2213211A should be grounded to the frame.

1.

Twisted cables should be used for actuator connections. The normal reading of resistance between terminals A &

B should be between 3.5Ω and 4.5Ω.

2.

Magnetic speed sensor connections to terminals C and D must be shielded for their entire length. The speed sensor

cable should only be connected to terminal D. The shield should be insulated to ensure no other part of the shield

comes in contact with engine ground. Otherwise, stray speed signals may be introduced to the speed control unit

resulting in instability, etc.

3.

Be cautious that the battery's polarity to terminals E and F should not be switched and a 10 amp fuse must be

installed between battery (+) and terminal F. After the wiring work, check the voltage between terminals which should

be 24VDC (±4V). Ground the terminal E to the frame (wiring (10)).

4.

As illustrated in DV2213211A, connecting the optional 5k Ω resistance enables fine adjustment of engine speed within

the range of preset speed ±210Hz range.

5.

In case of 12V system, or of actuator with current consumption over 5 amp or above, connect terminals G and H.

6.

Selector switch, switching over "IDLE mode" and "RUN mode" ON (close): idle mode OFF (open): run rated mode

7.

"DROOP" mode selector switch ON (close): DROOP mode OFF (open): Isochronous mode

8.

The signal from Auxiliary device for parallel operation system should be connected to terminal N. It is necessary to

use the shielded cable for the signal.

9.

Accessory power supply: The +10[V] and 20[mA] of current supply, Terminal P, can be utilized to provide power to

governor system accessory and for various other purposes

Caution: Wrong or erroneous wiring and battery voltage can cause fatal damage to the controller.

- 136 -

Maintenance of Major Components

● Magnetic speed sensor connections

1. With the engine stopped, adjust the gap between the

G

J

K

L

magnetic speed sensor and the ring gear teeth. The

gap should not be any smaller than 0.45mm. Usually,

backing out the speed sensor by 3/4 turn after

touching the ring gear teeth will achieve a satisfactory

air gap.

2. The signal from the speed sensor can be measured

between C and D in engine operation.

3. Signal VAC 3 or above is required for the controller.

● Remote speed adjustment

CW

1. As illustrated in DV2213106A, a remote speed adjust-

DV2213106A

ment potentiometer can be used to adjust the engine

speed over specific speed range. Select the desired

speed range and the corresponding potentiometer

value. When the minimum speed setting is used in

remote adjustment mode, the speed drop phenom-

enon may occur due to instability and load in the

system. To maintain engine stability at the minimum

speed setting above, a small amount of droop can be

added by turning ⑦ Droop counterclockwise. On the

other hand, at the maximum speed setting, the

governor performance will be near Isochronous

regardless of the droop adjustment setting

2. Potentiometer Value by Speed Range

Engine RPM for Each Ring

Pote

Speed

Gear

tiometer

range

value

160 teeth

152 teeth

146 teeth

900Hz

1K

337rpm

355rpm

370rpm

2,400Hz

5K

900rpm

947rpm

986rpm

3,000Hz

10K

1,125rpm

1,184rpm

1,230rpm

3,500Hz

25K

1,315rpm

1,381rpm

1,438rpm

3,700Hz

50K

1,387rpm

1,460rpm

1,520rpm

Maintenance of Major Components

- 137 -

3.

Factory-set Value

300611-00685

300611-00683

1,725rpm (No. of teeth =

Overspeed

1,725rpm (No. of teeth =

152)

Overspeed

160)

Run lamp

Maximum CW

Run lamp

Maximum CW

Gain

Mid-range (12 O’clock)

Gain

Mid-range (12 O’clock)

Stability

Mid-range (12 O’clock)

Stability

Mid-range (12 O’clock)

Starting Fuel

Full CW^a(Maximum Fuel)

Starting Fuel

Full CW^a(Maximum Fuel)

Speed Ramping

9 O’clock

Speed Ramping

9 O’clock

Droop

Full CCW^b

(Minimum)

Droop

Full CCW^b (Minimum)

Adjustment

(No. of teeth = 160)

Adjustment

(No. of teeth = 160)

Speed Adjustment

3,800Hz (1500rpm)

Speed Adjustment

4,000Hz (1500rpm)

Idle Adjustment

2,026Hz (800rpm)

Idle Adjustment

2,133Hz (800rpm)

a.

CW: Clockwise

b.

CCW: Countclockwise

a.

CW: Clockwise

b.

CCW: Countclockwise

300611-00686

300611-00684

2,070rpm (No. of teeth =

Overspeed

2,070rpm (No. of teeth =

152)

Overspeed

160)

Run lamp

Maximum CW

Run lamp

Maximum CW

Gain

Mid-range (12 O’clock)

Gain

Mid-range (12 O’clock)

Stability

Mid-range (12 O’clock)

Stability

Mid-range (12 O’clock)

Starting Fuel

Full CW^a(Maximum Fuel)

Starting Fuel

Full CW^a(Maximum Fuel)

Speed Ramping

9 O’clock

Speed Ramping

9 O’clock

Droop

Full CCW^b

(Minimum)

Droop

Full CCW^b (Minimum)

Adjustment

(No. of teeth = 160)

Adjustment

(No. of teeth = 160)

Speed Adjustment

4,053Hz (1800rpm)

Speed Adjustment

4,800Hz (1800rpm)

Idle Adjustment

2,026Hz (800rpm)

Idle Adjustment

2,133Hz (800rpm)

a.

CW: Clockwise

b.

CCW: Countclockwise

a.

CW: Clockwise

b.

CCW: Countclockwise

- 138 -

Maintenance of Major Components

● System inoperative

If the engine governing system does not function, the fault may be determined by performing the voltage tests described

in steps 1, 2 and 3. (+) and (-) refer to meter polarity. If normal values should be indicated as a result of following

the troubleshooting steps, the fault may be with the actuator or the wiring to the actuator. In that case, check the

actuator.

When to Take

Normal read-

Step

Terminal

Probable Cause of Abnormal Reading

Solution

the Reading

ings

1. Check battery line

When the

1

F(+) & E(-)

DC 24V

engine stopped

2. Replace battery

1. Low battery voltage

1. Check battery line

When starting

DC 15V or

2

F(+) & E(-)

the engine

above

2. Wiring error

2. Replace battery

1. Defective speed sensor

1. Check sensor line

300~1200Ω

When the

3

C & D

(tester ohmme-

engine stopped

2. Improper or defective wiring to the

2. Replace speed sensor

ter)

speed sensor

1. The gap between speed sensor and

1. Check sensor line

1.5V or above

gear teeth too great.

When starting

4

C & D

(tester AC volt-

the engine

meter)

2. Replace speed sen-

2. Defective speed sensor

sor

1. If the voltage reading is below

1. Check short/open

3.8 Ω => Short

actuator

When the

3.8~4.5 Ω (tes-

5

A & B

2. If the voltage reading is above

engine stopped

ter ohmmeter)

4.8 Ω => Open wire

2. Replace actuator

3. Defective actuator

6

P(+) & G(-)

KEY S/W ON

DC 9.5~10.5V

Defective speed controller

Replace controller

1. Speed adjustment set too low.

1. Check speed setting

DC 9~15V in

normal condi-

2. Short/open in actuator wiring

2. Check actuator line

When starting

7

F(+) & A(-)

tions DC 1~3V

the engine

3. Replace actuator

in abnormal

3. Actuator

when found to be

conditions

defective

- 140 -

Maintenance of Major Components

10.3.4. Fuel feed pump

1) General descriptions and construction

Priming pump

Check valve

Check valve

Outlet

Inlet

side

side

Tappet

Piston

Cam shaft

EQM4019I

The P-type injection pump is mounted with K-ADS or KP type feed pump. These pumps have the

same basic construction and operation, and the general descriptions of the KP type pump are

given below:

The figures show its construction (right figure) and operation (below figure). The piston in the fuel

feed pump is driven by the push rod and tappet via the camshaft of injection pump and performs

reciprocating operation to control the suction and delivery of fuel. When the cam reaches the Bot-

tom Dead Center as shown in the figure, the fuel is drawn in through the check valve on the inlet

side.

The fuel pressurized as the cam rotates on flows through the check valve on the outlet side as

shown in (B). If the feeding pressure increases abnormally, the spring is compressed, resulting in

interrupting further delivery of fuel as shown in (C).

Maintenance of Major Components

- 141 -

(A)

(B)

(C)

Inlet side

Outlet side

Interruption

EQM4020I

This feed pump is mounted with a priming pump designed to permit manual feeding of fuel from the

fuel tank with the injection pump mounted in the engine. During the manual feeding operation, air

must be bled from the fuel lines.

When using the priming pump, fix it securely to prevent the possible entry of moisture or other for-

eign substances in the inside of feed pump.

In addition, a strainer is fitted into joint bolt on the inlet side of the fuel feed pump to filtrate any for-

eign substances possibly mixed in fuel.

- 142 -

Maintenance of Major Components

2) Disassembly

42

25

16

18

20

10

18

15

15

14

14

Fuel tank side

strainer bolt (MESH 50)

30

35

32

1

5

36

6

32

8

7

EQM4021S

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

(35, 36).

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

● Take off the plug (7), gasket (8), spring (6), and piston (5) on the piston side.

● Pull out the snap ring (20) holding the tappet (10).

● Disassemble the snap ring, then take off the tappet (10) and push rod (1).

3)

Inspection

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

● Inspect the piston and tappet for damage.

● Replace the push rod if excessively worn, and replace together with the pump housing if

required. The inspection for wear should be performed in the same procedure as for suction

pressure test described below.

4)

Reassembly

● Reassembly operation is performed in reverse order of disassembly. All the gaskets must be

replaced with new ones at reassembly.

Maintenance of Major Components

- 143 -

5)

Testing

(1)

Suction capacity test

Connect one end of a hose to the

Outlet hose

inlet side of the feed pump and

immerse the other end of it into the

Feed pump

fuel tank as illustrated.

Hold the feed pump in position

about

1 m above the level of fuel in the fuel

Inlet hose

tank.

Operate the tappet at the rate of 100

rpm and check to see if fuel is drawn

in and delivered for 40 seconds or so.

Fuel tank

EQM4022I

(2)

Delivery test

Make a test with the feed pump

mounted on a pump tester as illus-

trated. Operate the pump at the rate

of 1,000 rpm and check to see if the

pump delivery is more than 405 cc /

15 seconds.

EAMC016I

(3) Sealing test

Plug up the delivery port on the feed

Compressed

Mass cylinder

pump and apply compressed air of 2

air 2kg / cm²

kg/cm2 into the inlet side.

Submerge the feed pump in a con-

tainer of diesel fuel and check for air

leak.

Feed pump

EQM4023I

- 144 -

Maintenance of Major Components

10.3.5. Injection nozzle

1) General descriptions

Pressurized fuel delivered from the fuel injection pump is sprayed into the combustion chamber

past the injection nozzle at proper spray pressure and spray angle, then burnt completely to

achieve effective engine performance.

(1) At valve closed

(2) At valve opened

EQM4024I

2) 1-spring type

(1) Disassembly

1

1. Cap nut

2

2. Adjusting screw

3

3. Spring

4. Push rod

5

4

5. Connector

9

6. Retaining nut

7. Needing valve

7

8. Nozzle

9. Nozzle holder

8

6

EI6OM004

Maintenance of Major Components

- 145 -

(2) Reassembly

● After removing carbon deposit,

1

submerge the nozzle in diesel oil

and clean it.

2

● Replace all the gaskets with new

5

ones.

9

● Assemble the parts and tighten

them to specified torque.

3

4

7

8

(3)

Adjustment

● Remove the cap nut and assemble

a nozzle to a nozzle tester.

● With the adjusting screw loosened,

operate the nozzle 2 ~ 3 times to

bleed it.

● Operate the nozzle tester lever at

the specified rate.

● Adjust the injection pressure to

EA0M3003

the standard pressure using the

adjusting screw.

● After adjusting the injection

pressure, tighten the cap nut to

specified torque.

● Re-check the injection pressure and

see if the spray pattern is normal.

(4)

Testing

● With the nozzle assembled to a

nozzle tester and pressure of 20

~

21 MPa

(200

~

210 bar)

applied, check the nozzle for fuel

leakage.

EAMC022I

- 146 -

Maintenance of Major Components

3) 2-spring type

(1) Disassembly

31

30

2

7

1

6

4

10

11

3

12

13

15

14

16

A

17

EQM4029I

1. Nozzle holder body

13. Lift pin

2. Push rod

14. Pin

3. Primary spring

15. Spacer

4. Adjusting screw

16. Pin

6. Gasket

17. Retaining nut

7. Cap nut

30 Gasket

10. Adjusting shim

31 Eye bolt

11. Secondary spring

A. Nozzle

12. Spring Seat

Maintenance of Major Components

- 147 -

(2) Inspection and adjustment

● Adjusting the primary opening

pressure. Install the plate of plate

assembly (157944-9520) onto a

vise.

NOTE :

Use the plate assembly

(157944-9520) in fixing a nozzle holder

EQM4030I

having a flange. A nozzle holder

without flange should be directly

installed onto a vise.

● With the nut, install the two pins

on the plate.

● Install the nozzle holder body (1)

1

onto the plate with the cap nut

side facing downward.

EQM4031I

● Assemble adjusting shim

(10),

12

secondary spring (11), and spring

11

seat

(12) on the nozzle holder

10

body in the order as described.

NOTE :

The secondary spring is the same one

as the primary spring.

EQM4032I

● Assemble the pin (14), lift piece

(13), and spacer

(15) with the

15

nozzle holder body.

14

13

EQM4033I

- 148 -

Maintenance of Major Components

● Install the pin (16) and nozzle (A)

onto the spacer.

A

16

EQM4034I

● After installing the gasket (6:157892-

1500) on the nozzle, use the cap nut

(7:157892-4000 : SW22 mm) to fix

6

1

the nozzle onto the nozzle holder.

NOTE :

7

While tightening the cap nut, keep

checking to see if the lock pin comes

all the way into the nozzle.

EQM4035S

NOTE :

Tighten the retaining nut until it resists

hand tightening, then further tighten it

using a torque wrench.

● Be sure to follow the specified

torque rating when tightening the

adjusting retaining nut.

Torque

6.0 ~ 8.0 kg⋅m

7

EQM4036I

● With the cap nut facing upward,

install the nozzle holder on the

plate.

Maintenance of Major Components

- 149 -

● Assemble the push rod (2), pri-

7

mary spring

(3), and adjusting

6

screw (4) on the nozzle holder in

3

the order described.

4

● Install the gasket (6) and cap nut

(7) onto the adjusting screw(4).

2

● Assemble the nozzle and nozzle

60

holder assembly to the nozzle

40

80

20

tester (105785-1010).

0

100

EQM4039I

● Adjust the primary opening pres-

sure to the specified pressure

using the adjusting screw (4).

EQM4040I

● With a monkey wrench, fix the noz-

zle holder securely and tighten the

cap nut (SW 19mm) to specified

torque.

Torque

3.0 ~ 4.0 kg⋅m

EQM4041I

- 150 -

Maintenance of Major Components

(3) Inspecting the needle valve for full lift

● Install gasket

(026508-1140) and

plug

(157892-1600

: SW12 mm)

onto the adjusting retaining nut

(157892-1400).

EQM4042I

● Install the nozzle holder on the

plate with the cap nut facing

upward.

● Install the holder(157892-4100

:

SW12 mm) into the cap nut.

● Install a nut (157892-1000 : SW

17 mm) on the holder.

● Assemble the pin (157892-4200

or

157892-4300) to the dial

gauge (157954-3800).

(mm)

Part No.

Limit

157892-4200

160

157892-4300

110

NOTE :

EQM4045I

“L” means the length of the pin except

the threaded portion.

Maintenance of Major Components

- 151 -

● Install the dial gauge on the

Dial gauge

holder assembly so that the pin is

brought into contact with the

Threaded part

upper end of the push rod, then

Holder

fix the pin with the nut.

NOTE :

Fix the dial gauge so that a stroke of 2

mm or so can be measured.

NOTE :

Overtightening the nut may cause a

sticking of the dial gauge seat.

EQM4046S

● Assemble the nozzle and nozzle

holder assembly to the nozzle

tester and zero the dial gauge.

● Operate the nozzle tester, bleed

the retaining nut, and check for

fuel leakage.

● Operate the nozzle tester and

L

increase 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”.

NOTE :

0

This testing is to be made in order to

Tester pressure

EQM4048I

check the nozzle seat portion for

unusual wear or whether the nozzle

assembly is a standard item.

- 152 -

Maintenance of Major Components

(4) Inspection of pre-lift

● If the nozzle tester handle is

released with the needle valve

200

300

engaged in a full lift condition, the

100

400

tester pressure drops, being accom-

panied by decrease in the needle

valve lift value (indicated value on

500

0

the dial gauge).

kgf /

cm²

EQM4049I

L

0

Tester pressure

EQM4050I

● Take the indicated value on the

Push rod.

Second spring

dial gauge at the point of time

Spring seat

when the secondary spring com-

pletes its operation and the needle

valve puts an end to descent (the

position of needle valve lift value

"ℓ " as shown in the above and

Lift piece

right figures) and check that the

value is within the specified limit.

Spacer

Needle valve

EQM4051I

(5) Measuring point for pre-lift

L

Take the indicated value on the dial

gauge at a point of primary opening

pressure approx. + 10 kgf⋅cm2.

NOTE :

Locate the point of primary opening

0

pressure approx.

+10 kgf⋅cm2 while

Primary opening pressure

Tester pressure

EQM4050I

dropping the pressure.

Maintenance of Major Components

- 153 -

● If the measured pre-lift value devi-

ates from the specified limit,

13

14

15

replace the pin (14, 16), lift piece

16

(13), spacer

(15), and nozzle

assembly (A) with a new “nozzle

A

service kit”.

EQM4053I

(6)

Inspection of secondary opening

L

pressure

● After confirming the pre-lift, operate

the nozzle tester and increase the

internal pressure up to 350 ~ 450

+0.05

kgf⋅cm2 to fully lift the needle valve.

● Release the nozzle tester handle

0

to decrease the tester pressure,

Primary

Secondary

350~450

then take a note of the move-

opening opening pressure

kgf/cm²

Tester pressure

EQM4054I

ments of the dial gauge.

● Take the indicated value on the

pressure gauge at the point of

60

time when the needle of the dial

40

0

80

20

gauge indicates the specified

0

100

needle valve lift value. (In gen-

eral, pre-lift "ℓ "

+

0.05 mm.

Refer to following figure).

EQM4055I

Read the pressure

Lift of needle valve

values of gauge

Ɏ+ 0.05 ɘ

0

90

200

300

10

80

20

100

400

70

30

500

0

60

40

50

Max. lift of needle valve

Dial Gauge

Pressure Gauge

EQM4056I

- 154 -

Maintenance of Major Components

(7)

Adjusting secondary opening pressure

● In the event that the measured

value deviates from the specified

limit, readjust the primary opening

pressure if the amount of deviation

is small. (to the standard range of

the primary opening pressure)

-

If the secondary opening pressure

is lower than the standard value:

EQM4040I

Adjust the primary opening pres-

sure up to the top limit of the stan-

dard vague, and then measure the

secondary opening pressure.

-

If the secondary opening pressure

is higher than the standard value:

In a reverse manner, readjust the

primary opening pressure down to

the bottom limit of the standard

value.

● If the secondary opening pressure

10

still deviates from the specified limit

in spite of the readjusting the pri-

mary opening pressure, take off

the nozzle fixing portion from the

nozzle holder and remove the

adjusting shim (10).

● If the secondary opening pres-

sure is higher than the standard

EQM4058I

value, fit a thinner adjusting shim

than the existing one.

● After replacing the existing adjust-

ing shim, measure the secondary

opening pressure and continue the

adjustment until a value satisfying

the standard value.

Adjusting shim for secondary opening pressure

(Out diameter = ൵ 9.5 , Inner diameter = ൵ 4.5)

Part No.

Thickness (mm)

Part No.

Thickness (mm)

1505380-4900

0.40

1505380-5300

0.56

1505380-5000

0.50

1505380-5400

0.58

1505380-5100

0.52

1505380-5500

0.60

1505380-5200

0.54

1505380-5600

0.70

Maintenance of Major Components

- 155 -

(8) Retaining nut

● Take out the dial gauge, nut,

holder and gasket from the cap

nut (7).

● Remove the adjusting retaining

nut and gasket, and install the

7

original retaining nut

(SW

19

mm).

EQM4036I

Cap nut

m

6.0 ~ 8.0 kg⋅

Tightening torque

(9) Inspection at completion

● Assemble the nozzle holder to a

40

60

nozzle tester and check the pri-

80

20

mary opening pressure, spray

100

0

patterns, oil tightness of seat

portion, and oil leakage from

each part.

EQM4039I

● When replacing the nozzle,

13

replace it with a new

“nozzle

service kit” integrated with a

15

nozzle, lift piece, and spacer as

a complete set.

A

NOTE :

If only a nozzle is replaced, the amount

of pre-lift will deviate from the

EQM4060I

specified value.

- 156 -

Maintenance of Major Components

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