Daewoo Excavadora Motor

March 24, 2018 | Author: Dino Martin Mercado Quispe | Category: Internal Combustion Engine, Turbocharger, Cylinder (Engine), Diesel Engine, Pump
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65.99897-8057 MAINTENANCE MANUAL DIESEL ENGINE DE12 DE12T DE12TI DE12TIS PS-MMA0507-E1A DE12/T/TI/TIS MAINTENANCE MANUAL FOREWORD This maintenance manual is designed to serve as a reference for DAEWOO Heavy Industries Ltd's (here after DAEWOO’s) customers and distributors who wish to gain basic product knowledge on DAEWOO's DE series diesel engines (DE12, DE12T, DE12TI and DE12TIS) These economical and high-performance diesel engines (6 cylinders, 4 strokes, in-line, direct injection type) have been so designed and manufactured to be used for overland transport industrial purpose. That meets all the requirements such as low noise, fuel economy, high engine speed, and durability. To maintain the engine in optimum condition and retain maximum performance for a long time, CORRECT OPERATION and PROPER MAINTENANCE are essential. In this manual, the following symbols are used to indicate the type of service operations to be performed. Removal Installation Disassembly Reassembly Align the marks Directional Indication Inspection Measurement Adjustment Cleaning Pay close attention-Important Tighten to specified torque Use special tools of manufacturer's Lubricate with oil Lubricate with grease During engine maintenance, please observe following instructions to prevent environmental damage; Take old oil to an old oil disposal point only. Ensure without fail that oil and diesel fuel will not get into the sea or rivers and canals or the ground. Printed in Mar. 2001 PS-MMA0507-E1A DE12/T/TI/TIS MAINTENANCE MANUAL Treat undiluted anti-corrosion agents, antifreeze agents, filter element and cartridges as special waste. The regulations of the relevant local authorities are to be observed for the disposal of spent coolants and special waste. If you have any question or recommendation in connection with this manual, please do not hesitate to contact our head office, dealers or authorized service shops near by your location for any services. For the last, the content of this maintenance instruction may be changed without notice for some quality improvement. Thank you. DAEWOO Heavy Industries & Machinery LTD. Mar. 2001 Printed in Mar. 2001 PS-MMA0507-E1A Fuel injection pump 4.4.4.4.3. Preventive Maintenance 2. Breaking-in 33 48 65 89 4.2.3.1.2. Engine Inspection 14 22 32 3. 2001 PS-MMA0507-E1A . Disassembly 3.2.3.3. General Repair Instruction 1. Inspection 3. Lubricating system 4. MAJOR MAINTENANCE 2. Turbocharger 91 95 99 123 164 5. GENERAL INFORMATION 1. MAINTENANCE OF MAJOR COMPONENTS 4. DISASSEMBLY AND REASSEMBLY OF MAJOR COMPONENTS 3. Engine Assembly 1. Cooling system 4.DE12/T/TI/TIS MAINTENANCE MANUAL CONTENTS 1. Diagnosis and Remedy 2.1.1. Reassembly 3. Engine Characteristics 1. Engine Specifications 1 2 3 8 2. SPECIAL TOOL LIST ● Appendix 166 ● WORLDWIDE NETWORK Printed in Mar.2.1. Lubricate rotating and sliding faces of parts with oil or grease before installation. Before performing service operation. oil seals. Used cotter pins. lock washer and self-lock nuts should be discarded and new ones should be prepared for installation as normal function of the parts can not be maintained if these parts are reused. 5. 11. 9. The use of proper tools and special tools where specified is important to efficient and reliable service operation. 8. O-rings. etc.DE12/T/TI/TIS MAINTENANCE MANUAL 1. 12. General Repair Instructions 1. Clean the parts before inspection or reassembly. Engine oil and anti-freeze solution must be handled with reasonable care as they cause paint damage. 7. 3. 4. 2001 PS-MMA0507-E1A . 10. GENERAL INFORMATION 1 Printed in Mar. Also clean oil ports. When necessary. Carefully observe all specifications for bolts and nuts torques. 2. GENERAL INFORMATION 1.1. To facilitate proper and smooth reassemble operation. gaskets. Use genuine DAEWOO parts necessarily. disconnect the grounding cable from the battery for reducing the chance of cable damage and burning due to short-circuiting. using compressed air to make certain they are free from restrictions. When service operation is completed. use a sealer on gaskets to prevent leakage. Use covers for preventing the components from damage or pollution. keep disassembled parts neatly in groups. make a final check to be sure service has been done property. 6. Keeping fixing bolts and nut separate is very important as they vary in hardness and design depending on position of installation. As the rim around the combustion bowl port of the upper of the piston has been machined in a smaller size than the interior of the combustion bowl. low emission combustion.DE12/T/TI/TIS MAINTENANCE MANUAL 1.1. 2 GENERAL INFORMATION Printed in Mar. OMEGA combustion bowl The OMEGA combustion bowl is a unit designed to perform high efficiency. fuel M1041A discharge very low level of hazardous exhaust hydrocarbon. strong swirl is produced in the combustion bowl and strong squish flow makes the fuel be mixed more sufficiently with air. gases ensure the such high DE12 as series smoke. 2001 PS-MMA0507-E1A . Engine characteristics 1.2. Due to the application of OMEGA combustion system and optimal utilization of intake and exhaust port configuration within the cylinder head.2. or carbon monoxide and thus performance consumption. diesel nitrogen and low engines oxide. D.C) 32° (A.5 : 1 16. Truck : 18 / 125 Thermostat type Air compressor type & capacity Power steering pump (cc/rev) (lit/bar) Alternator voltage .064 909 16. Water-cooled type Turbo charged DE12TI DE12TIS 4 cycle in-line.1 : 1 1.3.C) Full forced pressure feed type Gear type driven by crankshaft Cartridge type 1st : 160 2nd : 220 Intake and exhaust valve clearance(at cold) Intake valve Exhaust valve Lubrication method Oil pump type Oil filter type Open at Close at Open at Close at 18° (B.31) 12° Mechanical RFD-D Multi-hole(5-Ø 0.1 kW) Starting motor voltage .0 22 – 95 (2.45 .1.A) (V – A) Truck : 24 .D.1 : 1 1.D. 2001 PS-MMA0507-E1A .C) 46° (B.317 x 795 x 1.D.051 17.D.3.317 x 847 x 1.capacity Air heater capacity (V .D. of cylinder-bore x stroke (mm) DE12 4 cycle in-line.33) 1° Electrical RLD-J Multi-hole(5-Ø 0. Water-cooled type Turbo charged & intercooled Direct injection type Replaceable dry liner Gear driven type Compression ring 2.B.29) 220 1st : 160 220 2nd : 220 28 (at 200rpm) 0.B./min) (liter) Oil cooler type Water pump Cooling method Cooling water capacity (engine only) (liter) 17/14 Water cooled Centrifugal type driven by gear Fresh water forced circulation 19 Wax pallet type (83 ∼ 95 °C) Gear driven type.T.T.D.C) Lubricating oil capacity(max.B.T.C) 34° (A.C) 14° (A.output (V .kW) Battery capacity (V – AH) 24 – 200 GENERAL INFORMATION 3 Printed in Mar.D. Water-cooled type Naturally aspirated DE12T 4 cycle in-line. oil ring 1 6 – 123 × 155 Total piston displacement Compression ratio Engine dimension (length x width x height) (cc) 17.3 18° (B. Specification Engine Model Items Engine type Combustion chamber type Cylinder liner type Timing gear system No.29) Fuel injection timing (B.8 : 1 (mm) 1. of piston ring No.151 990 Engine weight (kg) Rotating direction (viewed from flywheel) Fuel injection order Counter clockwise 1–5–3–6–2–4 12° Mechanical RFD-C / RLD Multi-hole(5-Ø0.T. Bus : 24 – 150 24 – 6. Bus : 318 Bus : 16 / 100 .T.B.029 872 11.C) 70° (B. Truck : 220 .368 x 932 x 1. Engine Specification 1.DE12/T/TI/TIS MAINTENANCE MANUAL 1.C static) Injection pump type Governor type Injection nozzle type Fuel injection pressure Compression pressure (kg/cm ) (kg/cm2) (mm) 2 9° Mechanical RFD-C Multi-hole (5-Ø 0.D.C) 30° (A. 200 225 / 2.400 81.200 81 / 1.5 / 1.260 145 / 1.320±50 2.400 110 / 1. 4 GENERAL INFORMATION Printed in Mar.320±50 2.2.260 125 / 1.100 290 / 2.320±50 EURO-I DE12T EBHBA EBHBC EBIBA EBIBB DE12TI EBIBC EBIBD EBICA/ B/C/E/I/ L/M ECIBA ECICA ECICB ECICD ECIBD 1 340 / 2.260 115 / 1.260 600±25 2.3.260 600-650 600-650 600-650 600-650 600-650 600-650 600-650 600-650 2420±50 2420±50 2420±50 2. Engine power Production tolerance : ±5% Engine Model Injection timing (BTDC º) Performance Power (PS / rpm) Torque Low idle (kg.3502.320±50 2.400 600-650 2420±50 8 12 8 12 9 9 9 12 228 / 2.100 310 / 2.260 125 / 1.100 145 / 1.5 / 1.200 300 / 2.100 335 / 2. 2001 PS-MMA0507-E1A .200 340 / 2.DE12/T/TI/TIS MAINTENANCE MANUAL 1.100 340 / 2.100 280 / 2.100 360 / 2.260 DE12TIS ECICC ECIBB ECIBC ECIBE 1 1 1 1 320 / 2.100 300 / 2.100 310 / 2.400 EURO-II * Note : All data are based on operation without cooling fan at ISO 1585(SAE J1349).200 81.260 120 / 1.m / rpm) (rpm) High idle (rpm) Remark Model Suffix EBGBA EBGBB EBGBC EBGBD EBGBR EBGBE EBGBF EBGBJ EBGBK EBGBL EBGBM EBGBO EBGBQ EBGCA 12 225 / 2.320±50 2.260 115 / 1.400 600-650 2420±50 DE12 10 230 / 2.100 135 / 1.260 135 / 1.300 135 / 1.100 81.5 / 1. 3.100 rpm 1.3.m) / 1.h) GENERAL INFORMATION 5 Printed in Mar. Performance curve 1) DE12TIS – 360PS Performance Output Torque Fuel consumption (max.DE12/T/TI/TIS MAINTENANCE MANUAL 1.h (143 g / PS. 2001 PS-MMA0507-E1A .260 rpm 186 g/kW.421 N.) (max) (min.) ISO 1585 (SAE J1349) 265 kW (360PS) / 2.m (145 kg. 421 N.100 rpm 1.260 rpm 186 g/kW. 2001 PS-MMA0507-E1A .) ISO 1585 (SAE J1349) 250 kW (340PS) / 2.) (max) (min.h) 6 GENERAL INFORMATION Printed in Mar.m (145 kg.DE12/T/TI/TIS MAINTENANCE MANUAL 2) DE12TIS – 340PS Performance Output Torque Fuel consumption (max.m) / 1.h (143 g / PS. 100 rpm 1.m (115 kg.m) / 1.127 N.h) GENERAL INFORMATION 7 Printed in Mar.h (143 g / PS.) (max.260 rpm 186 g/kW.290PS Performance Output Torque Fuel consumption (max. 2001 PS-MMA0507-E1A .DE12/T/TI/TIS MAINTENANCE MANUAL 3) DE12TIS .) (min) ISO 1585 (SAE J1349) 223 kW (290PS) / 2. 2001 PS-MMA0507-E1A . Engine Assembly 1.4.1.DE12/T/TI/TIS MAINTENANCE MANUAL 1. Engine sectional view (longitudinal) 3 4 5 6 7 8 9 10 2 1 11 12 13 14 15 16 17 18 19 1 4 7 10 13 16 19 Cooling water pump Valve spring Push rod Chamber Oil pump Connecting rod Flywheel 2 5 8 11 14 17 Fuel filter Oil filler Piston pin Crank shaft pulley Crank shaft Cam shaft 3 6 9 12 15 18 Valve Tappet Piston Vibration damper Oil pan Flywheel housing 8 GENERAL INFORMATION Printed in Mar.4. DE12/T/TI/TIS MAINTENANCE MANUAL 1. 2001 PS-MMA0507-E1A . Engine sectional view (cross) 7 8 9 10 6 11 5 12 4 13 3 2 1 14 1 2 3 4 5 6 7 Oil filter Cylinder block Fuel injection pump Alternator Oil cooler Cooling water outlet Fuel injection nozzle 8 9 10 11 12 13 14 Rocker arm Cylinder head cover Cylinder head Exhaust manifold Piston ring Turbocharger Oil suction pipe GENERAL INFORMATION 9 Printed in Mar.4.2. 4.3. 2001 PS-MMA0507-E1A . Engine assembly views 1) DE12 (Bus) 4 3 2 1 5 6 7 8 9 19 20 21 10 11 22 12 13 14 15 16 17 18 23 24 4 29 30 25 26 27 28 1 2 3 4 5 6 7 8 9 10 Fly wheel Flywheel housing Oil pressure unit Lifting hook Oil cooler Intake manifold Air heater Cooling warning switch Thermostat Oil filler cap 11 12 13 14 15 16 17 18 19 20 Oil level gauge Pilot bearing Oil filter Oil drain plug Oil pan Fuel injection pump Mounting bracket Power steering pump Alternator Fuel filter 21 22 23 24 25 26 27 28 29 30 Air pipe Cooling water pump Air compressor Exhaust manifold Crank shaft pulley Vibration damper Mounting bracket Starting motor Fuel injection nozzle Cooling water pipe 10 GENERAL INFORMATION Printed in Mar.DE12/T/TI/TIS MAINTENANCE MANUAL 1. 2001 PS-MMA0507-E1A .DE12/T/TI/TIS MAINTENANCE MANUAL 2) DE12TI (Bus) 4 3 2 1 5 6 7 8 20 9 19 21 11 10 12 13 14 15 22 23 16 17 18 24 25 30 31 32 26 27 28 29 1 2 3 4 5 6 7 8 9 10 11 Fly wheel Flywheel housing Oil pressure unit Lifting hook Oil cooler Intake manifold Air heater Air pipe (Turbocharger to intercooler) 12 13 14 15 16 17 18 19 20 21 22 Pilot bearing Oil filter Oil drain plug Oil pan Fuel injection pump Mounting bracket Power steering pump Alternator Fuel filter Cooling water pump Air compressor 23 24 25 26 27 28 29 30 31 32 Air pipe (Air cleaner to turbocharger) Turbocharger Exhaust manifold Crank shaft pulley Vibration damper Mounting bracket Starting motor Air pipe (Intercooler to intake manifold) Thermostat Oil filler cap Oil level gauge Cooling water pipe Fuel injection nozzle GENERAL INFORMATION 11 Printed in Mar. Compressor Fan guide Cooling fan Oil filter Oil pan Oil level gauge Fan guide bracket Oil drain plug Fan clutch Air pipe (Turbocharger to intercooler) Air compressor Air pipe (Air cleaner to turbocharger) 12 GENERAL INFORMATION Printed in Mar.DE12/T/TI/TIS MAINTENANCE MANUAL 3) DE12TIS (Truck) 3 4 5 6 7 8 9 10 11 19 2 1 18 20 21 12 26 13 14 15 16 17 22 36 30 23 37 38 39 27 28 29 25 40 24 35 31 32 33 34 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Flywheel housing Oil cooler Breather hose Fuel filter Intake manifold Air heater Air pipe (Intercooler to intake manifold) 15 16 17 18 19 20 21 22 23 24 25 26 27 Fuel injection pump Engine mounting bracket Power steering pump Alternator Lifting hook(Front) Cooling water pump Oil hose(Power steering pump) 28 29 30 31 32 33 34 35 36 37 38 39 40 Turbocharger Exhaust elbow Cooling delivery pipe Engine mounting bracket Ladder frame Starting motor Fly wheel Pilot bearing Exhaust manifold Cylinder head cover Fuel injection nozzle Cooling water pipe Oil pressure unit Thermostat Air-con. 2001 PS-MMA0507-E1A . DE12/T/TI/TIS MAINTENANCE MANUAL 4) DE12TIS (Bus) 4 3 2 1 5 6 7 8 9 10 11 19 20 21 12 13 14 15 22 23 16 17 18 24 25 30 31 32 26 27 28 29 1 2 3 4 5 6 7 8 9 10 11 Fly wheel Flywheel housing Oil pressure unit Lifting hook Oil cooler Intake manifold Air heater Air pipe (Turbocharger to intercooler) 12 13 14 15 16 17 18 19 20 21 22 Pilot bearing Oil filter Oil drain plug Oil pan Fuel injection pump Mounting bracket Power steering pump Alternator Fuel filter Cooling water pump Air compressor 23 24 25 26 27 28 29 30 31 32 Air pipe (Air cleaner to turbocharger) Turbocharger Exhaust manifold Crank shaft pulley Vibration damper Mounting bracket Starting motor Air pipe (Intercooler to intake manifold) Thermostat Oil filler cap Oil level gauge Cooling water pipe Fuel injection nozzle GENERAL INFORMATION 13 Printed in Mar. 2001 PS-MMA0507-E1A DE12/T/TI/TIS MAINTENANCE MANUAL 2. MAJOR MAINTENANCE 2.1. Preventive Maintenance The preventive maintenance means that the operator performs the servicing of engine to obtain long life and best performance from DAEWOO diesel engine. 2.1.1. Cooling water Regarding the cooling water that is to be used for engine, the soft water not the hard water must be used. The engine cooling water can be used diluting it with antifreezing solution 40% and the additive for rust prevention (DCA4) 3 ～ 5 %. The density of above solution and additive must be inspected every 500 hours to maintain it properly. NOTE : The proper density control of antifreezing solution and rust preventing additive will be able to prevent the rusting effectively and maintain the stable quality of engine. For the improper control might give the fatal damage to the cooling water pump and cylinder liners, detail care is needed. Since DE12/T/TI and DE12TIS (diesel engine of DE12 series) cylinder liner is dry type, particularly the cooling water control should be applied thoroughly. The density of antifreezing solution and additive for rust prevention is able to be confirmed by the cooling water test kit. (Fleetguard CC2602M) How to use the cooling water test kit (1) When the cooling water temp. of engine is in the range of 10 ～ 55 °C, loosen the plug for cooling water discharge and fill the plastic cup about a half. NOTE : In taking the cooling water sample, if the water in auxiliary tank were taken, it is hard to measure the accurate density. Take the cooling water sample necessarily loosening the cooling water discharge plug. (2) At the state of a test paper soaked in the sampled water, after taking the paper out through water agitation, shake off the water. (3) Wait for about 45 sec. till the color change of test paper. 14 MAJOR MAINTENANCE Printed in Mar. 2001 PS-MMA0507-E1A DE12/T/TI/TIS MAINTENANCE MANUAL NOTE: However, it should not elapse longer than 75 sec, and if it did, the hue would change. (4) Make the numerical value by comparing the test paper which hue has changed with the color list of label on storage bottle. (5) By comparing the hue changed into yellowish green or so with the green color indication of test paper storage bottle, confirm the density. (Then, the density indication must be in the hue range of 33% to 50%). (6) The brown at the middle of test paper and the lower pink color indication represent the additive state for rust prevention, and the proper range is that the meeting numerical value of brown (vertical) and pink color (horizontal) locates in the range of 0.3 to 0.8 at the color list of label on the test paper storage bottle. (7) In case of less than 0.3, replenish the additive for rust prevention (DCA4), and in case of more than 0.8, pour out the cooling water about 50% and then readjust the density after refilling with clean fresh water. Amount of Anti-freeze in winter Ambient Cooling water (%) temperature (°C) Over -10 85 -10 80 -15 73 -20 67 -25 60 -30 56 -40 50 Anti-freeze (%) 15 20 27 33 40 44 50 2.1.2. Fan belt Use a fan belt of specified dimensions, and replace if damaged, frayed, or deteriorated. Check the fan belt for belt tension. If belt tension is lower than the specified limit, adjust the tension by relocating the alternator. (specified deflection: 10 ∼ 15 mm when pressed down with thumb) MAJOR MAINTENANCE 15 Printed in Mar. 2001 PS-MMA0507-E1A (lit) (lit) 17 17 17 14 14 14 Total (lit) 21 21 21 MAJOR MAINTENANCE Printed in Mar.000km every 20.DE12/T/TI/TIS MAINTENANCE MANUAL 2. Oil in the oil filter should be changed simultaneously. The oil level must be between Max and Min. DE12/T/TI DE12TIS SAE 15W40 SAE15W40 SAE10W40 API No. ACEA-E3 oil must be used. If the engine is warm.000km every 30. Check the oil level with the engine cooled.1. Engine Oil capacity Engine oil capacity Engine model DE12 DE12T DE12TI DE12TIS 16 Vehicle Bus Truck Bus Truck in Oil pan Max. Engine oil should be changed at the specified intervals. 2001 PS-MMA0507-E1A . cargo truck) The following oils are also recommended Recommend oil Engine model SAE No. allow time for 5 ∼ 10 minutes for oil drain into the crankcase before checking oil level. Engine oil Check oil level with the oil level gauge and replenish if necessary.000km Long-distance operation vehicles (express bus.000km (50hr) operation DE12/T/TI DE12TIS DE12/T/TI DE12TIS every 10. above CD or CE ACEA-E2 or ACEA-E3 (API CH-4) * If long oil change intervals are to be used. Min.3. dump truck) After 1.000km every 15. First oil change Short-distance operation vehicle (city bus. lines on the gauge. Change the oil filter cartridge simultaneously at every replacement of engine oil. and repair or replace the oil filter if necessary.4.5. G1019 2. replace it. Fuel filter Drain water in cartridge with loosening the cock under filter manually (6) from time to time. In case that elements are deformed. By the definite interval. the elements must be cleaned and replaced. 2001 PS-MMA0507-E1A . Oil filter Check for oil pressure and oil leaks.6. MAJOR MAINTENANCE 17 Printed in Mar. damaged or if the air cleaner has a crack. Air cleaner.1.1.1. EQM4010I 2.DE12/T/TI/TIS MAINTENANCE MANUAL 2. 1.DE12/T/TI/TIS MAINTENANCE MANUAL 2. then #1 cylinder become the compression state of top dead center.3 mm 1) Rotate the crankshaft to overlap the intake and the exhaust valves of #6.7. adjust it when in cold. As for the valve clearance. as follow. 3) Rotating the crankshaft by one revolution. The intercooler life and performance depends on the intake air condition greatly. Intercooler The intercooler is air to air type and has a large cooling fan capacity. Valve clearance adjust procedure After letting the #1 cylinder's piston come at the compression top dead center by turning the crankshaft. #6 cylinder become the compression 18 ” of lower figure. adjust the valve clearances. 2) Therefore adjust the valve clearance corresponding to “ At this time there are no force on the push rods of #1 cylinder. 2001 PS-MMA0507-E1A . Air/air intercooler with radiator (combined radiator) Air flow by cooling fan Hot air by turbo charger compressor Cooled air to intake manifold (max. So you always check whether the intake air systems like air filter element are worn or polluted.3 mm Exhaust Valve 0. Model DE12 DE12T DE12TI DE12TIS Intake Valve 0. MAJOR MAINTENANCE Printed in Mar. As a result of this. Loosen the lock nuts of rocker arm adjusting screws and push the feeler gauge of specified value between a rocker arm and a valve stem and adjust the clearance with adjusting screw respectively and then tighten with the lock nut. Fouled air pollutes and clogs the air fins of intercooler. the engine output is decreased and engine malfunction is occurred.8. 50°C) 2.1. Cooling Fan ” of lower figure. Engine rotation 200rpm (10 rotations) MAJOR MAINTENANCE 19 Printed in Mar. retighten if necessary. 1 Cylinder is located at the side where flywheel was installed.DE12/T/TI/TIS MAINTENANCE MANUAL state of top dead center. Flywheel Intake Valve Exhaust Valve Cylinder No. 4) Thereafter adjust the valve clearances corresponding to “ 5) After reinsuring the valve clearances. G1048 2. Cylinder compression pressure Stop the engine after warming up.1.9. 2001 PS-MMA0507-E1A . No. Standard value 28kg/cm2 over Limit value 24kg/cm2 Difference Within ± 10 % between each cylinder ♦ Condition : Water temperature 20°C. Install the special tool (compression gauge adapter) at the nozzle holder hole. and take out nozzle holder assembly. and connect the compression pressure gauge there. Injection nozzle Install a nozzle on the nozzle tester. Engine model Injection nozzle pressure DE12 220 kg/cm2 DE12T 220 kg/cm2 DE12TI 1st : 160 kg/cm2 2nd : 220 kg/cm2 DE12TIS 1st : 160 kg/cm2 2nd : 220 kg/cm2 Check the atomizing state and replace it if abnormal. If the inspected injection pressure is less than the specified value. 2. Inspect for amount of electrolytic solution. Battery Inspect for any leakage of electrolytic solution owing to battery crack. Check if the idle operation and speed regulating lever's sealing is removed. and replace it if abnormal.11.DE12/T/TI/TIS MAINTENANCE MANUAL 2. 20 MAJOR MAINTENANCE Printed in Mar.1. The adjustment and testing of fuel injection pump should necessarily be done at the test bench. if less than specified value (1.10. Measure the gravity of electrolytic solution. and replenish if insufficient. adjust using the adjusting shims.28). damage etc. 2. replenish. Fuel injection pump Check the housing crack. 2001 PS-MMA0507-E1A . and replace the battery in case of poor condition.12.12 ～ 1.1.1. Fuel supply pump Every time of engine oil replacement. 2. remove the air by operating the manual pump of fuel supply pump until bubble will disappear. Starting motor In case of engine maintenance. Then one thing to beware is to dip only impeller part and so do not support by impeller but bearing housing.1.13. frequent cleaning must be done on the impellers. an immediate repair must be done. after loosening the air removing screws of cartridge filter respectively. dip the impeller into solution and may be better to clean it with stiff brush.DE12/T/TI/TIS MAINTENANCE MANUAL 2. Air cleaner should be maintained carefully for nut or foreign material not to get in. Periodic inspection should be applied on the compressed air and exhaust gas pipes. Every time of engine replacement. If necessary. clean pinion and ring gear thoroughly putting in the fuel. Turbocharger The turbocharger needs not arty special equipment. a leakage or clogging of oil pipes should be inspected. in case of new installation of injection pump. Also. use plastic scraper If impeller is severely polluted.1. Tear down the impeller casing (attention: be careful not to bend) and must clean with non-acid solvent solution.1. 2001 PS-MMA0507-E1A . and coat them with grease. Air removal of fuel system The suction room of fuel injection pump has the function of air removal continuously during the operation through a relief valve. the fuel strainer installed at the fuel supply pump should be removed and cleaned. For leaking air will bring the overheat engine.15. 2. In case of washing car and so forth.14. for instance. During the operation that is surrounded by the dust and oil mixed air. In case that the suction room lacks fuel at all.16.1. inspect the wiring state being careful for not to get MAJOR MAINTENANCE 21 Printed in Mar. 2. 2.DE12/T/TI/TIS MAINTENANCE MANUAL 2. 2001 PS-MMA0507-E1A . Immediate countermeasures should be taken before a failure is inflamed if any symptom is detected. Diagnosis and Remedy The following description summarizes the probable cause of and remedy for general failure by item. Inspect the electrical parts problem with SCAN 200 and refer diagnostic manual. 22 MAJOR MAINTENANCE Printed in Mar. Overload 2. Continuous over-run Check fresh Radiator tank cap Inspect Radiator MAJOR MAINTENANCE 23 Printed in Mar.DE12/T/TI/TIS MAINTENANCE MANUAL Operating state 1. 2001 PS-MMA0507-E1A . Radiator core clogged 3. DE12/T/TI/TIS MAINTENANCE MANUAL 24 MAJOR MAINTENANCE Printed in Mar. 2001 PS-MMA0507-E1A . 2001 PS-MMA0507-E1A .DE12/T/TI/TIS MAINTENANCE MANUAL MAJOR MAINTENANCE 25 Printed in Mar. DE12/T/TI/TIS MAINTENANCE MANUAL Causes according to operating conditions 1. 4. 3. 2. 2001 PS-MMA0507-E1A . 5. Overload Frequent use of low gear position at high speed Frequent use of high gear position at low speed Clutch slip Too low tire inflation pressure 26 MAJOR MAINTENANCE Printed in Mar. continuous operation in low speed or extremely cold state MAJOR MAINTENANCE 27 Printed in Mar. 2001 PS-MMA0507-E1A .DE12/T/TI/TIS MAINTENANCE MANUAL Cause according to use conditions 1. Excessive oil infusing 2. DE12/T/TI/TIS MAINTENANCE MANUAL 28 MAJOR MAINTENANCE Printed in Mar. 2001 PS-MMA0507-E1A DE12/T/TI/TIS MAINTENANCE MANUAL Condition 1) Starting difficult (1) Starting motor trouble (2) Fuel system trouble (3) Compression pressure lack Causes Refer to diagnostics Refer to diagnostics Valve's poor shut, stem distortion Valve spring damage Cylinder head gasket's leak Wear of piston, piston ring or liner Injection timing incorrect Air mixing at injection pump Valve clearance incorrect Valve tightness poor Cylinder head gasket's leak Wear, stick, damage of piston ring Injection timing incorrect Fuel injection amount insufficient Nozzle injection pressure improper or stuck Supply pump's function lowered Fuel pipe system clogged Air suction amount insufficient Turbocharger poor Compression pressure insufficient Injection timing incorrect Fuel injection amount insufficient Injection pump timer's function insufficient Nozzle infection pressure, infection angle improper Supply pump's function lowered Air intake amount insufficient Engine oil insufficient or poor Cooling water insufficient Fan belt loosened, worn, damaged Cooling water pump's function lowered Water temp. regulator's operation poor Valve clearance incorrect Exhaust system's resistance increased Remedies Repair or replace Replace valve spring Replace gasket Adjust Adjust Remove air Adjust Repair Replace gasket Replace piston ring Adjust Adjust injection pump Adjust or replace Repair or replace Repair Clean or replace air cleaner Repair or replace Disassemble engine Adjust Adjust injection pump Repair or replace Repair, replace Repair or replace Clean or replace air cleaner Replenish or replace Replenish or replace Adjust or replace Repair or replace Replace Adjust Clean or replace 2) Idle operation abnormal 3) Engine output insufficient (1) Continuous output insufficient (2) Output insufficient when in acceleration 4) Overheating MAJOR MAINTENANCE 29 Printed in Mar. 2001 PS-MMA0507-E1A DE12/T/TI/TIS MAINTENANCE MANUAL Condition 5) Engine noisy Causes For noises arise compositely such as rotating parts, lapping parts etc., there is necessity to search the cause of noises accurately. As the wear of bearing or crankshaft progress, the oil clearances increase. Lopsided wear of crankshaft Oil supply insufficient due to oil passage clogging Stuck bearing Remedies (1) Crankshaft Replace bearing & grind crankshaft Grind or replace Clean oil passage (2) Con.-rod and Con.-rod bearing (3) Piston, piston pin & Piston ring (4) Others 6) Fuel Consumption Excessive Replace bearing & Grind Lopsided wear of con rod Replace bearing bearing Lopsided wear of crank pin Grind crankshaft Connecting rod distortion Repair or replace Stuck bearing Replace & grind crankshaft Oil supply insufficiency as Clean oil passage clogging at oil passage progresses Piston clearance increase Replace piston & as the wear of piston and piston ring piston ring progresses Wear of piston or piston pin Replace Piston stuck Replace piston Piston insertion poor Replace piston Piston ring damaged Replace piston Wear of crankshaft, thrust Replace thrust bearing bearing Camshaft end play Replace thrust plate increased Idle gear end play increased Replace thrust washer Timing gear backlash Repair or replace excessive Valve clearance excessive Adjust valve clearance Abnormal wear of tappet, Replace tappet, cam cam Turbocharger inner part Repair or replace damaged Injection timing incorrect Adjust Fuel injection amount Adjust injection pump excessive 30 MAJOR MAINTENANCE Printed in Mar. 2001 PS-MMA0507-E1A stick. wear Piston ring opening's disposition improper Piston skirt part damaged or abnormal wear Oil ring's oil return hole clogged Oil ring's contact poor Looseness of valve stem & guide Wear of valve stem seal Cylinder head gasket’s leak Looseness of connection parts Various parts' packing poor Oil seal poor Replace Replace piston. 2001 PS-MMA0507-E1A . piston ring Replace piston ring Correct position Replace piston Replace piston ring Replace piston ring Replace in set Replace seal Replace gasket Replace gasket. repair Replace packing Replace oil seal MAJOR MAINTENANCE 31 Printed in Mar. ring groove Piston ring's damage.DE12/T/TI/TIS MAINTENANCE MANUAL Condition 7) Oil Consumption Excessive (1) Oil level elevated Causes Remedies (2) Oil level lowered (3) Oil leak Clearance between cylinder liner & piston Wear of piston ring. 1. 2. clamp) Check the water level Check the V-belt tension Change the coolant water Check for leakage Check the oil level gauge Daily 1.DE12/T/TI/TIS MAINTENANCE MANUAL 2. 2001 PS-MMA0507-E1A .000 О О О ● О О ● 1st ● 1st О О О О О (О) (О) 10.3. the engine trouble would be preventively maintained and capable to keep up the maximum performances. only when the original parts that the manufacture recommends to use is used.000 40.2. Use of original parts for repair and replacement For engine is being mechanically harmonized with many parts.3. 32 MAJOR MAINTENANCE Printed in Mar.000 15. 2.3.3. clamp) Exhaust Clean and change System the air cleaner element Check the leakage for intercooler Fuel System Drain the water in separator Clean the fuel strainer of fuel feed pump Check the fuel line leakage Check fuel Injection timing Replace the fuel filter cartridge Check the injection nozzles Check the exhaust gas state When necessary ● When necessary О О When necessary When necessary Engine Adjust Check the battery charging Check the compression pressure Adjust Intake/Exhaust valve clearance * (О) The engine oil change interval is determine by engine use and oil grade. then turn the key switch to stop the engine.3. it may rather bring early engine failure.000 20. Engine Inspection 2. General engine inspection cycle О : Check & adjust Inspection time(km) ● : Replace Inspection Check for leakage(hoses. For the analogous parts not the original parts are poor in qualities and gives ill performances.000 Remark Cooling System Lubrication Change the lubricating oil System Replace the oil filter cartridge Intake & (hoses. Stopping engine After checking the engine for any unusual condition at the idling speed. cover the cap with a rag. 33 ENGINE DISASSEMBLY Printed in Mar. Cooling water Remove the radiator cap.2.1. CAUTION: When removing radiator filler cap while the engine is still hot.DE12/T/TI/TIS MAINTENANCE MANUAL 3.1. Disassembly and Reassembly of Major Components 3. Disassembly 3. 2001 PS-MMA0507-E1A . Open the drain plug at the radiator lower part to drain the coolant as the right figure.1. General precautions Maintenance operation should be carried out in a bright and clean place. Arrange the disassembled parts in the disassembly sequence and use care to prevent any damage to them. provide parts racks for storage of various tools and disassembled parts. 3. Drain valve Remove the drain plug from the cylinder block and drain out the cooling water into a container. Before disassembly.1. 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. 2001 PS-MMA0507-E1A . Reassemble the drain plug with the oil pan after draining out the engine oil. 3.4. 34 ENGINE DISASSEMBLY Printed in Mar.1.1.5. Pre stroke sensor sensor Rack sensor Air heater relay Ne sensor 3. (ECM) Engine control unit (ECU) Engine harness ECU connector Water temp. then take off the flange and cooling fan.3. Cooling fan Remove the flange fixing bolts. Engine oil Take out the oil level gauge. Remove the oil drain plug of oil pan and drain out the engine oil into a prepared container.1. Engine Control Unit : ECU (DE12TIS) Remove the wiring harness and the engine control unit.DE12/T/TI/TIS MAINTENANCE MANUAL 3. Oil level gauge guide tube Loosen the flange nut installed on the ladder frame to remove the guide tube.1.1.1.6. 2001 PS-MMA0507-E1A . V-Belt Loosen the tension adjusting nuts on the alternator. and take off the alternator belts. compressor. Air con. Air con. 35 ENGINE DISASSEMBLY Printed in Mar. 3.8.DE12/T/TI/TIS MAINTENANCE MANUAL 3.7. Remove the tension adjusting bolt and bracket. compressor Alternator Alternator 3. compressor fixing bolts and disassemble the air con. compressor Remove the air con. Fuel injection pipe Unscrew the hollow screws to disassemble the fuel return pipe. 3.9. Fuel filter Remove fuel hoses connected to the fuel injection pump.DE12/T/TI/TIS MAINTENANCE MANUAL 3. then disassemble the fuel filter.1. 3. Intercooler Tear down the various hoses and air pipes from the inter cooler. Remove the nuts installed on the fuel injection pump and nozzles. Remove the intercooler fixing bolts and tear it down. G1069 36 ENGINE DISASSEMBLY Printed in Mar.11.1. 3.1.1. take off the bracket fixing bolts. 2001 PS-MMA0507-E1A .10. Breather Loosen the clamp screw to remove the rubber hose.12. then disassemble the injection pipe. DE12/T/TI/TIS MAINTENANCE MANUAL 3. then disassemble the 37 ENGINE DISASSEMBLY Printed in Mar. Disassemble the intake pipes by loosening the nuts installed thereon.1. 3. 3. Disassemble the air heater and gasket. disassemble the exhaust manifold.1. then remove the heat shield and gasket.1. then disassemble the intake manifold. release the nuts installed on the turbocharger. Unscrew the exhaust pipe bracket fixing bolts.13.14. 2001 PS-MMA0507-E1A . Remove the turbocharger after removing the oil supply pipe and return pipe and releasing the fixing nuts. Turbo charger Release the clamp screw of the rubber hose connected to the intake manifold. and take off the intake pipes both simultaneously. Loosen the intake manifold fixing bolts.15.16. exhaust pipe. Air heater Remove the electrical wiring for the air heater.1. 3. Intake manifold Remove the air hose connected to the fuel injection pump. Exhaust manifold Release the exhaust manifold fixing bolts. 3. 3.19.17. Starter Unscrew the starter fixing bolts. Disassemble the water pipe by unscrewing the bolts and nuts installed on the cylinder head. 2001 PS-MMA0507-E1A . then disassemble the starter.DE12/T/TI/TIS MAINTENANCE MANUAL NOTE: Make sure to release the nuts one after another because the exhaust manifold will be removed if you unscrew two nuts simultaneously. 38 ENGINE DISASSEMBLY Printed in Mar. Disassemble the thermostat housing and remove the thermostat. then disassemble the thermostat housing. Unscrew the water pump fixing bolts and remove the water pump. Remove the water pipe and hoses connected to the water pump. Cooling water pump Remove the water pipe connected to the expansion tank.1. 3. unscrew the thermostat fixing bolts. Thermostat Remove the by-pass pipe connected to the water pump.1.1.18. then disassemble the injection pump.22. Loosen the oil filter fixing bolts and disassemble the oil filter head from the cylinder block. Release the pump fixing bracket bolts to disassemble cylinder block. air pipe connected to the air compressor.DE12/T/TI/TIS MAINTENANCE MANUAL 3. NOTE : Do not interchange the shims as they must be installed in their original positions at reassembly. NOTE : Place the No.21. Remove the pipe connected to the oil cooler.1 cylinder in 'OT' in exact position to disassemble the injection pump.1. loosen the injection pump attaching bolts. Unscrew the bolts connecting the coupling and drive shaft. then disassemble the air compressor from the timing gear case. 3. Air compressor Remove the oil hoses. Remove the air compressor fixing bolts. 3.1. Oil filter Using a filter remover wrench. 39 ENGINE DISASSEMBLY Printed in Mar.1. 2001 PS-MMA0507-E1A the bracket from the .20. remove the oil filter cartridge. water pipe. Fuel injection pump Remove the oil supply pipe and return pipe connected to the fuel injection pump. Unscrew the hex bolts and remove the steering pump. Power steering pump Remove the oil hoses.1.24.26. 2001 PS-MMA0507-E1A .23. Unscrew the vibration damper fixing bolts and disassemble the damper from the pulley. Idle pulley Remove the bolts and disassemble the fan drive pulley.1. 3.1.1. 3. Timing gear case cover Disassemble the oil seal using an oil seal removing jig. Vibration damper Unscrew the pulley fixing bolts and disassemble the pulley-vibration damper assembly.25. Remove the cover fixing bolts and disassemble the cover from the timing gear case. 3. 40 ENGINE DISASSEMBLY Printed in Mar.DE12/T/TI/TIS MAINTENANCE MANUAL 3. gear.1.1. Take out the push rods.30.1.29. Disassemble the idle gear pin using a rubber hammer to prevent damage to them. Idle gear Unscrew the idle gear fixing bolts and disassemble the thrust washer and idle gear. 41 ENGINE DISASSEMBLY Printed in Mar. Fuel injection pump drive Remove the dowel pin for the steering pump. bearings.27. 3. Cylinder head cover Unscrew the cover fixing bolts and disassemble the cover.DE12/T/TI/TIS MAINTENANCE MANUAL 3. then unscrew the bracket fixing bolts to take off the bracket and springs. Keep the bolts in an assembly state so that the gaskets and washers may not be lost. and housing are put together. Take off the snap rings to remove the washers and rocker arm.1.28. Unscrew the injection pump drive shaft bearing housing fixing bolts and remove the injection pump drive assembly in which the shaft. 3. and keep the cover gasket as assembled with the cover. 2001 PS-MMA0507-E1A . 3. Rocker arm Unscrew the rocker arm bracket bolts and remove the rocker arm assembly. 33. Remove the cylinder head gasket. Oil cooler Remove the water pipe connected to the water pump. does not come out during engine operation 3. etc. 42 ENGINE DISASSEMBLY Printed in Mar. Valve and stem seal Compress the valve spring retainer using a jig and take off the valve cotter pins.1. Remove and discard the valve stem seal using a general tool as it should not be re-used.34. Take off the valves. Cylinder head Unscrew the cylinder head fixing borts and take off the cylinder head. Remove the oil pipe connected to the cylinder block and oil filter. 3. 2001 PS-MMA0507-E1A the valve springs and Compress the spring . 3. Unscrew the oil cooler cover fixing bolts and disassemble the oil cooler assembly from the cylinder block.1. Disassemble retainers. Remove the nozzle tube using nozzle tube removing jig. Injection nozzle and tube Remove the nozzle fixing nuts and extract the nozzles.1. NOTE: Do not disassemble the nozzle tube if coolant or gas.31.32.DE12/T/TI/TIS MAINTENANCE MANUAL 3.1. 2001 PS-MMA0507-E1A . Release the oil pan fixing bolts. Unscrew the oil pump fixing borts and disassemble the oil pump. Oil pan Stand the engine with the flywheel housing facing the bottom. Disassemble the oil pipe feeding oil from the oil pump to the cylinder block.1. Relief valve Disassemble the relief valve. 3. releasing the pipe fixing bolts. 3.37.38.36. Oil pump and pipe Unscrew the oil suction pipe bracket bolts. remove the stiffeners then disassemble the oil pan.1. 3.DE12/T/TI/TIS MAINTENANCE MANUAL Unscrew the oil cooler fixing bolts and remove the oil cooler from the oil cooler cover.1. 3. then disassemble the oil suction pipe assembly. 43 ENGINE DISASSEMBLY Printed in Mar.35. Ladder frame Disassemble the ladder frame.1. DE12/T/TI/TIS MAINTENANCE MANUAL 3. Use care not to interchange the disassembled parts and keep them in the sequence of cylinder No. then disconnect the connecting rod from the piston. Disassemble the piston rings using ring pliers. 3. 2001 PS-MMA0507-E1A . Remove the piston pin snap rings.1. Unscrew the connecting rod fixing bolts and take off the pistons and connecting rods in the direction of piston. Cylinder liner Disassemble the cylinder liner using a liner puller.1.39. take off the piston pin. Piston and connecting rod Disassemble the pistons by two cylinders while turning the crankshaft.40. 44 ENGINE DISASSEMBLY Printed in Mar. Oil seal Take off the rear oil seal using an oil seal disassembling jig. Take off the cam shaft gear and thrust washer. Install flywheel disassembling bolts in the bolt holes machined on the flywheel. Flywheel housing Loosen the housing fixing bolts and disassemble the flywheel housing.42. If only the inside guide ring is removed.1. Fly wheel 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.44.1.DE12/T/TI/TIS MAINTENANCE MANUAL 3.1.43. and disassemble the flywheel. 3. 3. Cam shaft and tappet Remove the cam shaft gear. 45 ENGINE DISASSEMBLY Printed in Mar. 3.1. Take out the cam shaft care not to damage the cam shaft. use a special tool to take off the outside seal.41. Slide out the tappets by hand. 2001 PS-MMA0507-E1A . Maintain the removed bearing caps in the order of cylinders. Crankshaft gear and oil pump idle gear Loosen the socket head bolts and take out the oil pump idle gear. Temporarily install the bolts at the both side of crankshaft. Use a puller to remove the crankshaft gear.1. 46 ENGINE DISASSEMBLY Printed in Mar. Timing gear case Unscrew the case fixing bolts and disassemble the timing gear case.DE12/T/TI/TIS MAINTENANCE MANUAL 3. 3. NOTE : Do not mingle with the metal bearings and bearing caps randomly. Crank shaft Remove the main bearing cap fixing bolts in the opposite direction of assembling.1. 3.47.46.45.1. and lift the shaft with a rope. temporarily assemble the metal bearings to the corresponding bearing caps in turn. To prevent mixing. 2001 PS-MMA0507-E1A . DE12/T/TI/TIS MAINTENANCE MANUAL 3. 47 ENGINE DISASSEMBLY Printed in Mar. Oil spray nozzle Unscrew the fixing bolt and remove the oil spray nozzles. 2001 PS-MMA0507-E1A .48.1. Cylinder block 1) Clean the cylinder block thoroughly and make a visual inspection for cracks or damage. Lower face warpage and height Standard Warpage Thickness : t (reference) 0. 4) Make a hydraulic test to check for any cracks or air leaks. Hydraulic test : Stop up each outlet port of water/oil passages in the cylinder block.2 mm or less 114. then immerse the cylinder block in water for about 1 minute to check any leaks.3 mm 113. retrace the head with grinding paper of fine grain size to correct such defect. apply air pressure of about 4kg/cm2 against the inlet ports. Cylinder head 1) Inspection Carefully remove carbon from the lower lace of the cylinder head using nonmetallic material to prevent scratching of the valve seat faces.95 ∼ 115. (Water temperature: 70 °C) 3.1. 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) Replace if cracked or severely damaged. If the measured value exceeds the standard value.DE12/T/TI/TIS MAINTENANCE MANUAL 3.2.2. 3) Check oil and water flow lines for restriction or corrosion.2. Inspection and Measurement 3. 2) Distortion at the lower face Measure the amount of distortion using a straight edge and a feeler gauge at six positions (A ∼ F) as shown in the right figure. replace the cylinder head.0 mm M1068 M1067 Limit 0. and correct if slightly damaged. If the measured value exceeds the maximum allowable limit.2.9 mm 48 INSPECTION & MEASUREMENT Printed in Mar. 2001 PS-MMA0507-E1A . 2001 PS-MMA0507-E1A .935 ∼ φ10.84 mm Valve seat contacting faces Check the valve seat contacting faces for scratches or wear.955 mm Limit φ10. Dimension Description Intake valve stem Exhaust valve stem Standard φ10.950 ∼ φ10.2 mm 3. (top.2. INSPECTION & MEASUREMENT 49 Printed in Mar.3. then inspect them as follows: Valve stem outer diameter Measure the valve stem outer diameter at 3 positions. and correct the faces with grinding paper as necessary.DE12/T/TI/TIS MAINTENANCE MANUAL 3) flatness Measure flatness of the intake/exhaust manifolds fitting surfaces on the cylinder head using a straight edge and a feeler gauge. Standard 0. and bottom) If the amount of wear is beyond the limit. replace the valve. Valve and valve guide 1) Valve Clean the valves with clean diesel oil.970 mm φ10.87 mm φ10.05 mm 4) Hydraulic test Hydraulic test method for the cylinder head is same as that for cylinder block. Limit 0. middle. Replace if severely damaged. 07 mm Limit 0.5 mm 1. and replace the valve if the measured value is beyond the limit. measure the valve and replace either the valve or the valve guide. 2001 PS-MMA0507-E1A . then check and see if it is centered with the valve seat using a special tool.9 mm or less 2) Valve guide Install the valve into the valve guide and measure the clearance between them by valve movement.2 mm Exhaust valve 0.09 mm 0. M1076 Measuring Point Valve stem end play Standard Intake valve 0. and replace if the measured value exceeds the specified limit. Dimension Description Standard Limit Intake valve Exhaust valve 1.25 mm Install the valve into the cylinder head valve guide. 50 INSPECTION & MEASUREMENT Printed in Mar.06 ∼ 0.04 ∼ 0. If the clearance is excessive.DE12/T/TI/TIS MAINTENANCE MANUAL Valve head thickness Measure the valve head thickness. whichever worn more.5 mm 1 mm or less 0. 3) Valve seat Contacting face amount Measure the contacting face between the intake valve seat and exhaust valve seat for valve seat wear. 2001 PS-MMA0507-E1A . For removal of the valve seat. apply arc welding work to two points of valve seat insert. and replace if necessary. and check the amount of depression of the valve from the lower portion of the cylinder head using a dial gauge. then wipe out the lapping compound. 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). replace the valve seat.DE12/T/TI/TIS MAINTENANCE MANUAL Install the valve into the valve seat on the cylinder head. Valve depression Standard Intake & Exhaust 0 ∼ 0. INSPECTION & MEASUREMENT 51 Printed in Mar. 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.03 mm Valve Valve seat Limit 0. 4) Valve spring Visual check Visually check the exterior of the valve springs for damage.55 mm If the amount of depression is beyond the specified limit. and pull out the valve seat insert with inner extractor. Standard φ23.75 mm 52 INSPECTION & MEASUREMENT Printed in Mar.959 mm G1066 Limit φ 23. measure the rocker arm shaft diameter at the point where the rocker arms have been installed.4. 2001 PS-MMA0507-E1A .2.Measure the spring inclination with a square.Measure free length and spring tension with a valve spring tester.Compare the measured value with the standard value to determine whether to replace or repair.978 ∼ φ23.7 mm Limit 2. Limit 0.DE12/T/TI/TIS MAINTENANCE MANUAL Functional check .2 mm Rocker arm shaft diameter With an outside micrometer. If the amount of this run-out is small.0 mm 1.0 mm 3. Replace the shaft if the measured value exceeds the limit. press the shaft with a bench press to correct the run-out. (Refer to appendix) . Rocker arm shaft assembly 1) Rocker arm shaft Rocker arm shaft run-out Place the rocker arm shaft on two V blocks and inspect the shaft for bend using a dial gauge. . Standard Valve DE12/T/TI spring inclination DE12TIS 1. Replace the rocker arm if the amount of wear is beyond the specified limit. If the clearance exceeds the limit. <Clearance> Standard 0. Diameter of the rocker arm bushing Measure the inside diameter of the rocker arm bushing with an inside micrometer or vernier calipers. If the wear is small. and compare the measured values with the rocker arm shaft diameter.020 ∼ 0.15 mm INSPECTION & MEASUREMENT 53 Printed in Mar. whichever worn more.077 mm Limit 0. Standard 0. Rocker amount replaced. replace tappets. correct it with an oil stone or grinding paper of fine grain size. 2001 PS-MMA0507-E1A . replace either bushing or shaft.2 mm 3) Tappet and push rod Clearance Measure the clearance of the tappet and tappet holes of the cylinder block. If the value is beyond the specified limit.DE12/T/TI/TIS MAINTENANCE MANUAL 2) Rocker arm Visual check Visually check the face of the rocker arm in contact with the valve stem end for scores and step wear.035 ∼ 0.093 mm M1087 arm of with step a wear considerable should be Limit 0. If the measured value is less than the specified limit. 2001 PS-MMA0507-E1A .15 mm Tappet diameter φ19.944 ∼ φ19.DE12/T/TI/TIS MAINTENANCE MANUAL Visual check of tappet Visually check the face of the tappets in contact with the cam for pitting. Roll the push rod along a smooth flat surface as shown in the figure. 3. If the amount of cracks or pitting is small. replace tappets. and replace if severely damaged. correct with an oil stone or grinding paper.2.3 mm or less Use a feeler gauge to measure the feeler gauge M1084 Use a micrometer to measure the cam lobe height and journal diameter. Standard Tappet Clearance 0.5. scores or cracks. 54 INSPECTION & MEASUREMENT Printed in Mar. Outside diameter With an outside micrometer.035 ∼ 0. Cam shaft 1) Cam Cam lobe height M1095 0. measure the tappet outside diameter If the measured value is beyond the limit.077 mm Limit 0.965 mm Push rod run-out Limit push rod run-out. the camshaft must replaced. DE12/T/TI/TIS MAINTENANCE MANUAL Standard Cam lobe height (C) Intake Exhaust φ59.86 ∼ φ59. 2) Cam shaft Clearance between camshaft journal and camshaft bush With an outside the micrometer.B) φ59. M1090 camshaft <Clearance> Standard 0. But.2 mm INSPECTION & MEASUREMENT 55 Printed in Mar. Correct or replace the cam shaft if the amount of run-out is beyond the value indicating need for servicing. Standard 0. and compare the measured value with the camshaft outside diameter to determine the clearance.88 mm Limit φ49. 2001 PS-MMA0507-E1A . Slight step wear or damage on the cam face may be corrected with oil stone or oiled grinding paper.86 ∼ φ59.86 ∼ φ59.88 mm φ59. journal measure diameter.05 mm Limit 0. replace if severely damaged.52 mm Cam surface Inspect the cam face for scratch or damage.2 mm Replace the bushing if the measured value is beyond the specified limit. Measure the inside diameter of the camshaft bushing on the cylinder block using a cylinder bore indicator.88 mm Cam journal diameter (A.050 ∼ 0. Run-out Support the camshaft on two V blocks and check for run-out using a dial indicator.128 mm Limit 0.5 mm φ59. have the crankshaft grind and install undersize bearings. Using a magnetic particle test and color check. Feeler gauge Standard 0. If the amount of wear is beyond the limit. 2001 PS-MMA0507-E1A . you can correct the wear using an oil stone or oiled grinding paper of fine grain size. and replace the crankshaft which has cracks. However. measure the clearance between the thrust plate and camshaft gear.DE12/T/TI/TIS MAINTENANCE MANUAL 3) Cam shaft end play Push the thrust plate toward the cam gear. and compare the measured values to determine the amount of wear.27 mm 3.2. inspect the crankshaft for cracks. With a feeler gauge. Crank shaft 1) Defect check Limit 0. If the end play is excessive. (Be sure to use grinding paper which has been immersed in 56 INSPECTION & MEASUREMENT Printed in Mar.6. replace the thrust plate. if the amount of wear is within the limit. 2) Wear With an outside micrometer measure the diameter of the crankshaft journals and pins in the directions as shown.13 ∼ 0.30 mm Visually check the crankshaft journal and crank pins for scores or cracks. the fillet section 'R' should be finished correctly.00 (Inside diameter is 1.50 mm lesser than the standard size. 2001 PS-MMA0507-E1A .966 mm * Undersize bearings available Standard 0. Turn the crankshaft with a dial indicator placed on the surface plate and take the amount of crankshaft run-out. and the crankshaft can be reground to the above sizes. * Standard values of 'R' ① Crankshaft Pin 'R': 4. Avoid sharp corners or insufficient fillet.) 1.966 ∼ φ82.966 mm φ81. NOTE : When regrinding the crankshaft as described below.00 mm lesser than the standard size. Standard 0.) Undersize bearings are available in 4 different sizes as indicated above.DE12/T/TI/TIS MAINTENANCE MANUAL oil.) 0.1 mm Limit 0.988mm Limit φ94.25 (Inside diameter is 0.15 mm INSPECTION & MEASUREMENT 57 Printed in Mar.) Standard Journal diameter Pin diameter φ95.966 ∼ φ95.75 (Inside diameter is 0.25 mm lesser than the standard size.75 mm lesser than the standard size.5 ② Crankshaft journal 'R': 4 3) Crankshaft run-out Support the crankshaft on V blocks.50 (Inside diameter is 0.988mm φ82.) 0. 02 ∼ φ83. Torque Standard 58 28 kg.m φ96. 2) Oil clearance between crankshaft and bearing. Torque Standard 30 kg.06 ∼ φ96.142 mm Limit 0.25 mm Connecting rod bearing clearance Install the connecting rod bearing in the connecting rod bearing cap.072 ∼ 0. tighten the bearing cap to specified torque.7. then measure the inside diameter.DE12/T/TI/TIS MAINTENANCE MANUAL 3. 2001 PS-MMA0507-E1A . uneven wear or damage. then measure the inside diameter. tighten the connecting rod cap bolts to the specified torque.m φ83.092 mm INSPECTION & MEASUREMENT Printed in Mar. <Main bearing oil clearance> Standard 0. Main bearing clearance Install the main bearing in the cylinder block. Crank shaft bearing and connection rod bearing 1) Visual check Visually check the crankshaft bearing and connecting rod bearing for scores.2.108 mm M1116 Compare the two values obtained through measurement of main bearing inside diameter with the outside diameters of crankshaft journals to determine the oil clearance. 13 mm Standard INSPECTION & MEASUREMENT 59 Printed in Mar. unscrew out one bolt completely.20 mm If the clearance deviates from the specified range.049 ∼ 0. retighten the bolts to specified torque.DE12/T/TI/TIS MAINTENANCE MANUAL Compare the two values obtained through measurement of connecting rod bearing inside diameter with the outside diameters of crankshaft pins to determine the oil clearance. have the crankshaft journals and pins grind and install undersize bearings.11 ∼ 0. Standard 0.119 mm Limit 0. Crankshaft bearing crush Install the bearing and cap in the cylinder block. 3) Bearing spread and crush Inspection Check to see that the bearing requires a considerable amount of finger pressure at reassembly operation. then measure the clearance between the bearing cap and cylinder block using a feeler gauge. 2001 PS-MMA0507-E1A . 0. 116 mm Standard 4) crank shaft end play Assemble the crankshaft to the cylinder block. Piston 1) Visual check Visually check the pistons for cracks. then measure the clearance between the bearing cap and connecting rod big end using a feeler gauge. 2) Clearance between the piston and cylinder liner With an outside micrometer.873 ∼ φ122.2. paying particular attention to the ring groove. Standard φ122. Standard 0. unscrew out one bolt completely.887 mm Position of measuring outside diameter 60 INSPECTION & MEASUREMENT Printed in Mar. scuff or wear. measure 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. retighten the bolts to specified torque. measure crankshaft end play. 0.DE12/T/TI/TIS MAINTENANCE MANUAL Connecting rod bearing crush Install the bearing and cap in the connecting rod big end.8. 2001 PS-MMA0507-E1A .15 ∼ 0.086 ∼ 0.325 mm Limit 0. With a dial gauge.5 mm 3. Standard φ123 ∼ φ123. Measure the piston ring gap with a feeler gauge. if the clearance is beyond the specified limit. and oil ring contacting face on BDC) in a direction at an angle of 45°.152 mm INSPECTION & MEASUREMENT 61 Printed in Mar.223 mm The clearance the is computed piston by subtracting outside diameter from the cylinder liner inside diameter. Take the mean value with the largest and smallest values excepted.9.023 mm Limit φ123. measure cylinder liner inside diameter at 3 points (cylinder top ring contacting face. Replace either piston or cylinder liner. M1104 feeler gauge 0.113 ∼ 0. 2001 PS-MMA0507-E1A .DE12/T/TI/TIS MAINTENANCE MANUAL Using a cylinder bore gauge. whichever damaged more. Clearance between piston and liner Standard 3. middle.2. 2) Piston ring gap Insert the piston ring into the upper portion of the cylinder liner bore so that it is held at a right angle to the cylinder liner wall. Piston rings 1) Visual check Replace the piston rings with new ones if detected worn or broken when the engine is overhauled. 05 ∼ 0.30 ∼ 0.50 mm 0.5 mm 1. 62 INSPECTION & MEASUREMENT Printed in Mar. With a feeler gauge.15 mm 0. Replace the piston ring if the measured value is beyond the limit.005 mm or greater).27 ∼ 3.085 mm Limit 0.0 ∼ 3. measure piston ring tension.10.5 mm Replace piston rings with new ones if the gap is beyond the limit 3) Piston ring side clearance Fit the compression ring and oil ring in the piston ring groove. measure side clearance of each ring.70 mm Limit 1.15 mm 4) Piston ring tension With a tension tester. Piston pin 1) Wear Measure the amount of wear on the piston pin at the points as shown.35 ∼ 0.03 ∼ 5.40 ∼ 0.07 ∼ 0. If the measured values are beyond the limit (0. Standard 2.0 kg 4.5 mm 1.45 mm 0.102 mm 0.41 kg 2.2.57 kg Top ring 2nd ring Oil ring 3.50 mm 0.DE12/T/TI/TIS MAINTENANCE MANUAL Top ring 2nd ring Oil ring DE12/T/TI DE12TIS Standard 0. replace the pin. G1071 feeler gauge Standard Top ring 2nd ring Oil ring 0. and replace either the ring or piston if the measured value is beyond the specified limit.30 ∼ 0. 2001 PS-MMA0507-E1A . If it is possible to force the pin into the piston heated with piston heater.2. As shown in the figure below. Limit 3) Condition check Check the engaged condition of the piston and piston pin. Connecting rod 1) Distorsion Check the connecting rod for distortion.11.DE12/T/TI/TIS MAINTENANCE MANUAL Standard φ 44. 2001 PS-MMA0507-E1A .990 mm or less 2) Clearance Measure the clearance between the piston pin and connecting rod bushing.0 mm Limit φ 44. be sure to replace the piston pin together. install the connecting rod to the connecting rod tester. When replacing the piston. and check for distortion using a feeler gauge.011 mm 3. and replace either of them. never re-use it but replace with a new one. If the connecting rod is found distorted. whichever damaged more. the piston is normal. 0. INSPECTION & MEASUREMENT 63 Printed in Mar.995 ∼ φ 45. if the measured value is beyond the limit. 2001 PS-MMA0507-E1A . Assemble the connecting rod to the piston and measure connecting rod small end side clearance.1 mm or less M1107 0. replace the seal ring.11.2. replace the connecting rod. If the measured values are beyond the limit.5 mm DE12/T/TI 2mm 3. Limit 3. At this time also.05 mm 3) Wear Assemble the connecting rod to the crankshaft and measure connecting rod big end side clearance using a feeler gauge. Fuel injection nozzle Insert a seal ring and injection nozzle on the cylinder head. use both connecting rod tester and feeler gauge.4~3.DE12/T/TI/TIS MAINTENANCE MANUAL 2) Holes alignment (parallelism) Measure the alignment of the connecting rod small bushing hole with connecting rod big end hole.5mm DE12TIS 3mm 2. If the measured values are beyond the limit. Standard A (Thickness of seal ring) B (Projection of nozzle) Fuel injection nozzle Cylinder head Nozzle tube feeler gauge Limit 0.5mm 64 INSPECTION & MEASUREMENT Printed in Mar. Standard 0. Measure the clearance between the cylinder head bottom and nozzle tip.4~2. Check the bolts for looseness after preliminary reassembly.3. particularly oil and water ports.3. using compressed air.3. seal rings. Arrange the general and special tools in order for engine assembly operation.3.2. gaskets. Apply only the specified torque for bolts in the specified tightening order and avoid over-tightening. Keep your hands clean during the working. and consumable parts. 65 ENGINE REASSEMBLY Printed in Mar.1. Reassembly 3. After completing the engine reassembly operation. General precautions Wash clean all the disassembled parts. prepare the clean engine oil. Prepare service materials such as sealant. 3. then check that they are free from restrictions. 3. To wet each sliding part. Discard used gaskets. Cylinder block Cover the floor of the workshop with wood plate or thick paper to prevent damage to the cylinder head and place the cylinder block with the head fitting surface facing downward. Oil spray nozzle Tighten and assemble the oil spray nozzle flange with fixing bolts using the spray nozzle jig. 2001 PS-MMA0507-E1A .DE12/T/TI/TIS MAINTENANCE MANUAL 3. check if there is missing parts or shortage of parts. Be sure to check that all the engine parts operate smoothly after being reassembled. etc. and replace with new ones.3. 3. Wet the cam bush inside diameter and camshaft assemble camshaft. 66 ENGINE REASSEMBLY Printed in Mar. then apply oil to the bearing surface. After the pressing operation.5. with them oil. measure the inside diameter of the cam bush to check if it is not deformed.3.4. Check to see that the camshaft rotates smoothly. Crankshaft Install the main bearing machined with two holes in the cylinder block so that the key is aligned with the key groove. and carefully the while turning 3. 2001 PS-MMA0507-E1A . Apply engine oil to the entire face of the tappets and slide them into the tappet holes on the cylinder block. Tappet and cam shaft Undercool a new bush with dry ice for about 2 hours and press it into position in the cylinder block using a bench press.DE12/T/TI/TIS MAINTENANCE MANUAL 3. then apply sealant (Loctite # 641) to the inside wall of the heated crankshaft gear evenly before inserting it to the end of crankshaft. G1051 Semi-tighten a bolt at both sides of the crankshaft. 2001 PS-MMA0507-E1A . apply engine oil to journals and pins.DE12/T/TI/TIS MAINTENANCE MANUAL Heat the crankshaft gear for at least 10 minutes to 120°C. Install the bearing and thrust washers to the bearing cap and apply oil to the bearing and thrust washers. 67 ENGINE REASSEMBLY Printed in Mar. then assemble the crankshaft with the cylinder block by tightening the fixing bolts. Install the oiled thrust washers with the oil groove facing outward. with the bearing cap No.m .m for the first stage and 25 kg. Using the dowel pin and guide bar.DE12/T/TI/TIS MAINTENANCE MANUAL Install the bearing cap by matching the cylinder block No.m for the second stage respectively.m After semi-tightening both bolts evenly.6. Torque 68 ENGINE REASSEMBLY Printed in Mar. Flywheel housing Temporarily install the guide bar on the cylinder block. then tighten them completely to the specified torque using a torque wrench.3. 3. Torque 30 kg. Apply oil to the entire part of the bearing cap bolts. then tighten in tightening sequence to specified torque. Check to see that the assembled crankshaft turns smoothly. install the flywheel housing and tighten the fixing bolts in a diagonal sequence to specified torque. Tighten the bearing cap in the sequence of 4-3-5-2-6-1-7. Apply gasket to the cylinder block. tighten them diagonally to about 15kg. 2001 PS-MMA0507-E1A 12 kg. 0 mm) and fix lock nut.1 mm) Flywheel housing Tolerance limit 18 kg. Then rotate (Counter clockwise) the pick-up sensor for 270° (gap 1. and lift the flywheel to align the dowel pin with the pin hole on the flywheel for temporary assembly operation. until the end of it reach on fly wheel ring gear. Rotate (Clockwise) the pick-up sensor on flywheel housing. 2001 PS-MMA0507-E1A .7. Flywheel Install a guide bar into a bolt hole on the crank shaft. Install bolts in the remaining holes. Magnetic pick-up sensor Move the lock nut to hexagonal side of sensor completely. take out the guide bar. Tolerance limit is 27°.8.m Lock nut 69 ENGINE REASSEMBLY Printed in Mar. then install a bolt in the hole where the guide bar had been inserted. (gap ± 0. then assemble the oil seal using an oil seal fitting jig.9. Oil Seal Fitting Jig G1052 3. Torque 3.3. Rear oil seal Apply lubricating oil to the outside of the oil seal and flywheel housing inside diameter and fit them over the crank shaft.3. Tighten the fixing bolts using a torque wrench in a diagonal sequence to specified torque.DE12/T/TI/TIS MAINTENANCE MANUAL 3.3. Timing gear case Mount gasket using dowel pin on the cylinder block.3.3.m 70 ENGINE REASSEMBLY Printed in Mar. G1054 Mark “2” Mark “1” Mark “o” Torque 7.8 kg. and idle gear.4 kg. Idle Gear Pin G1053 Install the idle gear by coinciding the marks impressed on the crank gear.13 ~ 0. 2001 PS-MMA0507-E1A . Install a thrust washer over the camshaft and assemble the cam gear by aligning it with camshaft key groove.30mm Idle Gear Pin With the oil port on the idle gear pin facing the cylinder block. cam gear.27mm 3. Timing gear Install the oil pump idle gear onto the No.7 bearing cap. 3. fuel injection pump drive gear.m Limit 0. Torque End play 0.10.11.DE12/T/TI/TIS MAINTENANCE MANUAL 3. Install the timing gear case by aligning the dowel pin with the dowel pin hole on the timing gear case. install the idle gear pin. Install a thrust washer on the idle gear and tighten to specified torque. Fuel injection pump drive gear Mount gasket by aligning the bolt holes with the pin holes on the bearing housing. Tighten the fixing bolts in the direction of fuel injection pump. 2001 PS-MMA0507-E1A . Tighten the fixing bolts beginning with the oil pan fitting face. Mount a gasket by aligning the fixing bolt holes with those on the gasket. then assemble the oil seal using an oil seal fitting jig.3. Thoroughly clean the liner flange fitting surface and bore inside with compressed air to prevent the entry of foreign substances.15 ∼ 0. Oil Seal Fitting Jig 3. Align the dowel pin with the cover pin hole.25 mm 3. then install the cover with light tap. Timing gear case cover Install dowel pin on the timing gear case.DE12/T/TI/TIS MAINTENANCE MANUAL Check gauge.12. and adjust the amount of backlash between gears using a feeler Backlash 0. 3.14. Cylinder liner Stand the cylinder block so that the flywheel faces downward. 71 ENGINE REASSEMBLY Printed in Mar.15.13.3.3. Front oil seal Apply lubricating oil to the outside of the oil seal and timing gear case inside diameter and fit them over the crankshaft. 3.3. 2001 PS-MMA0507-E1A .16. On the piston head surface. make the cylinder liner dried up and push it into the cylinder block by hand. the longer side of connecting rod big end is in opposite direction from the valve seating surface as well as in the same direction with the narrow margin of combustion chamber. Install the snap rings and check to see 72 ENGINE REASSEMBLY Printed in Mar. Noting the direction of the piston.3. 3. Wet the liner inside diameter with engine oil.DE12/T/TI/TIS MAINTENANCE MANUAL After the cleaning operation. Piston and connecting rod Use a piston heater to heat the piston approximately 100 °C (212 °F) for 5 minutes. make the longer side (machined with key groove on the bearing) of the connecting rod ‘ big end and the mark of ‘ impressed on the inside of the piston face each other in opposite directions. M1127 Align the piston pin hole with the oiled connecting rod small end and press the piston pin (by lightly tapping with a rubber hammer) to assemble the connecting rod with the piston. Install the bearing by aligning it with the connecting rod key groove and apply oil to the bearing and piston. Make sure that the manufacture serial numbers impressed on the connecting rod cap and connecting rod big end are identical. and install the connecting rod cap by aligning it with dowel pin. . Use care not to damage the cylinder liner and piston. semi73 ENGINE REASSEMBLY Printed in Mar. 2001 PS-MMA0507-E1A Tappet hole Valve Seating Serial No. Use care not to match the ring gaps with the pin direction. and slightly lift and insert the piston into the cylinder so that the ring may not be damaged by the fillet of the liner. Wet the fixing bolts with oil. Identify the mark "Y" or "TOP" on the ring end to prevent the top and bottom of the piston ring from being interchanged and make the marked portion face upward.DE12/T/TI/TIS MAINTENANCE MANUAL that it is securely assembled. Adjust the angle among individual piston ring gaps to 90° and fit a piston assembling jig onto the piston. Install the bearing in the connecting rod cap and apply oil. Position the valve seating surface G1055 2nd Ring Gap 45° 45° Top Ring Gap 90° Piston Pin Piston Oil Ring Gap toward the tappet hole and insert the piston with hand. Install the piston ring in the piston using piston ring pliers. 17. 3. Relief valve Assemble the relief valve. 3. and release and reassemble it if no movement is detected. Oil pump and oil pipe Install a dowel pin in the No.m Move the bearing cap with hand.7 bearing cap.m for 1st stage and 22 kg. and finally to specified torque. case cover and flywheel housing.m for 2nd stage respectively. Torque 28 kg. tighten them to 15 kg. Apply silicon to each joint and attach gasket to the cylinder block. 2001 PS-MMA0507-E1A 4. Tighten fixing bolts at both ends. Torque 74 ENGINE REASSEMBLY Printed in Mar. then assemble the oil pump with specified torque. intermediate bolts and remaining bolts in the described order.m .3.19.3.18.DE12/T/TI/TIS MAINTENANCE MANUAL tighten them with hand.3. 3. Ladder frame Cut out the gasket protruding from the joints of the timing gear case.4 kg. Torque 2. then install the bracket on the bearing cap. Tap the valve stem lightly with a rubber hammer to check that the valve is assembled correctly. assemble the valve stem seal with the valve guide.3. Using the valve stem seal fitting jig. 3.DE12/T/TI/TIS MAINTENANCE MANUAL Assemble the oil suction pipe with the delivery pipe. Align the bolt holes with gasket holes to prevent damage to the gasket and tighten to specified torque.20.3. then install cotter pin. press the retainer with a jig. Oil pan Mount gasket and put the oil pan thereon.21.2 kg. Intake and exhaust valves Identify the marks of "IN" and "EX" impressed on the valve head before assembling the valve with the valve head. After installing valve springs and spring retainer. 75 ENGINE REASSEMBLY Printed in Mar. Place stiffeners and tighten bolts.m 3. 2001 PS-MMA0507-E1A . Tighten the bolts until the expander is forced out of the cylinder head bottom. Guider Apply engine oil to an expander and install it onto the special tool (guider). Install a guider of the nozzle tube insert assembly (Guider + Expander) on the cylinder head. 2001 PS-MMA0507-E1A .4 kg. 76 ENGINE REASSEMBLY Printed in Mar.3. Torque 4.DE12/T/TI/TIS MAINTENANCE MANUAL 3. Test pressure 3. Rocker arm assembly Apply lubricating oil to the rocker arm bush and shaft.m 2 kg/cm2 Semi-install valve clearance adjusting bolts onto the rocker arm. make a hydraulic test to check for water leaks.22. Nozzle tube Apply sealant (LOCTITE # 620) to the nozzle tube and place the O-ring over the cylinder head fitting face on the nozzle tube. then tighten the nozzle fixing nuts.3.23. and assemble the intermediate bracket with the rocker arm using fixing bolts. then install the nozzle tube in the cylinder head. Expander After mounting the nozzle tube. on the cylinder block by aligning the holes with dowels.DE12/T/TI/TIS MAINTENANCE MANUAL Install the spring. rocker arm. Clean the head bolt holes on the cylinder block with compressed air to remove foreign substances and thoroughly clean the gasket fitting face of the cylinder block. lift the cylinder head again and then remount it. 77 ENGINE REASSEMBLY Printed in Mar. with 'TOP' mark facing upward. Cylinder Head gasket Asbestos core type Rubber color : Black G1056 Semi steel type Rubber color : Red Use bolt TY 12. Cylinder head Install the injection nozzle fixing stud bolts and water pipe fixing stud bolts.24. 2001 PS-MMA0507-E1A . 3. spring. If the dowel pin is not in alignment.3. Be careful not to damage the head gasket. rocker arm. and mount cylinder assembly in the block by aligning the dowel pin with the dowel pin hole. Install head gasket.9T TY 10. washer.9T Check carefully the inside the of combustion head chamber for foreign substances. Coat the head bolts with engine oil. and snap ring in the described sequence. bracket. then tighten them in proper sequence to the specified torque. Install the rocker arm and bracket in the same direction. 5×153 M14×1. In time.5×150 1st : 6kg. Adjust the valve clearance as following guide.3 mm - By cranking the engine.DE12/T/TI/TIS MAINTENANCE MANUAL <Cylinder Head Bolts> Type 1 TY 12. as follow. adjust the valve clearance corresponding to “ ” of lower 78 ENGINE REASSEMBLY Printed in Mar.m Coat the push rod with engine oil and insert it into the push rod hole. Loosen the lock nuts of rocker arm adjusting screws and push the feeler gauge of specified value between a rocker arm and a valve stem and adjust the nut.5 kg.9T Type 3(12.3 mm Exhaust Valve 0. <Guide for valve clearance adjustment> After letting the #1 cylinder's piston come at the compression top dead center by turning the crankshaft. 2001 PS-MMA0507-E1A . adjust the valve clearances.5×150 1st : 6kg.m 2nd : 90° + 90° Finished : 30° Tighten torque 24. clearance with adjusting screw respectively and then tighten with the lock Model DE12 DE12T DE12TI DE12TIS Intake Valve 0. adjust it when in cold.9T) Type M14×1. As for the valve clearance.9T Type 2 TY 10. let #6 cylinder's valves overlap.m 2nd : 180° Finished : 150° M14×1. DE12/T/TI/TIS MAINTENANCE MANUAL figure.3. the valve clearance ” of lower corresponding to “ Flywheel Intake Valve Exhaust Valve Cylinder No. Adjust figure. Rotating the crankshaft by one revolution. Injection nozzle 79 ENGINE REASSEMBLY Printed in Mar. No. Torque 4. retighten if necessary. After reinsuring the valve clearances. 1 Cylinder is located at the side where flywheel was installed.m M1013 Valve clearance adjust 3.25. #6 cylinder become the compression state of top dead center.4 kg. 2001 PS-MMA0507-E1A . Cooling Fan G1048 Adjust valve clearance with a feeler gauge and tighten the fixing nuts to specified torque. 3. 80 ENGINE REASSEMBLY Printed in Mar. Connect a connection pipe between the water pump and oil cooler. 2001 PS-MMA0507-E1A . Install a connection pipe between the oil cooler and oil filter. Be sure to follow the specified torque. 3. Mount a seal ring on the seal ring seating surface of the nozzle tube and assemble nozzle holder assembly with the stud bolt with the nozzle pipe installing direction facing outward. Oil filter Install the oil filter onto the cylinder block.28. Torque 1.26.3. Cooling water pipe and thermostat Install the water pipe onto the cylinder head. With socket head bolt. Do not damage the gasket and install the cover onto the cylinder block.DE12/T/TI/TIS MAINTENANCE MANUAL Install the dust seal with its round portion facing downward. With the hollow screw.0 kg. Carefully apply the gasket to prevent oil leakage. and tighten the fixing bolts. assemble the oil pipe connected between the oil cooler and cylinder block.m 3. install the thermostat housing onto the water pipe.27.3. Oil cooler Install the oil cooler onto the oil cooler cover.3. Insert the thermostat in the housing. 4 kg.D. Torque 4. After measuring the amount of run-out with an alignment setting jig. Injection timing Notch mark DE12 DE12T DE12TI Fuel injection timing (B. Injection pump Install the injection pump bracket in the cylinder block. Run out 0. Tighten the fixing bolts in a diagonal sequence to specified torque. 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.2 mm or less Mount the top/bottom adjusting shims in the bracket and then mount the fuel injection pump.T. 3.C static) DE12TIS Flywheel Ring gear Timing Check hole 12° 9° 12° 1° 81 ENGINE REASSEMBLY Printed in Mar. disassemble the bracket.DE12/T/TI/TIS MAINTENANCE MANUAL Assemble the cartridge using a filter wrench. then reassemble it. adjust the shims.29.m Turn the flywheel until No.3. 2001 PS-MMA0507-E1A . 1 piston is placed in the "OT" position of notch marks on the flywheel. 30. Torque 4.m Tighten the drive shaft connecting flange fixing bolts to specified torque Torque 7. Torque 82 ENGINE REASSEMBLY Printed in Mar. Vibration damper and pulley Install the vibration damper on the crankshaft pulley.0 kg. Power steering pump Mount gasket.3.4 kg.4 kg.DE12/T/TI/TIS MAINTENANCE MANUAL Turn the timer until the notch mark of the indicator plate attached to the fuel injection pump is aligned with the notch mark of the timer.5 kg.31.3.m Install the oil delivery pipe and return pipe. Install the crankshaft pulley assembly on the crankshaft. 2001 PS-MMA0507-E1A 13. Torque 6. then tighten the bolts and thrust washers.m 3. 3. align the dowel pin with the pin hole. then assemble the power steering pump by using hammer not to damage the gears. Notch mark Tighten the Coupling fixing bolts and nuts to specified torque.5 ∼ 8.m . 33. Idle pulley Install the fan drive pulley onto the timing gear case cover. 3. Connect water pipes and by-pass pipe to the water pump.34. Install the water pump drive pinion over the air compressor spline. G1057 3. Semi-assemble the exhaust manifold and install the heat resisting plate. Connect the air hoses and pipes to the air compressor.3.DE12/T/TI/TIS MAINTENANCE MANUAL 3.32.35. 2001 PS-MMA0507-E1A . Install water hoses to the water pump. Connect a water pipe to the expansion tank. Using hollow screw. 83 ENGINE REASSEMBLY Printed in Mar. 3. assemble the oil delivery pipe with the adapter.3. Exhaust manifold Install the exhaust manifold gasket over the stud bolts by aligning the gasket with the exhaust port on the cylinder head so that the face and back of the gasket can be positioned correctly. Air compressor Mount gasket and assemble the air compressor assembly with care to prevent damage.3. Water pump Mount a new O-ring.3. 3.3.37. 2001 PS-MMA0507-E1A .38. Install the oil supply pipe and return pipe.DE12/T/TI/TIS MAINTENANCE MANUAL 3. Mount the air heater gasket on the intake manifold. 3. Air pipe Semi-assemble the bracket to the intake pipe. Starter Assemble the starter in position on the flywheel housing. then assemble the air heater with the intake manifold.3. then assemble the bracket completely. Connect the air hoses to the boost compensator mounted on the fuel injection pump. 3. Intake manifold Fit a gasket on the intake manifold before assembling the intake manifold. Turbocharger Fit a new gasket over the stud bolts of the exhaust manifold before tightening those turbocharger fixing bolts.36. 3.3.39. 84 ENGINE REASSEMBLY Printed in Mar. connect a rubber hose between the turbocharger and intake pipe using the clamps. Torque 3. Fuel filter Assemble the fuel filter with the air pipe bracket. Injection pipe Semi-assemble a nut at both ends of the fuel high pressure pipe and tighten them up one by one to specified torque.3. 2001 PS-MMA0507-E1A .DE12/T/TI/TIS MAINTENANCE MANUAL 3.41.2 kg. then tighten the fixing bolts in sequence to specified torque. Cylinder head cover Assemble the cover packing with the cover. Assemble the fuel feed hose according to the direction of an arrow impressed on the fuel filter head so that fuel can be fed in the sequence of FUEL FEED PUMP → FUEL FILTER → FUEL INJECTION PUMP. install the cover on the head.m Tighten hollow screws to assemble the fuel return pipe.m Assemble the breather hose with PCV valve.3. 3. Torque 1.42.3. 3. 85 ENGINE REASSEMBLY Printed in Mar. Assemble the fuel return hose on the fuel injection pump.0 kg.40. DE12/T/TI/TIS MAINTENANCE MANUAL 3. then tighten the fixing bolts. Tighten the fixing bolts. the air con.3. Alternator Install the alternator mounting bracket. 3.belt Install the V-belt on the crank pulley and alternator pulley Adjust the V-belt tension using the tension adjusting bolt. V. Air con. Install the alternator with fixing bolts to the mounting bracket. Cooling fan Install the cooling fan and flange. Install the alternator mounting bracket on the timing gear case. compressor Install case. compressor Alternator 86 ENGINE REASSEMBLY Printed in Mar.3. compressor mounting bracket on the timing gear 3.46.3. then install air con. Air con.44.3. compressor fixing bolts.43.45. 3. 2001 PS-MMA0507-E1A . Connect the harness connector and various sensors.3. Engine control unit (ECU) Engine harness ECU connector Water temp. 3. Pre stroke sensor sensor Rack senso Air heater relay Ne sensor 87 ENGINE REASSEMBLY Printed in Mar.3. 3.49.DE12/T/TI/TIS MAINTENANCE MANUAL Alternator 3.48. 2001 PS-MMA0507-E1A .3. Engine control unit : DE12TIS Assemble the engine control unit(ECU). Cooling fan guide Install the three fan guide brackets then assemble the fan guide and bracket. Oil level gauge Assemble the oil level gauge and guide tube on the oil pan.47. 4. ▲ Abrupt start and stop of the engine should be avoided. Check points for break-in During the break-in (the initial running of the engine) period. see your DEALER for possible switch or oil pump and line malfunction. b) Watch the oil pressure warning lamp. Both of these conditions reflect normal engine operation. cold oil will generally show higher oil pressure for any specific RPM than hot oil. ▲ Maintenance and inspection must be accomplished thoroughly. and fall as RPM decreases. If level is correct and the status still exists. ▲ Engine speed must be under 70% of its maximum speed. 89 BREAKING-IN Printed in Mar. Breaking-in 3. NOTE : If you have a problem getting a good oil level reading on oil level gauge 180° and re-insert for check. NOTE : Oil pressure will rise as RPM increases. Therefore the following things must be obeyed by all means. 2001 PS-MMA0507-E1A .000km(50 hours) ▲ Engine should be run at fast idling until the temperature of the engine becomes normal operating condition. Operation of a new engine (Breaking-In) Because the sliding surfaces of a new engine are not lapped enough. 3. Do not overfill.4. Up to the first 1. In addition.4. If the lamp blinks. be particularly observant as follows: a) Check engine oil level frequently." and “max." marks on oil level gauge. it may be the oil pick-up screen is not covered with oil.DE12/T/TI/TIS MAINTENANCE MANUAL 3. between the "min. if required. ▲ High speed operation with no load should be prevented. Check oil level gauge oil to the oil pan. Maintain oil level in the safe range.2. ▲ Overload or continuous high speed operation should be avoided. the oil film can be destroyed easily by overload or overspeed and the engine life-time may be shortened.1. DE12/T/TI/TIS MAINTENANCE MANUAL c) Watch the engine water temperature gauge and be sure there is proper water circulation. remove break-in oil and replace the oil filter cartridge. Min. (lit) (lit) 17 17 17 14 14 14 Total (lit) 21 21 21 Recommend oil API No. Fill oil pan with recommended engine oil. Refer to following table. The water temperature gauge needle will fluctuate if water level in expansion tank is too low. ACEA-E3 oil must be used. At the end of the break-in period. 90 BREAKING-IN Printed in Mar. API CD grade or above CE grade ACEA-E2 or ACEA-E3 (API CH-4) * If long oil change intervals are to be used. <Engine Oil capacity> Engine oil capacity Engine model DE12 DE12T DE12TI DE12TIS Model Bus Truck Bus in Oil pan Max. 2001 PS-MMA0507-E1A . Cooling fan and belt Fan diameter – Number of blades Fan belt tension Specification Centrifugal type About 350 liter/min 2. and circulates to the water pump if water temperature is lower than the valve opening temperature on the thermostat.1. Heat from the combustion chamber and engine oil heat are cooled down by coolant and radiated to the outside.1. At the radiator.DE12/T/TI/TIS MAINTENANCE MANUAL 4. the heat absorbed in the coolant is radiated to cool down and the coolant recirculates to the water pump. 2001 PS-MMA0507-E1A .9 15mm / deflection by thumb 91 MAINTENANCE of MAJOR COMPONENTS Printed in Mar. Thermostat Water pipe Radiator Cylinder head Cylinder block Water pump Oil cooler Air compressor Specification Item 1.1. resulting in the normal operation of the engine. while circulating to the radiator at water temperature higher than the valve opening temperature. Looking into the cooling system. General information This engine is water-cooling type. the water pumped up by the water pump circulates around the oil cooler through the water pipe to absorb the oil heat. The water absorbing the oil heat and combustion chamber heat goes on to the thermostat through the water pipe. Cooling system 4. Thermostat Operating temperature 3. MAINTENANCE OF MAJOR COMPONENTS 4. and then flows through the water jacket of the cylinder block and water passage of the cylinder head to absorb the heat of the combustion chamber. Water pump Type Delivery Pumping speed Pumping back pressure 2.100 rpm 760 mmHg 83 ∼ 95°C 700mm . Shaft 8. Pipe 7.DE12/T/TI/TIS MAINTENANCE MANUAL 4. then remove it using a puller jig. Heat the impeller (5) slightly. 12. Stopper ring 11. Remove the mechanical seal. With a press. 13.1. To reassemble the impeller. Mechanical seal 9.2. Remove the shaft and bearing assembly from the housing. Ball bearing 3. Impeller 10. 15 Spline shaft Gasket Housing cover Bolt Pipe 92 MAINTENANCE of MAJOR COMPONENTS Printed in Mar. Reverse the disassembly sequence for reassembly operation. Replace the oil seal (6) with a new one at reassembly. 2001 PS-MMA0507-E1A .6 mm) between the impeller and pump housing using a feeler gauge. Water pump Loosen the bolt (14) to disassemble the housing cover (13). remove the spline shaft and bearing. Space 4. 14.3 ～ 0. Water pump housing 6. Oil seal 2. Ball bearing 5. Thickness <Construction of water pump> 1. maintain a constant gap (0. DE12/T/TI/TIS MAINTENANCE MANUAL 4. 93 MAINTENANCE of MAJOR COMPONENTS Printed in Mar. when the coolant temperature rises to open wide the thermostat valve. thermal when efficiency of the of engine by preventing heat loss. the temperature coolant is low.1 mm (starting to open) at temperature of 83 °C and 8 mm or more (opening wide) at Wood plate Ruler Thermometer In moderate climates Wax-pallet type 83 °C 95 °C 8 mm or more In tropical climates Wax-pallet type 71 °C 85 °C Truck : 8 mm or more temperature of 95 °C. Thermostat General descriptions and main data The thermostat maintains a constant temperature of coolant (90 ∼ 95 °C) and improves Namely. Inspecting (1) Check the wax pallet and spring for damage.3. then heat the water slowly and check temperature with a thermometer. the bypass circuit is closed and the water passage to the radiator is opened so that the coolant is forced to flow into the radiator. 2001 PS-MMA0507-E1A . the thermostat is normal. the thermostat valve is closed to make the coolant bypass to directly enter the water pump. One is named by 71 °C type and the other is 83 °C. Specifications Item Type Open at Open wide at Valve lift NOTE: There are 2 kinds of thermostats according to surrounding and operating conditions. (2) Put the thermostat in a container of water.1. If the valve lift is 0. to avoid a sharp rise of coolant temperature.1. do it slowly so that air is bled sufficiently from the entire cooling system. Engine overheating Possible causes Lack of coolant Radiator cap pressure valve spring weakened Fan belt loosened or broken Fan belt fouled with oil Thermostat inoperative Water pump defective Restrictions in water passages due to deposit of scales Injection timing incorrect Restriction in radiator core Gases leaking into water jacket due to broken cylinder head gasket Thermostat inoperative Ambient temperature too low Radiator leaky Radiator hoses loosely connected or damaged Radiator cap valve spring weakened Water pump leaky Heater hoses loosely connected or broken Cylinder head gasket leaky Corrections Replenish coolant Replace cap Adjust or replace fan belt Replace fan belt Replace thermostat Repair or replace Clean radiator and water passages Adjust injection timing correctly Clean exterior of radiator Replace gasket cylinder head 2. In cold weather. 4. Lack of coolant 94 MAINTENANCE of MAJOR COMPONENTS Printed in Mar. 2001 PS-MMA0507-E1A . (2) When draining out or replenishing coolant. Diagnostics and troubleshooting Complaints 1. it is essential to idle the engine sufficiently before running it. Therefore. Engine overcooling Replace thermostat Install radiator curtain Correct or replace Retighten clamps or replace hoses Replace cap Repair or replace Tighten or replace hoses Replace gasket cylinder head 3.DE12/T/TI/TIS MAINTENANCE MANUAL 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 temperature of coolant. retrace with a new one. (3) Replacing thermostat If the thermostat is detected defective. Such relatively slow reaction is mainly due to the large heat capacity of the wax pellet type thermostat.4. do not run the engine at overload or overspeed it immediately after engine starting. and fuel injection pump in order to ensure normal engine performance. 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. Lubricating system 4.2.2.5 ∼ 1.8 ∼ 2.3 kg/cm2 4. Specifications Item Specifications Forced pressure circulation Item Specifications Lubricating system Oil filter type Full flow 1. 2001 PS-MMA0507-E1A . 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.8 kg/cm2 Oil pump type Gear type Bypass for filter element Relief valve opening pressure 10±1.8 kg/cm2 Diagram of lubricating system Air compressor 95 MAINTENANCE of MAJOR COMPONENTS Printed in Mar.5 kg/cm2 Valve opening pressure Bypass for oil cooler Bypass for entire oil filter Opening pressure 5+1 kg/cm2 Valve opening pressure Adjusting valve for spray nozzle Opening pressure 1.1. Cooling system noisy Cylinder head or cylinder block cracked Water pump bearing defective Fan loosely fitted or bent Fan out of balance Fan belt defective Replace cylinder head block Replace bearing Retighten or replace fan Replace fan Replace fan belt 4.0 ～ 4.DE12/T/TI/TIS MAINTENANCE MANUAL 4. (2) Remove the oil pump cover fixing nuts and disassemble the oil pump cover. Disassemble the drive gear. Steel plate End play 0. (3) Disassemble the drive gear and driven gear. b.089 mm Feeler gauge (2) With a feeler gauge.2. c.DE12/T/TI/TIS MAINTENANCE MANUAL 4. Replace if the measured value is beyond the limit.64 mm 96 MAINTENANCE of MAJOR COMPONENTS Printed in Mar. Backlash 0. Unscrew the screw and disassemble the oil relief valve.2. 2001 PS-MMA0507-E1A .50 ∼ 0. Oil pump Disassembly (1) Disassembly of oil pump drive gear a. Replace if the measured value is beyond the limit. measure the amount of backlash between the oil pump drive gear and driven gear. Unfold the washer for the oil pump drive gear fixing nut and remove the nut. measure the axial end play of the oil pump gear. Inspection and correction (1) With steel rule and feeler gauge. The oil pump cover is fixed with the two dowel pins.025 ∼ 0. DE12/T/TI/TIS MAINTENANCE MANUAL (3) Measuring clearance between drive shaft and bushing a. Measure the outside diameters of the drive shaft and driven shaft, and replace if the measured values are less than the limit. Standard φ16.95 ∼ φ16.968 mm b. Measure the inside diameter of the pump body bushing to determine the clearance between the bushing and shaft, and compare the measured value with the standard value to determine whether to replace or not. Clearance 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. 0.032 ～ 0.077 mm M1226 97 MAINTENANCE of MAJOR COMPONENTS Printed in Mar. 2001 PS-MMA0507-E1A DE12/T/TI/TIS MAINTENANCE MANUAL 4.2.4. Diagnostics and troubleshooting Complaints 1. Oil consumption excessive Possible causes Poor oil Oil seal or packing leaky Pistons or piston rings worn Cylinder liner worn Piston rings sticking Valve guide oil seals or valve guides, or valve stem worn Poor oil Relief valve sticking Restrictions in oil pump strainer Oil pump gear worn Oil pump feed pipe cracked Oil pump defective Oil pressure gauge defective Various bearings worn Restriction in oil filter Gases leaking Wrong oil used Corrections Use suggested oil Replace Replace pistons and/or piston rings Replace cylinder liner Replace pistons and/or piston rings Replace 2. Oil pressure too low Use suggested oil Replace Clean strainer Replace Replace Correct or replace Correct or replace Replace Replace filter element Replace piston rings and cylinder liner Use suggested oil 3. Oil deteriorates quickly 98 MAINTENANCE of MAJOR COMPONENTS Printed in Mar. 2001 PS-MMA0507-E1A DE12/T/TI/TIS MAINTENANCE MANUAL 4.3. Electrical System (DE12TIS) 4.3.1. Electrical parts of engine assembly 2 1 3 4 8 7 5 6 10 9 11 1 4 7 10 Oil pressure unit Rack sensor Alternator Water temperature sensor 2 5 8 11 Air heater Fuel injection pump Fuel filter Engine control unit (ECU) 3 6 9 Actuator sensor NE pick-up sensor Starting motor 99 MAINTENANCE of MAJOR COMPONENTS Printed in Mar. 2001 PS-MMA0507-E1A Engine control system 1) Engine control unit (ECU) connector Engine control unit(ECU) Signal name TW(SIG) POWER(+) SIG POWER(+) SIG NE(SIG) A/H RELAY + GND SHILD GND(-) NE(GND) TW(GND) PRE STROKE ACT. 6 1 1 2 2 3 2 5 3 4 1 3 2 Function color W Y/R Br Br W/Y B W/L Y L/R L R/G R/Y Pre stroke actuator (-) Water temperature sensor (+) Pre stroke sensor (POWER) Pre stroke sensor (SIGNAL) Rack sensor power (+5V) Rack sensor (SIGNAL) Engine pick-up sensor (SIGNAL) Air heater relay Pre stroke actuator power (+) Pre stroke sensor ground (-) Pre stroke sensor shield wire Rack sensor ground (-) Engine pick-up sensor ground (-) Water temperature sensor ground (-) Pre stroke actuator power (VB) Diagnostic switch Tachometer gauge signal SCAN 200 signal Maker diagnostic-3 (DATA) : not exited Maker diagnostic-3 (CLOCK) : not exited Maker diagnostic-3 (STB) : not exited Pre stroke shut off relay Engine control unit power (+) Engine control unit ground (-) Engine control unit memory clear switch Engine cranking signal Tachometer gauge ground (-) Air heater lamp Diagnostic lamp Engine control unit chassis ground (GND) Engine control unit ground (-) Engine control unit ground (-) 100 MAINTENANCE of MAJOR COMPONENTS Printed in Mar. 1 5 6 7 8 9 10 12 14 19 20 21 23 24 27 29 31 32 33 34 35 36 37 38 39 40 42 44 45 46 ECU GROUND(-) ECU GROUND(-) 47 48 Harness Connector pin no.DE12/T/TI/TIS MAINTENANCE MANUAL 4.2.3. GND A/H LAMP DIAG LAMP Engine control unit connector pin no. 2001 PS-MMA0507-E1A . POWER DIAG SW SIGNAL RXD DATA CLOCK STB PRE STROKE SHUT OFF RELAY ECU POWER(+) ECU POWER(-) MEMORY CLEAR SW CRANK REQ. DE12/T/TI/TIS MAINTENANCE MANUAL 2) Engine control unit (ECU) circuit diagram (A) GROUN 101 MAINTENANCE of MAJOR COMPONENTS Printed in Mar. 2001 PS-MMA0507-E1A . 14 : SCAN 200 data output (K-LINE) 102 MAINTENANCE of MAJOR COMPONENTS Printed in Mar. 3 : SCAN 200 power (+) Pin no. 1 : SCAN 200 ground (-) Pin no. 2001 PS-MMA0507-E1A .DE12/T/TI/TIS MAINTENANCE MANUAL 3) Engine control unit (ECU) circuit diagram (B) SCAN 200 Connector Engine Connector Vehicle Connector Pin no. 2001 PS-MMA0507-E1A .DE12/T/TI/TIS MAINTENANCE MANUAL 4) Engine harness 103 MAINTENANCE of MAJOR COMPONENTS Printed in Mar. Engine electrical components (Fuel injection pump) 1) Pre stroke actuator – drive shaft Replace the drive shaft if the ball section is bent.1 11. 104 MAINTENANCE of MAJOR COMPONENTS Printed in Mar.95 5. Their resistance are shown below. Check the conductance between each of the pre-stroke actuator terminals and connectors using a circuit tester.45～2.DE12/T/TI/TIS MAINTENANCE MANUAL 4. check that Resistance ( Ω) 2.5～6. worn or damaged. 2001 PS-MMA0507-E1A .3.5～6.0～12.1 the resistance between the terminals and the housing is ∞.3. . Terminal no.2 5. 1 and 2 4 and 5 4 and 6 5 and 6 Also. 2) Pre-stroke actuator inspection Check the resistance between the pre stroke actuator terminals shown in the figure at left using a circuit tester. check that the resistance between the terminals and the housing is 4) NE pick-up sensor inspection Check the resistance between the speed sensor terminals (if installed) shown in the figure using a circuit tester. 1 2 3 4 5 6 4 5 GND 3 2 1 Harness color Green Yellow Black/ White Black White Blue Remarks Actuator drive (-) Actuator drive (+) Shield Pre stroke sensor (GND) Pre stroke sensor (signal) Pre stroke sensor (OSC) 3) Rack sensor inspection Check the resistance between each of the rack sensor terminals shown in the figure using a circuit tester. Terminal no. no.5～101.5～101.5 ∞ Also.5 1 and 2 185. 2 and 3 Harness color Red (OSC) ～ white (MDL) Black (GND) ～ white (MDL) Black (GND) ～ red (OSC) Resistance(Ω) 92.0～203. check that the resistance 105 MAINTENANCE of MAJOR COMPONENTS Printed in Mar. Their resistance is shown in the table below. Their resistance at 25℃ are shown in the table below. Terminal no. 2001 PS-MMA0507-E1A .1～2. 2 and 3 Harness color Yellow (SIG) ～ black (GND) Resistance(kΩ) 2.5 1 and 3 92.0 Also.DE12/T/TI/TIS MAINTENANCE MANUAL Connector Actuator terminal Terminal no. Confirm that the actuator's pre-stroke position sensor plate moves smoothly when moved with a finger.5～0.5kg. 5) Pre-stroke actuator installation Insert the ball on the end of the actuator's shaft into the top of the U. Torque 0. Install the actuator cover on the actuator and tighten the bolts to the specified torque. Temporarily tighten the pre-stroke actuator's five bolts. Torque 0. as shown at right.m NOTE : When installing the actuator.m 106 MAINTENANCE of MAJOR COMPONENTS Printed in Mar.7kg.1～0. 2001 PS-MMA0507-E1A .shaped link's opening.DE12/T/TI/TIS MAINTENANCE MANUAL between the terminals and the housing is ∞. turn it as far as possible clockwise (viewed from the drive side) to facilitate later adjustment. DE12/T/TI/TIS MAINTENANCE MANUAL 6) Water temperature sensor Check the resistance between the water temperature sensor terminals shown in the figure using a circuit tester.. Their resistance is shown in the table below.322～0. Temperature(°C) 20 40 60 80 Resistance(kΩ) 2. Name Remarks 107 MAINTENANCE of MAJOR COMPONENTS Printed in Mar.73 1. dial and terminal.650 0.059～1. The figure below shows the names and functions of each control panel switch. In addition to the control unit.27～2. 2001 PS-MMA0507-E1A .298 7) Pre-stroke actuator adjustment (1) Adjustment checker (Including control unit) This control unit is used is especially for adjustment of TICS pumps.538～0. a constant voltage power supply and a digital voltmeter (both commercially available) are necessary. Key no.281 0. DE12/T/TI/TIS MAINTENANCE MANUAL 1 2 3 4 5 6 7 8 Power switch Pilot lamp Target dial Actuator operation switch Rack sensor output terminals Pre-stroke actuator output terminals 5 volt output terminals Fuse Used to turn the checker`s power ON and OFF Used to set the pre-stroke actuator`s output voltage Switch to “NORMAL” when operating the actuator, and “ACT-OFF” when not operating the actuator. Used to connect the rack sensor to the digital voltmeter. Used to connect the pre-stroke actuator output terminals Not used at present - (2) Wiring Harness The wiring harness layout is as shown below. Position each switch on the checker (407980-2090) as shown at right. CAUTION : Leave the power switch OFF to prevent the pre-stroke actuator from overheating. 108 MAINTENANCE of MAJOR COMPONENTS Printed in Mar. 2001 PS-MMA0507-E1A DE12/T/TI/TIS MAINTENANCE MANUAL Reinstall the measuring device (105782-4371) on the No 1 cylinder as described in “Injection timing adjustment”. Adjust the pump test stand's fuel oil supply pressure to as low a pressure as possible (eg, 0.2 kgf/cm2). Turn the pump test stand's flywheel and adjust the No 1 cylinder`s lift to 4±0.05mm Set the constant voltage power supply at 24V. Turn on the digital voltmeter's power switch. Turn the checker's power ON. Turn the “NORMAL ACT-OFF switch to “NORMAL”. Turn the target dial until the fuel stops flowing. If the pre-stroke sensor output is not 2.62 ±0.01 V, turn the pre-stroke actuator in a counter clockwise direction (viewed from the drive side) until 2.62 ±0.01 V is obtained. 3) Installation confirmation Set the control unit's power switch OFF to cut the power to the actuator. Turn the pump test stand's flywheel and confirm that the pre-stroke is 6.4 ±0.03mm. 109 MAINTENANCE of MAJOR COMPONENTS Printed in Mar. 2001 PS-MMA0507-E1A DE12/T/TI/TIS MAINTENANCE MANUAL Turn the checker's power switch on and then turn the “NORMAL ACT-OFF” switch to “ACT-OFF”. At this time confirm that the prestroke sensor output is 1.2±0.2 V. Set the control unit's “NORMAL ACT-OFF” switch to “NORMAL”, and position each switch, etc, as shown at right. Turn the target dial, and adjust the rack sensor output to 3 -0.02 V. Turn the pump test stand's flywheel and confirm that the NO 1 cylinder's pre-stroke does not exceed 3.4 mm. If the above results cannot be obtained, repeat all procedures from “Timing rod assembly”. The relationship between pre-stroke and pre-stroke sensor output is shown at right. NOTE: The values at left are only examples. Refer to the data sheet. 4) Injection quantity adjustment Setting the control rod's '0' position Remove the measuring from the device No 1 (105782-4371) cylinder and reinstall the delivery valve, the delivery valve spring, and 110 MAINTENANCE of MAJOR COMPONENTS Printed in Mar. 2001 PS-MMA0507-E1A mounted on the end of the control rod. operate the pre-stroke actuator with the pre-stroke set as specified.000~1.01 V. 5) Injection quantity adjustment When adjusting the TC(S)∙HD type pump's fuel injection quantity.200 rpm and push the end of the measuring device. loosen the idling spring's plate plug to loosen the idling spring. 2001 PS-MMA0507-E1A .62 ±0. Then. tighten the delivery valve holder to the specified torque. adjust the fuel injection quantity until the specified quantities 111 MAINTENANCE of MAJOR COMPONENTS Printed in Mar.05 mm. Attach the measuring device (105782-6370) to the end of the control rod. Increase the pump speed to 1. Fully lighten the governor shaft to loosen the governor spring. Then. Turn the “NORMAL ACT-OFF” switch to the “NORMAL” position and rotate the target dial to set the sensor output to 2. fully toward the governor side until the control rod to stops to obtain the “0” position.0 ±0.DE12/T/TI/TIS MAINTENANCE MANUAL the delivery valve holder. Then. corresponding to a pre-stroke of 4. Lock the control lever near the idling position. 2001 PS-MMA0507-E1A . and then check the idling fuel quantity.03mm. If not as specified.DE12/T/TI/TIS MAINTENANCE MANUAL are obtained at the specified pump speed and in the specified control rod position.05 ±0.m 6) Rack limiter adjustment Secure the control rod in the position where the fuel quantity “I” is obtained. increases. NOTE: When the sleeve flange is turned as shown in the figure at left (right helix plunger). loosen the injection pipe. tighten the flange fixing nuts to the specified torque. loosen the two nuts fixing the plunger barrel’s flange. the injection quantity Torque 4～4.01 V. corresponding to a pre-stroke of 6. and then turn the flange right or left to adjust the Injection quantity. Idle fuel quantity confirmation Rotate the target dial to set the sensor output to V=V1 + 0.5kg. When the variation between each cylinder's injection quantity satisfies the specified value.3 ±0. 112 MAINTENANCE of MAJOR COMPONENTS Printed in Mar. 2001 PS-MMA0507-E1A . apply grease to the 0-ring. After adjusting the distance “Y”. NOTE : If not as specified. 113 MAINTENANCE of MAJOR COMPONENTS Printed in Mar. Install the joint and measure the distance “Y”. add or remove shims until it is as specified. install the joint and check the fuel injection quantity. NOTE: Before installing the bobbin in the joint.DE12/T/TI/TIS MAINTENANCE MANUAL Install the block and measure the distance “X”. Screw in the bobbin until the edge of the bobbin contacts the bottom of the joint. Install the core and adjust the dimension “X” using shims until it equals “Y”. 2001 PS-MMA0507-E1A . 114 MAINTENANCE of MAJOR COMPONENTS Printed in Mar. adjust the depth that the bobbin is screwed in so that the rack sensor output voltage is 2.01 V. Read the specified output voltage and the specified rack position from the rack position.01V when it is returned to the fuel position. After adjustment. NOTE: The values at left vary with the pump.00 ±0. Read the pump speed that corresponds to the specified rack position from the governor graph of the fuel injection quantity adjustment table and set the pump speed to the speed specified. tighten the bobbin using the nut.00 ± 0. Move the pump's lever 2～3 times and confirm that the voltage is 2. Then.DE12/T/TI/TIS MAINTENANCE MANUAL 8) Rack sensor adjustment Secure the control lever in the full speed position. voltage graph in the calibration data. Refer to the data sheet at adjustment. c) Trouble code clear System Fault Codes can be cleared from memory with a SCAN 200 or by turning the ignition key to the ON position and operating the memory clear switch pin no. Diagnostic connector SCAN 200 115 MAINTENANCE of MAJOR COMPONENTS Printed in Mar. 2001 PS-MMA0507-E1A .4. 2) SCAN 200 Inspect the electrical parts problem with SCAN 200 and refer diagnostic manual. Engine control system related problems that affect emissions or drive ability of the vehicle will set a system fault code and illuminate the malfunction indicator lamp.3. Engine diagnostics 1) Function selection menu a) System Fault Code (SFC) When a SFC code is set. The system has a dash mounted malfunction indicator lamp for indication of system problems. the ECU will illuminate the malfunction indicator lamp on the instrument panel and save the code in memory. The system fault codes can be read by using either the malfunction indicator lamp or a SCAN 200 b) Malfunction indicator lamp (MIL) The ECU system has built-in diagnostics for trouble shooting. 39.DE12/T/TI/TIS MAINTENANCE MANUAL 4. Diagnostic indicator lamp The malfunction indicator lamp located on the instrument panel the operator of a program.5se Key-on Key-off 0. (5) Check the SFC code.(pin No. (2) The engine is not running.) Example is one fault code 21 Finished fault code 21 three times 1sec 1sec Pause 3sec Finished fault code 21 three times Pause 3sec 0. pausing. then flashing the second digit.DE12/T/TI/TIS MAINTENANCE MANUAL 3) Malfunction indicator lamp (1) The key is in the ON position. a code 21 would be two flashed followed by one flashes. (for example. System fault codes can be detected and displayed by using the check engine light (1) Turn the diagnostic switch ON. There will be a long pause between codes. 29 of diagnostic switch) (2) The MIL displays two digit codes by flashing the first digit. (normal open on the pin No. 29) (4) The malfunction indicator lamp will begin to flash. (3) Push the diagnostic switch.5sec 116 MAINTENANCE of MAJOR COMPONENTS Printed in Mar. 2001 PS-MMA0507-E1A . then check light the malfunction indicator lamp. then key switch off. 2001 PS-MMA0507-E1A . 39.DE12/T/TI/TIS MAINTENANCE MANUAL Example is two fault codes 13 and 22 Finished fault code 13 three times 1sec 1sec 0.5 sec Fault code clear System Fault Codes can be cleared from memory with turning the ignition key to the ON position and operating the memory clear switch pin no. 117 MAINTENANCE of MAJOR COMPONENTS Printed in Mar.5sec Pause 3sec Finished fault code 22 three times Pause 3sec Key-on Key-off 0. 2) Repair the pre stroke sensor 118 MAINTENANCE of MAJOR COMPONENTS Printed in Mar. 19 of ECU . 6 and pin No. 29 and battery ground No 1) Check the contacts of pre stroke actuator connector 2) Repair the pre stroke control servo.Pin No. 6 and pin No. .Pin No. 6 and pin No. 3) Check the ECU pin No.Pin No. Fault code 13 : Pre stroke sensor error 1) Key-on (not starting the engine) 2) Check the resistance of pre stroke actuator sensor as follow. 6 and pin No. 29 of ECU 1) Check the contacts of pre stroke actuator Does SCAN 200 display resistance of 0 or ∞? yes connector 2) Check if cable is short or open. 7 and pin No. 19 of ECU . . 7 and pin No. 29 of ECU Does SCAN 200 display resistance of 0 or ∞? Ye 1) Check the contacts of pre stroke actuator connector 2) Check if cable is short or open 3) Repair the pre stroke sensor No 1) Check the contacts of pre stroke actuator connector. 7 of ECU .DE12/T/TI/TIS MAINTENANCE MANUAL 2) Engine self-diagnostic and repair hint Fault code 12 : Pre stroke control servo error 1) Key-on (not starting the engine) 2) Check the resistance of pre stroke actuator sensor as follow. 2001 PS-MMA0507-E1A .Pin No.Pin No.Pin No. 7 of ECU . SFC 15 : Pre stroke actuator power error 1) Key-on (not starting the engine) 2) Check the voltage between pin No 27 and pin No. 2001 PS-MMA0507-E1A . 47 and battery ground 119 MAINTENANCE of MAJOR COMPONENTS Printed in Mar. . 7 of ECU . 29 and battery ground No 1) Check the contacts of ECU connector. 47 of ECU Yes Does SCAN 200 display voltage more than 24 ? 1) Check the contact of ECU connector.DE12/T/TI/TIS MAINTENANCE MANUAL Fault code 14 : Pre stroke offset learning error 1) Key-on (not starting the engine) 2) Check the resistance of pre stroke actuator sensor as follow. 6 and pin No. 2) Inspect the ECU or require after service. 6 and pin No. 2) Inspect the ECU or require after service.Pin No. 7 and pin No. 19 of ECU . 2) Check the relay of pre stroke actuator. 3) Check the contact ECU pin No.Pin No. 29 of ECU Does SCAN 200 display resistance of 0 or ∞ ? Yes 1) Check the contacts of pre stroke actuator connector 2) Check if cable is short or open 3) Check the ECU pin No.Pin No. 27 and connector 4) Check the contact ECU pin No. No 1) Check the fuse of pre stroke actuator. 23 of ECU. 120 MAINTENANCE of MAJOR COMPONENTS Printed in Mar. 10 and Pin No.DE12/T/TI/TIS MAINTENANCE MANUAL Fault code 16 : Engine speed sensor error 1) Measure the resistance between pin No. 2001 PS-MMA0507-E1A . at 20℃ : 2.281kΩ 60℃ : 538~650Ω. Fault code 21 : Water temper sensor error 1) Key-on (not starting the engine) 2) Measure the resistance between pin NO. 24 of ECU. Yes Does SCAN 200 display resistance 400~600 ? 1) Check the contact of ECU connector. 2) Replace the water temperature sensor. No 1) Check if cable is short or open. 80℃ : 322~298Ω Yes Does SCAN 200 display resistance correct ? 1) Check the contact of ECU connector.059~1. 2) Inspect the ECU or require after service. 2) Inspect the ECU or require after service.73kΩ.27~2. No 1) Check if cable is short or open 2) Replace the NE pick-up sensor. 40℃ : 1. 5 and pin No. 12 and pin No. Fault code 23 : Intake air heater relay error 1) Key-on (not starting the engine) 2) Measure the voltage between pin No.DE12/T/TI/TIS MAINTENANCE MANUAL Fault code 22 : Fuel rack sensor error 1) Key-on (starting the engine) 2) Check the engine idle 3) Measure the voltage between pin No. 8 and pin No. No 1) Check the contact of ECU connector. 2001 PS-MMA0507-E1A . 2) Inspect the ECU or require after service.49 at the engine idle speed ? 1) Check the contact of ECU connector. No 1) Check if cable is short or open. 9 of ECU. 2) Inspect the ECU or require after service. 2) Replace the fuel rack sensor. Does SCAN 200 display 0 voltage ? Yes 1) Check if cable is short or open 2) Replace the heater relay. Yes Does SCAN 200 display voltage less than 3. 47 of ECU. 121 MAINTENANCE of MAJOR COMPONENTS Printed in Mar. 1 of NE pickup sensor. 16 at NE pick-up sensor.6 at between pin No. 122 MAINTENANCE of MAJOR COMPONENTS Printed in Mar.5sec? Yes 1) Push the memory clear switch.DE12/T/TI/TIS MAINTENANCE MANUAL Fault code 24 : Engine starting abnormal 1) This fault code occur can not starting the initial engine in 2. 10 and pin No 23 connector of ECU 2) Probe the NE pick-up sensor voltage 1) Refer to the fault code No. 2001 PS-MMA0507-E1A . Yes No Require after service. 1) Check the gap 1mm±0.5sec Does engine started in 2. then restart the engine No 1) Disconnect the NE pick-up sensor 1) Does occur fault code 16? Yes more than 0. 13. 9. Fuel filter Fuel water drain plug Air bleeding screw (for fuel filter) Injection nozzle Overflow tube Fuel pipe (filter → injection pump) Overflow valve 7. 8. For adjustment of fuel injection volume. 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. 123 MAINTENANCE of MAJOR COMPONENTS Printed in Mar.DE12/T/TI/TIS MAINTENANCE MANUAL 4.4. 3. Fuel injection pipe Fuel pipe (manual pump → filter) Fuel tank Fuel return pipe Suction pipe Feed pump Injection pump 4. 6. Make sure that servicing should be performed at the professional maintenance shop as authorized by Bosch or Zexel Company. 4. 1a. 12. injection pump.4.4. 2001 PS-MMA0507-E1A .2. refer to the 'Specifications of fuel injection pump' described on the following pages. fuel filter. 10. injection nozzle. 2. F1029 1. and fuel lines such as pipes and hoses necessary to connect those components.1. 5. General information of fuel system The fuel system consists of the fuel tank. Fuel Injection Pump 4. 11. 4 8.DE12/T/TI/TIS MAINTENANCE MANUAL 1) DE12 (A) (1) Fuel injection pump ` Fuel injection pump Governor Timer Fuel feed pump Coupling Micro switch : 65.9 5.10102-6045 (105029-1340 DOOWON) : 65.87kgf/mm 124 MAINTENANCE of MAJOR COMPONENTS Printed in Mar.35 kgf/mm 100mm3/st .29) Opening pressure : 220 kg/cm2 φ1.4 9.5 100 이상 Pressure (mmHg) - Governor weight Governor spring Start spring Adapter spring Plunger Timer spring 740 g k=10.014 kgf/mm k=4.10301-6151 65.09 18.11101-7260 (106671-4834 ZEXEL) : KP-PE6P120/721RS3000 (106061-7330) : KP-EP/RFD200/1450PF23CHR (105489-4341) : KP-EP/SP800-1100Z6R (105636-2330) : KP-FP/K-P (105207-1470) : 105663-0740 : 153169-3320 : 65.0– 650 mm Temperature :40 ±5°C Nozzle (5 x φ0.10102-6045 65.2 Pump speed (rpm) 700 1.000 st) Test condition for inj.10101-7296 (105160-4361 DOOWON) : 65.5 kgf/mm Lever ratio (min.0 x φ6. 2001 PS-MMA0507-E1A .10301-6152 :1–5–3–6–2–4 : BTDC 12° 105160-4361 ISO4113 65.0 kgf/mm k=0.5 kgf/mm k=0.5 ±1.10301-6152 Opening pressure : 175 bar φ2.5kgf/cm2 k=0.10301-6151 . 65.10101-7296 65. t=0. pump 123 ±2 117 ±3 110 ±2 14.8 x φ6 – 550mm (2) Nozzle holder assembly (3) Nozzle (4) Fuel injection pipe (5) Injection order (6) Injection timing Nozzle & holder ass`y Fuel injection pipe (ID x OD – L) Test oil Nozzle & holder ass`y (B) Engine standard parts Fuel injection pipe (ID x OD – L) (A) Test condition for Fuel injection pump Rack diagram and setting valve at each point Check point A B C D E Rack position (mm) 9. / max.0 kgf/mm φ12 right hand 30 lead k=2. / 1 : 2 K=0.100 500 250 100 Injection quantity on RIG (mm3 / 1.) Idle spring Damper spring Retraction pressure Delivery valve Opening pressure Spring 1 : 1. 6 kgf/mm k=0.87kgf/mm 125 MAINTENANCE of MAJOR COMPONENTS Printed in Mar.10101-7296 65.29) Opening pressure : 220 kg/cm2 φ1.5R (105636-2180) : KP-FP/K-P (105207-1470) : 105663-0740 : 65.11 19.10301-6151 65.100 500 250 100 Injection quantity on RIG (mm3 / 1. 2001 PS-MMA0507-E1A .3 8.10102-6045 65.5 kgf/mm Lever ratio (min.10301-6151 .8 x φ6 – 550mm (2) Nozzle holder assembly (3) Nozzle (4) Fuel injection pipe (5) Injection order (6) Injection timing Nozzle & holder ass`y Fuel injection pipe (ID x OD – L) Test oil Nozzle & holder ass`y (B) Engine standard parts Fuel injection pipe (ID x OD – L) (B) Test condition for Fuel injection pump Rack diagram and setting valve at each point Check point A B C D E Rack position (mm) 12 12.10301-6152 :1–5–3–6–2–4 : BTDC 8° 105160-4361 ISO4113 65. t=0.000 st) Test condition for inj.) Governor spring (inner) Idle spring (inner) Damper spring Retraction pressure Delivery valve Opening pressure Spring 1:1/1:2 K=0.0 kgf/mm k=0.5 95 ±3 Pressure (mmHg) - Governor weight Governor spring (outer) Idle spring (outer) Start spring Plunger Timer spring 850 g k=1.2kgf/cm2 k=0.3 11.10101-7296 (105160-4361 DOOWON) : 65.DE12/T/TI/TIS MAINTENANCE MANUAL 2) DE12 (B) (1) Fuel injection pump ` Fuel injection pump Governor Timer Fuel feed pump Coupling : 65.5 ±1.0 x φ6.5 Pump speed (rpm) 700 1.5 kgf/mm k=0.0– 650 mm Temperature :40 ±5°C Nozzle (5 x φ0.10301-6152 Opening pressure : 175 bar φ2. / max. pump 99 ±2 95 ±3 81 ±2 14.11101-7656 (106671-9460 ZEXEL) : KP-PE6P120/721RS3000 (106067-1160) : KP-EP/RLD300/120095JFR (105923-2311) : KP-EP/SP600-1100Z5.05 kgf/mm k=0.10102-6045 (105029-1340 DOOWON) : 65.005 kgf/mm φ12 right hand 27+45 lead k=4.7 kgf/mm 120mm3/st . 65. 2 Pump speed (rpm) 700 1. 2001 PS-MMA0507-E1A .0 kgf/mm k=0.000 st) Test condition for inj.10301-6151 65.10101-7300 65.11 19.0– 650 mm Temperature :40 ±5°C Nozzle (5 x φ0.) Idle spring (inner) Damper spring Boost spring Retraction pressure Delivery valve Opening pressure Spring 1:1/1:2 k=0.11101-7261 (106671-921S ZEXEL) : KP-PE6P120/721RS3000 (106067-0660) : KP-EP/RFD200/1450PF8CWR (105489-5102) : KP-EP/SP700-1100Z3R (105636-2530) : KP-FP/K-P (105207-1470) : 105663-0740 : 65. pump 161.2 x φ6.0 x φ6.6 kgf/mm k=0.9 10.0 – 650mm (2) Nozzle holder assembly (3) Nozzle (4) Fuel injection pipe (5) Injection order (6) Injection timing Nozzle & holder ass`y Fuel injection pipe (ID x OD – L) Test oil Nozzle & holder ass`y (B) Engine standard parts Fuel injection pipe (ID x OD – L) (C) Test condition for Fuel injection pump Rack diagram and setting valve at each point Check point A B C D E Rack position (mm) 10.31) Opening pressure : 220 kg/cm2 φ2.5 kgf/mm Lever ratio (min.5 100 이상 Pressure (mmHg) 450 - Governor weight Governor spring Start spring Adapter spring Boost start spring Plunger Timer spring 740 g k=10.10301-6152 Opening pressure : 175 bar φ2.5 ±2 152 ±3 (97 ±2) 14.014 kgf/mm k=2.5 ±1.10301-7004B :1–5–3–6–2–4 : BTDC 9° 105160-4351 ISO4113 65.87kgf/mm 126 MAINTENANCE of MAJOR COMPONENTS Printed in Mar.2kgf/cm2 k=0. t=0.5 kgf/mm k=3.100 500 250 100 Injection quantity on RIG (mm3 / 1.10102-6046 (105029-1330 DOOWON) : 65.6 kgf/mm k=0.10101-7300 (105160-4351 DOOWON) : 65.DE12/T/TI/TIS MAINTENANCE MANUAL 3) DE12T (1) Fuel injection pump ` Fuel injection pump Governor Timer Fuel feed pump Coupling : 65.. / max.9 5.1 kgf/mm φ12 right hand 22+45 lead k=2.2 kgf/mm 120mm3/st .10102-6046 65. 10101-7294A (9134-153C DOOWON) : 65.0 x φ6. pump 135 ±2 16 ±1.1 Pump speed (rpm) 1. t=0.5 90 이상 150 ±3 (115 ±3) Pressure (mmHg) 600 or more - Governor weight Governor spring Start spring Plunger Lever ratio (min.2 5.7 7.0+0.0– 650 mm Temperature :40 ±5°C Nozzle (5 x φ0.10101-7293 65.7+0.05 kgf/mm K=0.15 20.000 st) Test condition for inj. 2001 PS-MMA0507-E1A .10301-7004B :1–5–3–6–2–4 : BTDC 9° Opening pressure 1st : 175 bar 2nd :220 bar φ2.1 8.54 kgf/mm 51mm3/st .8kgf/cm2 k=1.9 Idle spring Boost spring Retraction pressure Delivery valve Opening pressure Spring k=0.10102-6042 65.DE12/T/TI/TIS MAINTENANCE MANUAL 4) DE12TI (280PS) (1) Fuel injection pump ` Fuel injection pump Governor Timer Fuel feed pump Coupling : 65.63kgf/mm 127 MAINTENANCE of MAJOR COMPONENTS Printed in Mar. / max.6 kgf/mm k=0.005 kgf/mm φ10 right hand 20+50 lead 1 : 1.) 740 g k=1.11101-7296 (106671-9430 ZEXEL) : KP-PE6P120/721RS3S (106067-0850 ZEXEL) : KP-EP/RFD200-1400PF57DZR(105487-7010) : KP-EP/SPG700-110023/R (105681-1910) : KP-FP/K-PS (105207-1540) : 105663-0740 : 65.2 x φ6 – 650mm (2) Nozzle holder assembly (3) Nozzle (4) Fuel injection pipe (5) Injection order (6) Injection timing Nozzle & holder ass`y (D) Test condition for Fuel injection pump Fuel injection pipe (ID x OD – L) Test oil Nozzle & holder ass`y (B) Engine standard parts Fuel injection pipe (ID x OD – L) 65.10101-7294A ISO4113 65.10102-6043 (105029-1320 DOOWON) : 65.15 / 1 : 3.33) Opening pressure : 214 kg/cm2 φ2.050 250 100 500 500 Injection quantity on RIG (mm3 / 1.10301-7007 Rack diagram and setting valve at each point Check point A B C D E Rack position (mm) 8. 8kgf/cm2 k=1.0– 650 mm Temperature :40 ±5°C Nozzle (5 x φ0.) 740 g k=1.0 x φ6.0+0.10301-7007 Rack diagram and setting valve at each point Check point A B C D E Rack position (mm) 9.10101-7294A ISO4113 65. t=0. pump 154 ±2 16 ±1.7 7.6 kgf/mm k=0.11101-7297 (106671-9430 ZEXEL) : KP-PE6P120/721RS3S (106067-0850 ZEXEL) : KP-EP/RFD200-1400PF57DZR(105487-7010) : KP-EP/SPG700-110023/R (105681-1910) : KP-FP/K-PS (105207-1540) : 105663-0740 : 65.63kgf/mm 128 MAINTENANCE of MAJOR COMPONENTS Printed in Mar. / max.2 5.005 kgf/mm φ10 right hand 20+50 lead 1 : 1. 2001 PS-MMA0507-E1A .10102-6042 65.05 kgf/mm K=0.9 Idle spring Boost spring Retraction pressure Delivery valve Opening pressure Spring k=0.10101-7294A (9134-153C DOOWON) : 65.DE12/T/TI/TIS MAINTENANCE MANUAL 5) DE12TI (310PS) (1) Fuel injection pump ` Fuel injection pump Governor Timer Fuel feed pump Coupling : 65.1 Pump speed (rpm) 1.050 250 100 500 500 Injection quantity on RIG (mm3 / 1.5 100 170 ±3 115 ±3 Pressure (mmHg) 600 or more - Governor weight Governor spring Start spring Plunger Lever ratio (min.54 kgf/mm 51mm3/st .10102-6043 (105029-1320 DOOWON) : 65.1 9.2 x φ6 – 650mm (2) Nozzle holder assembly (3) Nozzle (4) Fuel injection pipe (5) Injection order (6) Injection timing Nozzle & holder ass`y (E) Test condition for Fuel injection pump Fuel injection pipe (ID x OD – L) Test oil Nozzle & holder ass`y (B) Engine standard parts Fuel injection pipe (ID x OD – L) 65.10101-7293 65.7+0.15 20.000 st) Test condition for inj.15 / 1 : 3.33) Opening pressure : 214 kg/cm2 φ2.10301-7004B :1–5–3–6–2–4 : BTDC 9° Opening pressure 1st : 160 bar 2nd :220 bar φ2. 7+0.10101-7294A (9134-153C ZEXEL) : 65.33) Opening pressure : 214 kg/cm2 φ2. t=0.0+0.DE12/T/TI/TIS MAINTENANCE MANUAL 6) DE12TI (340PS) (1) Fuel injection pump ` Fuel injection pump Governor Timer Fuel feed pump Coupling : 65.0– 650 mm Temperature :40 ±5°C Nozzle (5 x φ0.05 kgf/mm K=0.0) Pressure (mmHg) 600 or more - Governor weight Governor spring Start spring Plunger Lever ratio (min.005 kgf/mm φ10 right hand 20+50 lead 1 : 1.5 115 ±1.2 x φ6 – 650mm (2) Nozzle holder assembly (3) Nozzle (4) Fuel injection pipe (5) Injection order (6) Injection timing Nozzle & holder ass`y (F) Test condition for Fuel injection pump Fuel injection pipe (ID x OD – L) Test oil Nozzle & holder ass`y (B) Engine standard parts Fuel injection pipe (ID x OD – L) 65. 2001 PS-MMA0507-E1A . pump 171 ±2 145 ±1.10101-7293 65.5 R1±0.000 st) Test condition for inj.10102-6042 65.9 Idle spring Boost spring Retraction pressure Delivery valve Opening pressure Spring k=0.0 x φ6.10102-6043 (105029-1320 ZEXEL) : 65.5 Pump speed (rpm) 1.10101-7294A ISO4113 65.) 740 g k=1.63kgf/mm 129 MAINTENANCE of MAJOR COMPONENTS Printed in Mar.15 20.10301-7007 Rack diagram and setting valve at each point Check point A B C D E Rack position (mm) R1 R2 R1±0.54 kgf/mm 51mm3/st .6 kgf/mm k=0. / max.0) (122 ±3.8kgf/cm2 k=1.10301-7004B :1–5–3–6–2–4 : BTDC 9° Opening pressure 1st : 160 bar 2nd :220 bar φ2.5 (186.050 250 100 500 500 Injection quantity on RIG (mm3 / 1.15 / 1 : 3.11101-7657A (106671-9430 ZEXEL) : KP-PE6P120/721RS3S (106067-0850 ZEXEL) : KP-EP/RFD200-1400PF57DZR(105487-7010) : KP-EP/SPG700-110023/R (105681-1910) : KP-FP/K-PS (105207-1540) : 105663-0740 : 65.5 ±3. 5 15.7 kgf/mm φ12 right hand 35 lead Lever ratio (min.049 kgf/mm k=14.29) Opening pressure : 216 kg/cm2 φ2.2 x φ6.11101-7347 (108622-4031 ZEXEL) : NP-TC6HD120/72ARS2 (108062-4020 ZEXEL) : NP-EP/RLD250-1050T6JXR(105923-4831) : NP-FP/KD-HD (105237-5360) : 156643-5120 : 159601-7720 : 134178-5120 : 134180-1220 : 65.6 630 1050 100 166±2 (159±3) (185) 101 or more 101 or more - Governor weight Governor spring (outer) Idle spring (outer) Start spring Boost spring Plunger 850 g k=9.7kgf/mm 130 MAINTENANCE of MAJOR COMPONENTS Printed in Mar.49 kgf/mm 0mm3/st 0.0– 650 mm Temperature :40 ±5°C Nozzle (5 x φ0.87 MPa k=12.DE12/T/TI/TIS MAINTENANCE MANUAL 7) DE12TIS (290PS) (1) Fuel injection pump Fuel injection pump Governor Fuel feed pump Coupling Actuator Plunger & barrel Delivery valve : 65.1 / 1 : 1 k=3.0 – 650mm (2) Nozzle holder assembly (3) Nozzle (4) Fuel injection pipe (5) Injection order (6) Injection timing Nozzle & holder ass`y (G) Test condition for Fuel injection pump Fuel injection pipe (ID x OD – L) Test oil Nozzle & holder ass`y (B) Engine standard parts Fuel injection pipe (ID x OD – L) 105101-8460 ISO4113 65. 65.10301-6011A Rack diagram and setting valve at each point Check point Rack position (mm) Pump speed (rpm) Injection quantity on RIG (mm3 / 1.4 13. 2001 PS-MMA0507-E1A .10301-6008A 65.000 st) Test condition for inj.10102-6053 (105025-2240 ZEXEL) : 65.10102-6053 65.9 kgf/mm k=0.8 kgf/mm k=4.10301-6008A . pump Pressure (kPa) A B I 14.10101-7298 65.10301-6011A :1–5–3–6–2–4 : BTDC 1° Opening pressure 1st : 160 bar 2nd :220 bar φ2.) Governor spring (inner) Idle spring (inner) Retraction pressure Delivery valve Opening pressure Spring 1 : 1.92 kgf/mm k=0.2 x φ6. / max.10101-7298 (105101-8460 ZEXEL) : 65. DE12/T/TI/TIS MAINTENANCE MANUAL (7) Rack curve 13. 2001 PS-MMA0507-E1A .25 1190 131 MAINTENANCE of MAJOR COMPONENTS Printed in Mar.6 10. 9 kgf/mm k=0. pump Pressure (kPa) A B I 15.10301-6011A :1–5–3–6–2–4 : BTDC 1° Opening pressure 1st : 160 bar 2nd :220 bar φ2.0 – 650mm (2) Nozzle holder assembly (3) Nozzle (4) Fuel injection pipe (5) Injection order (6) Injection timing Nozzle & holder ass`y (H) Test condition for Fuel injection pump Fuel injection pipe (ID x OD – L) Test oil Nozzle & holder ass`y (B) Engine standard parts Fuel injection pipe (ID x OD – L) 105101-8460 ISO4113 65.2 x φ6.92 kgf/mm k=0. 65.49 kgf/mm 0mm3/st 0.87 MPa k=12.29) Opening pressure : 216 kg/cm2 φ2.0– 650 mm Temperature :40 ±5°C Nozzle (5 x φ0.1 / 1 : 1 k=3.0 15. / max.049 kgf/mm k=14.000 st) Test condition for inj.) Governor spring (inner) Idle spring (inner) Retraction pressure Delivery valve Opening pressure Spring 1 : 1.10102-6053 (105025-2240 ZEXEL) : 65.10301-6008A 65.10101-7298 (105101-8460 ZEXEL) : 65. 2001 PS-MMA0507-E1A .2 630 1050 100 181 ±2 (171±3) (185) 101 or more 101 or more - Governor weight Governor spring (outer) Idle spring (outer) Start spring Boost spring Plunger 850 g k=9.9 12.7kgf/mm 132 MAINTENANCE of MAJOR COMPONENTS Printed in Mar.7 kgf/mm φ12 right hand 35 lead Lever ratio (min.8 kgf/mm k=4.10102-6053 65.DE12/T/TI/TIS MAINTENANCE MANUAL 8) DE12TIS (310PS) (1) Fuel injection pump Fuel injection pump Governor Fuel feed pump Coupling Actuator Plunger & barrel Delivery valve : 65.10101-7298 65.10301-6008A .10301-6011A Rack diagram and setting valve at each point Check point Rack position (mm) Pump speed (rpm) Injection quantity on RIG (mm3 / 1.11101-7346 (108622-4021 ZEXEL) : NP-TC6HD120/72ARS2 (108062-4020 ZEXEL) : NP-EP/RLD250-1050T6JXR(105923-4831) : NP-FP/KD-HD (105237-5360) : 105664-2490 : 159601-7720 : 134178-5120 : 134180-1220 : 65.2 x φ6. DE12/T/TI/TIS MAINTENANCE MANUAL (7) Rack curve 12.2 10.25 1190 133 MAINTENANCE of MAJOR COMPONENTS Printed in Mar. 2001 PS-MMA0507-E1A . 5 ±2 (183±3) (185) 101 or more 101 or more - Governor weight Governor spring (outer) Idle spring (outer) Start spring Boost spring Plunger 850 g k=9.10101-7298 (105101-8460 ZEXEL) : 65.87 MPa k=12. 2001 PS-MMA0507-E1A .10301-6008A .1 / 1 : 1 k=3.0– 650 mm Temperature :40 ±5°C Nozzle (5 x φ0.DE12/T/TI/TIS MAINTENANCE MANUAL 9) DE12TIS (320PS) (1) Fuel injection pump Fuel injection pump Governor Fuel feed pump Coupling Actuator Plunger & barrel Delivery valve : 65.10301-6011A :1–5–3–6–2–4 : BTDC 1° Opening pressure 1st : 160 bar 2nd :220 bar φ2.10301-6011A Rack diagram and setting valve at each point Check point Rack position (mm) Pump speed (rpm) Injection quantity on RIG (mm3 / 1.0 – 650mm (2) Nozzle holder assembly (3) Nozzle (4) Fuel injection pipe (5) Injection order (6) Injection timing Nozzle & holder ass`y (I) Test condition for Fuel injection pump Fuel injection pipe (ID x OD – L) Test oil Nozzle & holder ass`y (B) Engine standard parts Fuel injection pipe (ID x OD – L) 105101-8460 ISO4113 65.10102-6053 (105025-2240 ZEXEL) : 65.10301-6008A 65.1 13.49 kgf/mm 0mm3/st 0.29) Opening pressure : 216 kg/cm2 φ2.9 kgf/mm k=0.7kgf/mm 134 MAINTENANCE of MAJOR COMPONENTS Printed in Mar.10102-6053 65.10101-7298 65.8 kgf/mm k=4. pump Pressure (kPa) A B I 15.2 x φ6.2 16. 65.) Governor spring (inner) Idle spring (inner) Retraction pressure Delivery valve Opening pressure Spring 1 : 1.049 kgf/mm k=14.7 kgf/mm φ12 right hand 35 lead Lever ratio (min.92 kgf/mm k=0.11101-7339 (108622-4060 ZEXEL) : NP-TC6HD120/72ARS2 (108062-4020 ZEXEL) : NP-EP/RLD250-1050T6JXR(105923-4831) : NP-FP/KD-HD (105237-5360) : 156643-5120 : 159601-7720 : 134178-5120 : 134180-1220 : 65.3 630 1050 100 196.2 x φ6.000 st) Test condition for inj. / max. 2001 PS-MMA0507-E1A .1 15.3 10.2 13.25 1190 135 MAINTENANCE of MAJOR COMPONENTS Printed in Mar.DE12/T/TI/TIS MAINTENANCE MANUAL (7) Rack curve 16. 65.6 13.10102-6053 (105025-2240 ZEXEL) : 65.10301-6008A .10102-6053 65.45 630 1050 100 207 ±2 (192±3) (185) 103 or more 103 or more - Governor weight Governor spring (outer) Idle spring (outer) Start spring Boost spring Plunger 850 g k=9.10301-6011A :1–5–3–6–2–4 : BTDC 1° Opening pressure 1st : 160 bar 2nd :220 bar φ2.29) Opening pressure : 216 kg/cm2 φ2.DE12/T/TI/TIS MAINTENANCE MANUAL 10) DE12TIS (335PS or 340PS) (1) Fuel injection pump Fuel injection pump Governor Fuel feed pump Coupling Actuator Plunger & barrel Delivery valve : 65.) Governor spring (inner) Idle spring (inner) Retraction volume Delivery valve Opening pressure Spring 1 : 1.7 16.10101-7298 (105101-8460 ZEXEL) : 65.10101-7298 65.9 N/mm k=0.10301-6008A 65.10301-6011A Rack diagram and setting valve at each point Check point Rack position (mm) Pump speed (rpm) Injection quantity on RIG (mm3 / 1.2 x φ6.92 N/mm k=0.0 – 650mm (2) Nozzle holder assembly (3) Nozzle (4) Fuel injection pipe (5) Injection order (6) Injection timing Nozzle & holder ass`y (J) Test condition for Fuel injection pump Fuel injection pipe (ID x OD – L) Test oil Nozzle & holder ass`y (B) Engine standard parts Fuel injection pipe (ID x OD – L) 105101-8460 ISO4113 65.049 N/mm k=14.1 / 1 : 1 k=3.2 x φ6.11101-7345 (108622-4011 ZEXEL) : NP-TC6HD120/72ARS2 (108062-4020 ZEXEL) : NP-EP/RLD250-1050T6JXR(105923-4831) : NP-FP/KD-HD (105237-5360) : 105664-2490 : 159601-7720 : 134178-5120 : 134180-1220 : 65. / max.0– 650 mm Temperature :40 ±5°C Nozzle (5 x φ0.49 N/mm 0mm3/st 0.000 st) Test condition for inj.7kgf/mm 136 MAINTENANCE of MAJOR COMPONENTS Printed in Mar. pump Pressure (kPa) A B I 15. 2001 PS-MMA0507-E1A .8 N/mm k=4.87 MPa k=12.7 N/mm φ12 right hand 35 lead Lever ratio (min. 2 1190 137 MAINTENANCE of MAJOR COMPONENTS Printed in Mar.45 12. 2001 PS-MMA0507-E1A .DE12/T/TI/TIS MAINTENANCE MANUAL (7) Rack curve 16.9 13.7 15. When the cam reaches the Bottom Dead Center as shown in the figure. These pumps have the same basic construction and operation. 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. 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. resulting in interrupting further delivery of fuel as shown in (C). Fuel feed pump 1) General descriptions and construction The P-type injection pump is mounted with K-ADS or KP type feed pump. If the feeding pressure increases abnormally. The fuel pressurized as the cam rotates on flows through the check valve on the outlet side as shown in (B). air must be bled from the fuel lines. 2001 PS-MMA0507-E1A . fix it securely to prevent the possible entry of moisture or other foreign substances in the inside of feed pump. the spring is compressed. and the general descriptions of the KP type pump are given below: The figures show its construction (right figure) and operation (below figure).3. a strainer is fitted into joint bolt on the inlet side of the fuel feed pump to filtrate any foreign substances possibly mixed in fuel. 138 MAINTENANCE of MAJOR COMPONENTS Printed in Mar.4. When using the priming pump. the fuel is drawn in through the check valve on the inlet side. During the manual feeding operation. In addition.DE12/T/TI/TIS MAINTENANCE MANUAL 4. spring (15). Take off the priming pump (25). replace it with a new one. strainer (31) and gaskets (35. and piston (5) on the piston side. Pull out the snap ring (20) holding the tappet (10). Replace the push rod if excessively worn. Take off the prig (7). plug (16). then take off the tappet (10) and push rod (1). Disassemble the snap ring.DE12/T/TI/TIS MAINTENANCE MANUAL 2) disassembly M1232 Clamp the feed pump with a vise and disassemble the plugs (30. 139 MAINTENANCE of MAJOR COMPONENTS Printed in Mar. The inspection for wear should be performed in the same procedure as for suction pressure test described below. and check valve (14). Inspect the piston and tappet for damage. both gaskets (18). and replace together with the pump housing if required. gasket (8). 32). 36). spring (6). 2001 PS-MMA0507-E1A . 3) Inspection If the check valve is damaged or scored on its seat face. 2001 PS-MMA0507-E1A .000 rpm and check to see if the pump delivery is more than 405 cc/15 seconds. 140 MAINTENANCE of MAJOR COMPONENTS Printed in Mar. Operate the pump at the rate of 1.DE12/T/TI/TIS MAINTENANCE MANUAL 4) Reassembly Reassembly operation is performed in reverse order of disassembly. Submerge the feed pump in a container of diesel fuel and check for air leak. All the gaskets must be replaced with new ones at reassembly. 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. NOTE : Check the item no. (3) Sealing test Plug up the delivery port on the feed pump and apply compressed air of 2 kg/cm2 into the inlet side. Clean it when fuel filter cartridge is replaced. (2) Delivery test Make a test with the feed pump mounted on a pump tester as illustrated. 5) Testing (1) Suction capacity test Connect one end of a hose to the inlet side of the feed pump and immerse the other end of it into the fuel tank as illustrated. Hold the feed pump in position about 1 m above the level of fuel in the fuel tank. 30 before assembling it whether it is the fuel strainer bolt. Retaining nut 7. Adjusting screw 3. Connector 6. 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. DE12T) (1) Disassembly 1.4. Cap nut 2.DE12/T/TI/TIS MAINTENANCE MANUAL 4. Needle valve 8. 2001 PS-MMA0507-E1A . Spring 4. Nozzle 9. then burnt completely to achieve effective engine performance. Nozzle holder 141 MAINTENANCE of MAJOR COMPONENTS Printed in Mar. 2) 1-spring type (DE12. Push rod 5.4. Replace all the gaskets with new ones. Re-check the injection pressure and see if the spray pattern is normal. submerge the nozzle in diesel oil and clean it. Adjust the injection pressure to the standard After pressure the by spring injection tension shims. check the nozzle for fuel leakage. (3) Adjustment Remove the cap nut and assemble a nozzle to a nozzle tester.DE12/T/TI/TIS MAINTENANCE MANUAL (2) Reassembly After removing carbon deposit. (4) Testing With the nozzle assembled to a nozzle tester and pressure of specified applied. Operate the nozzle tester lever at the specified rate. tighten the cap nut to specified torque. adjusting pressure. With the adjusting screw loosened. 142 MAINTENANCE of MAJOR COMPONENTS Printed in Mar. Assemble the parts and tighten them to specified torque. 2001 PS-MMA0507-E1A . operate the nozzle 2 ∼ 3 times to bleed it. 2001 PS-MMA0507-E1A the primary opening . Push rod 3.DE12/T/TI/TIS MAINTENANCE MANUAL 3) 2-spring type (DE12TI. DE12TIS) This inspection data is base DE12TI engine. Install the plate of plate assembly (157944-9520) onto a vise. Adjusting screw 6. (1) Disassembly 1. Spacer 16. Gasket 31. Pin 17. Pin 15. Nozzle holder body 2. Eye bolt A. Gasket 7. Cap nut 10. 143 MAINTENANCE of MAJOR COMPONENTS Printed in Mar. Secondary spring 12. Lift pin 14. Adjusting shim 11. A (157944-9520) in fixing a nozzle having nozzle holder without flange should be directly installed onto a vise. NOTE : Use holder the plate a assembly flange. Retaining nut 30. Spring seat 13. Nozzle (2) Inspection and adjustment Adjusting pressure a. Primary spring 4. e. Install the nozzle holder body (1) onto the plate with the cap nut side facing downward. secondary spring (11). Assemble adjusting shim (10). c. and spacer (15) with the nozzle holder body. 144 MAINTENANCE of MAJOR COMPONENTS Printed in Mar. 2001 PS-MMA0507-E1A . Assemble the pin (14). install the two pins on the plate. lift piece (13). and spring seat (12) on the nozzle holder body in the order as described. d. Install the pin (16) and nozzle (A) onto the spacer. NOTE : The secondary spring is the same one as the primary spring. With the nut.DE12/T/TI/TIS MAINTENANCE MANUAL b. f. 0 ∼ 8. After the cap installing nut the gasket : (157892-1500) on the nozzle. 145 MAINTENANCE of MAJOR COMPONENTS Printed in Mar. Note : While tightening the cap nut. With the cap nut facing upward. NOTE : Tighten the retaining nut until it resists hand tightening. Be sure to follow the specified torque rating when tightening the adjusting retaining nut.DE12/T/TI/TIS MAINTENANCE MANUAL g. use (157892-4000 (6) (1) SW22mm) to fix the nozzle onto the nozzle holder.m (7) (7) i. keep checking to see if the lock pin comes all the way into the nozzle. 2001 PS-MMA0507-E1A .0 kg. Torque 6. install the nozzle holder on the plate. then further tighten it using a torque wrench. h. n.DE12/T/TI/TIS MAINTENANCE MANUAL j. Adjust pressure the to primary the opening specified pressure using the adjusting screw (4).m 146 MAINTENANCE of MAJOR COMPONENTS Printed in Mar. m.0 ～ 4. 2001 PS-MMA0507-E1A . and adjusting screw (4) on the nozzle holder in the order described. k. Assemble the nozzle and nozzle holder assembly to the nozzle tester (105785-1010). With a monkey wrench. Install the gasket and cap nut onto the adjusting screw. Assemble the push rod (2). primary spring (3).0 kg. l. fix the nozzle holder securely and tighten the cap nut (SW 19mm) to specified torque. Torque 3. e. Install gasket (026508-1140) and plug (157892-1600 : SW12mm) onto the adjusting retaining nut (1578921400). Install the holder into the cap nut.DE12/T/TI/TIS MAINTENANCE MANUAL ♦ Inspecting the needle valve for full lift a. d. 157892-4200 157892-4300 NOTE : "L" means the length of the pin except the threaded portion. 147 MAINTENANCE of MAJOR COMPONENTS Printed in Mar. 2001 PS-MMA0507-E1A to the dial gauge L (mm) 160 110 . c. Assemble the pin (157892-4200 or 157892-4300) (157954-3800). Part No. b. Install a nut (157892-1000 : SW 17mm) on the holder. Install the nozzle holder on the plate with the cap nut facing upward. and check for fuel leakage. h. NOTE 1 : Fix the dial gauge so that a stroke of 2 mm or so can be measured. 148 MAINTENANCE of MAJOR COMPONENTS Printed in Mar. Operate the nozzle tester and increase the tester pressure up to 350 ～ 450kgf/cm2 in order that the needle valve can be fully lifted.DE12/T/TI/TIS MAINTENANCE MANUAL f. Install the dial gauge on the holder assembly so that the pin is brought into contact with the upper end of the push rod. Operate the nozzle tester. bleed the retaining nut. then fix the pin with the nut. g. 2001 PS-MMA0507-E1A . Assemble the nozzle and nozzle holder assembly to the nozzle tester and zero the dial gauge. record the full lift value "L". NOTE 2 : Overtightening the nut may cause a sticking of the dial gauge seat. I. Then. If the nozzle tester handle is released with the needle valve engaged in a full lift condition. 2001 PS-MMA0507-E1A G1065 . the tester pressure drops. Take the indicated value on the dial gauge at the point of time when the secondary spring completes its λ operation and the needle valve puts an end to descent (the position of needle valve lift value " λ " as shown in the above and right figures) and check that the value is within the specified limit. ♦ Inspection of pre-lift a. 149 MAINTENANCE of MAJOR COMPONENTS Printed in Mar.DE12/T/TI/TIS MAINTENANCE MANUAL 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. being accompanied by decrease in the needle valve lift value (indicated value on the dial gauge). λ b. lift piece (13). 16). c. Release the nozzle tester handle to decrease the tester pressure. spacer (15). b. and nozzle assembly (A) with a new "nozzle service kit". 10kgf/cm2 while dropping the pressure. ♦ Inspection of secondary opening pressure a. If the measured pre-lift value deviates from the specified limit. 2001 PS-MMA0507-E1A . then take a note of the movements of the dial gauge. 150 MAINTENANCE of MAJOR COMPONENTS Printed in Mar. 1 0 kgf/cm2. replace the pin (14. After confirming the pre-lift. operate the nozzle tester and increase the internal pressure up to 350 ∼ 450 kgf/cm2 to fully lift the needle valve.DE12/T/TI/TIS MAINTENANCE MANUAL Measuring point for pre-lift Take the indicated value on the dial gauge at a point of primary opening pressure + approx. NOTE : Locate the point of primary opening pressure + approx. (In general. 2001 PS-MMA0507-E1A . Refer to following figure. readjust the primary opening pressure if the amount of deviation is small.) ♦ Adjusting secondary opening pressure a. and then measure the secondary opening pressure. (to the standard range of the primary opening pressure) If the secondary is lower value: opening than the the pressure standard Adjust primary opening pressure up to the top limit of the standard vague. In the event that the measured value deviates from the specified limit. Take the indicated value on the pressure gauge at the point of time when the needle of the dial gauge indicates the specified needle valve lift value.DE12/T/TI/TIS MAINTENANCE MANUAL c.05mm. pre-lift " λ " + 0. 151 MAINTENANCE of MAJOR COMPONENTS Printed in Mar. 5) Part No.5 .54 150538-5600 Thickness (mm) 0.60 0.50 150538-5400 150538-5100 0.DE12/T/TI/TIS MAINTENANCE MANUAL - If the secondary opening pressure is higher than the standard value: In a reverse manner. fit a thinner adjusting shim than the existing one. c. d. take off the nozzle fixing portion from the nozzle holder and remove the adjusting shim (10). 150538-4900 0. readjust the primary opening pressure down to the bottom limit of the standard value.56 0. 2001 PS-MMA0507-E1A . After replacing the existing adjusting shim.52 150538-5500 150538-5200 0. If the secondary opening pressure still deviates from the specified limit in spite of the readjusting the primary opening pressure.40 150538-5300 150538-5000 0. Inner diameter = φ 4.58 0. b.70 152 MAINTENANCE of MAJOR COMPONENTS Printed in Mar. If the secondary opening pressure is higher than the standard value. Adjusting shim for secondary opening pressure (Out diameter = φ 9. measure the secondary opening pressure and continue the adjustment until a value satisfying the standard value. Thickness (mm) Part No. lift piece. replace it with a new "nozzle service kit" integrated with a nozzle.DE12/T/TI/TIS MAINTENANCE MANUAL ♦ Retaining nut a. and oil leakage from each part. the amount of pre-lift will deviate from the specified value. and spacer as a complete set. holder and gasket from the cap nut.0 ∼ 8. (SW 19mm) Torque 6. 153 MAINTENANCE of MAJOR COMPONENTS Printed in Mar. NOTE : If only a nozzle is replaced. Remove the adjusting retaining nut and gasket.m (7) ♦ Inspection at completion a. nut. oil tightness of seat portion. b.0 kg. spray patterns. Assemble the nozzle holder to a nozzle tester and check the primary opening pressure. and install the original retaining nut. 2001 PS-MMA0507-E1A . b. When replacing the nozzle. Take out the dial gauge. correct Adjust Adjust Replace Replace Adjust Replace Check feed pump 5. Diagnostics and troubleshooting Complaints 1. Engine starts but stalls immediately Adjust Clean Bleed Disassemble. Engine lacks power 4. correct Clean Bleed Disassemble.DE12/T/TI/TIS MAINTENANCE MANUAL 4. Engine won't start 1) Fuel not being pumped Out from feed pump Possible causes ① Fuel pipes clogged or air into pipe fine ② Feed pump valve defective ③ Feed pump piston or Push rod sticking ① Fuel filter element restricted ② Air in fuel filter or injection pump ③ Plunger and/or delivery valve sticking or defective ① Injection pump not properly installed on pump bracket ② Injection pump tappet incorrectly adjusted ③ Cams on cam shaft worn excessively ① Needle valves sticking ② Fuel leaking past clearance between nozzle and needle valve ③ injection pressure incorrect ① Pipe from feed pump to injection pump clogged or filter clogged ② Air in fuel ③ Feed pump delivery insufficient ④ Fuel delivery insufficient due to clogging of fuel tank air breather ① Plunger worn excessively ② Injection timing incorrect ③ Delivery valves defective ④ Nozzle leaks excessively ⑤ Nozzle not working normally ① Injection timing too fast ② Nozzle injection pressure too high ③ Nozzles not working normally ① Injection timing incorrect ② Nozzle injection pressure too low ③ Nozzle spring broken ④ Nozzles not working normally ⑤ Plungers worn excessively ⑥ Delivery valves seat defective ⑦ Supply of fuel excessively Corrections Correct Replace Disassemble. Engine knocking Replace Adjust Replace Correct or replace Disassemble.4. correct Check. correct Replace Correct or replace Correct or replace 2) Fuel not being injected From injection pump 3) Fuel injection timing Incorrect 4) Injection nozzles inoperative 2. 2001 PS-MMA0507-E1A . correct Replace breather 3.5. correct Adjust Adjust Disassemble. correct Check. Engine knocks seriously producing excessive exhaust smoke 154 MAINTENANCE of MAJOR COMPONENTS Printed in Mar. correct Disassemble. 2001 PS-MMA0507-E1A . correct Disassemble. correct 7. correct Disassemble.DE12/T/TI/TIS MAINTENANCE MANUAL Complaints 6. correct Disassemble. correct Disassemble. Engine idling Unstable ② Governor defective ① Movement of control rod sluggish ② Operation of plungers unsmooth ③ Control pinions not engaged 0 with control rod correctly 155 MAINTENANCE of MAJOR COMPONENTS Printed in Mar. correct Disassemble. Engine output unstable ① ② ③ ④ ⑤ ⑥ ⑦ ⑧ ① Possible causes supply of fuel insufficient Air in fuel Water in fuel Operation of plungers unsmooth Movement of control rack sluggish Nozzles defective Injection starting pressure of each barrel incorrect Automatic timer defective Nozzles not working normally Corrections Check feed pump Bleed Replace fuel Disassemble. Engine does not reach maximum speed 8. correct Adjust Disassemble. correct Disassemble. 000 rpm 750 °C External oil supply 14 kg 2) Operating principle The turbocharger is a system designed to make use of the engine exhaust gas energy to charge high-density air into the cylinders.DE12/T/TI/TIS MAINTENANCE MANUAL 4.0 m3/min DE12TIS GT42 Approx. 22.5.000 rpm Approx. allowable temperature of exhaust gas at turbine inlet Lubricating system Weight DE12T TBP45 Approx.1.800 rpm 750 °C External oil supply 14 kg 2 DE12TI T45 Approx.2 kg/cm2 Approx. Main data and specifications 1) Main data and specifications Specification Turbocharger Model Air pressure at compressor outlet Air suction volume Speed of turbine revolution Maximum allowable speed Max. 96.5 m3/min At maximum output Approx. 90. Turbocharger 4. 20.000 rpm 750 °C External oil supply 14 kg 109. 1. 2001 PS-MMA0507-E1A . 156 MAINTENANCE of MAJOR COMPONENTS Printed in Mar. 1.5. thereby to increase the engine output.15 kg/cm Approx. 94.0 3 m /min Approx.000 rpm 112.000 rpm 113.3 kg/cm2 Approx. 1. 22. 2001 PS-MMA0507-E1A .DE12/T/TI/TIS MAINTENANCE MANUAL 3) Construction 1 2 3 4 5 6 7 8 9 Bolt Clamp Lock nut V-band O-ring Compressor housing Lock nut V-band Turbine housing 10 11 12 13 14 15 16 17 18 Lock nut Compressor wheel Piston ring Wheel assembly Wheel shroud Bolt Plate assembly Piston ring Thrust spacer 19 20 21 22 23 24 25 Seal ring Screw Thrust bearing Thrust collar Retainer ring Journal bearing Housing assembly 157 MAINTENANCE of MAJOR COMPONENTS Printed in Mar. takes in and compresses ambient air with rotating force transmitted from the turbine shaft.2. the greater engine output can be obtained as a greater volume of air charged into the cylinders burns so much more fuel. the volume of air enough to burn the fuel completely should be supplied into the cylinders. which is connected to the turbine over the one and same shaft to form a rotating body. the compressing of air to supply into the cylinders is called "Supercharging" and the making use of the energy of exhaust gas discharged from the combustion chamber to charge the compressed air into the cylinders is called "Turbocharging".5. As the dual oil film plays a role as a damper. 4) Sealing-Compressor shaft The compressor is of a dual construction type composed of seal plate and seal ring 158 MAINTENANCE of MAJOR COMPONENTS Printed in Mar. General descriptions The engine output is determined by the fuel delivery volume and engine efficiency. 4. Therefore. Functions 1) Turbine Exhaust gas discharged from the combustion chamber distributes its own energy to the turbine blades while passing the inside of the turbine housing. To burn the supplied fuel completely to change into effective power for the engine. 3) Bearings (1) Thrust bearing The turbine wheel creates thrust force. resulting in assurance of stability in its movement. Then. As explained. the engine output is determined substantially by the cylinder capacity.DE12/T/TI/TIS MAINTENANCE MANUAL 4. the sliding speed of the bearing surface becomes lower than the rotating speed of the shaft. with the result that the turbine shaft can get rotating force. the compressed air is delivered to the intake stake. and a greater volume of compressed air is charged into cylinders of given capacity.5. exercise care so that the shaft is not deviated from its the original position due to this thrust. This is the operating principle of 'turbine'. Therefore. 2) Compressor The compressor.3. (2) Journal bearing This journal bearing of floating type forms a dual oil film on both the inside and outside of the bearing so that the bearing can rotate independently. This is the operating principle of the compressor. which is mounted with seal rings and heat protector to prevent exhaust gas from affecting the bearings adversely. 2001 PS-MMA0507-E1A . DE12/T/TI/TIS MAINTENANCE MANUAL to prevent the leak of compressed air or lubricating oil. and air oil. be damaged beyond repair. such parts that a sufficient amount of oil has not reached can be seized up. and air. loosen the oil pipe connections and operate the starter motor until oil is discharged. Precautions for operation 1) Precautions for operation of engine The following precautions should be observed when starting. being operated at high load. oil 3) In the case of the engine stopped for extended time or in a cold filter element. 2) If unusual sound or vibration is 2) The engine Is operated heard or felt. gas. or lubricating place. be sure to retighten the oil pipe connections portion before starting the engine. 159 MAINTENANCE of MAJOR COMPONENTS Printed in Mar. or when having stopped pipes can be deteriorated the engine for extended period of time. it can cause. gas. bearing due to insufficient supply of oil.8 kg/cm2 1) Excessively low oil pressure causes unusual wear or seizure of or more At full load: 3. 2) Check each part for leakage of 2) Leakage of oil. or in a cold place.8 the bearing. and take proper (especially. in oil pressure and loss of oil results in seizure of the bearing.5.0～4. oil leak) causes drop measure. 4. or stopping the engine: Operations When starting the engine Precautions 1) Check oil level Reasons Immediately after starting During operation When stopping the engine 2) Crank the engine with starter to 2) Abrupt starting of the engine check the increase in oil causes the engine to rotate with pressure(until the needle of oil not being distributed not only pressure gauge starts to move or to each part but also to the pressure indicator lamp is turbocharger. oil fluidity within the parts. resulting in actuated) before starting the abnormal wear or seizure on the engine. operating.4. reduce engine continuously with unusual sound revolutions slowly and locate the or vibration not corrected. After completing the operation. 2001 PS-MMA0507-E1A . Check the followings: 1) Oil pressure At idle: 0. heat from the red-hot turbine blades is transmitted to the bearing portion and burns oil to cause seizure of the bearing metal and rotating shaft. Too high pressure kg/cm2 causes oil leakage. abruptly applied with the engine and turbocharger rotating unsmoothly. 1) Run the engine at idle for 5 1) Applying load abruptly If load is minutes after starting off. 3) When having replaced oil. 1) Run the engine at idle for 5 1) If the engine is put to a stop after minutes before stopping. 2001 PS-MMA0507-E1A . the cleaner draws in oil to foul the case. Therefore. lowers charging effect. cleaning effect is poor. Suggested engine oils for the turbocharger-mounted engine are as follows: 160 MAINTENANCE of MAJOR COMPONENTS Printed in Mar. Walk-around check and servicing As the condition of turbocharger depends greatly on how well the engine is serviced. turbocharger fixing portions. In addition. Besides of it. etc. 4) Lubricating system Pay particular attention to oil quality and oil filter change intervals when servicing the lubricating system. if the rotor is fouled. if the level of oil surface is lower than specified. temperature of exhaust gas rises up to affect the turbocharger adversely.5. it is very important to use a good quality air cleaner all the time. In the case of wet-type air cleaner. it is very important to maintain the engine in accordance with the specified maintenance procedure. the turbocharger rotates at excessively rapid speed and may suffer damage. the sophisticatedly-tuned balance is broken to create vibration and to cause seizure and unusual wear to the bearing. do not interchange these nuts with ordinary steel nuts. if too high. it is essential to clean it to reduce intake resistance as much as possible. To avoid such trouble. 1) Intake system Pay particular attention to the air cleaner when servicing the intake system. apply anti-seizure coating to fixing nuts on the portions as designated. 2) Exhaust system Pay particular attention to prevent gas leaks and seizure when servicing the exhaust system because leakage of exhaust gas from discharge pipes. Deteriorated engine oil affects adversely not only the engine but torso the turbocharger. if spray pattern from the fuel injection nozzles is bad or the injection timing is incorrect. 3) Fuel system If the full load stopper regulating the maximum injection volume and the maximum speed stopper regulating the maximum speed in the fuel injection pump are adjusted without using a pump tester.DE12/T/TI/TIS MAINTENANCE MANUAL 4. In the case of dry-type air cleaner. be sure to make a nozzle test. Especially. As such components as turbine chamber that becomes red-hot during operation use heat resisting steel nuts.5. the turbocharger should be replaced or repaired. If a sound detecting bar is used. it means that the rotor assembly is not normal. Periodical checking and servicing Make it a rule to check the turbocharger assembly for condition and contamination periodically. ACEA-E3 oil must be used. In this case. If a high-pitch sound is heard continuously. 2001 PS-MMA0507-E1A . install its tip on the turbocharger housing and increase the engine revolutions slowly. above CD or CE ACEA-E2 or ACEA-E3 (API CH-4) * If long oil change intervals are to be used. DE12/T/TI DE12TIS SAE 15W40 SAE15W40 SAE10W40 API No. (1) Rotor axial play 161 MAINTENANCE of MAJOR COMPONENTS Printed in Mar. When disassembling the turbocharger. then check the rotor axial play and radial play. 2) Guide for checking rotor end play Disassemble the turbocharger from the engine.5. 4. as the metal bearing and rotor are likely to be in abnormal conditions.6. 1) Guide for checking the rotor for rotating condition The inspection of the rotor assembly for rotating condition should be performed by the degree of unusual sound. etc. be sure to plug the oil inlet and outlet ports with taps.DE12/T/TI/TIS MAINTENANCE MANUAL Recommend oil Engine model SAE No. 162 MAINTENANCE of MAJOR COMPONENTS Printed in Mar. (2) Intake system Check the inside of the intake system for foreign matters. replace or repair the turbocharger. Clean not only the pipes installed between the engine and oil inlet port but also the oil outlet pipe and check them for damage or foreign matters. exercise extreme care to prevent foreign matters from entering the inside of the turbocharger. (1) Lubricating system Before reassembling the turbocharger onto the engine. be sure to observe the following precautions: Especially. inject new oil in the oil inlet port and lubricate the journal and thrust bearings by rotating them with hand . Assemble each joint on the intake duct and air cleaner securely to prevent air leaks. 2001 PS-MMA0507-E1A . Assemble each joint on oil pipes securely to prevent oil leaks.DE12/T/TI/TIS MAINTENANCE MANUAL (2) Rotor radial play (3) If the measured axial and radial plays are beyond the limit of wear. 3) Guide for disassembling/cleaning and checking the turbocharger First. disassemble the turbocharger from the engine and clean/check it with the oil inlet and outlet plugged with tape and so on. 4) Precautions for reassembling the turbocharger onto the engine For reassembly of the turbocharger or handling it after reassembly operation. Unusual sound or vibration 163 MAINTENANCE of MAJOR COMPONENTS Printed in Mar. 2001 PS-MMA0507-E1A . Do not interchange them with ordinary steel bolts and nuts when performing reassembly operation. Assemble each joint on the exhaust pipes securely to prevent gas leaks 4. Diagnostics and troubleshooting Complaints 1. Apply anti-seizure coating to the bolts and nuts. Excessive white smoke 3.5.DE12/T/TI/TIS MAINTENANCE MANUAL (3) Exhaust system Check the inside of the exhaust system for foreign matters. Be sure to use heat resisting steel bolts and nuts. Low engine output 4.7. Excessive black smoke Possible causes 1) Air cleaner element clogged 2) Restrictions in air duct 3) Leakage at intake manifold 4) Turbocharger seized up and not rotating 5) Turbine blades and compressor blades coming in contact with each other or damaged 6) Exhaust piping deformed or clogged 1) Oil leak into turbine and compressor 2) Worn or damaged seal ring due to excessive wear of bearing 1) Gas leak at each part of exhaust system 2) Air cleaner element restricted 3) Turbocharger fouled or damaged 4) Leakage at discharge port on compressor side 1) Rotor assembly coming in contact 2) Unbalanced rotation of rotor 3) Seized up 4) Each joint loosened Corrections Replace or clean Check and correct Check and correct Disassemble/repair or replace Disassemble/repair or replace Check and correct Disassemble/repair or replace Disassemble/repair or replace Check and correct Replace or clean Disassemble/repair or replace Check and correct Disassemble/repair or replace Disassemble/repair or replace Disassemble/repair or replace Check and correct 2. 5 M6 8.5 M16 x 1.9T 10.m 4.m 166 APPENDIX Printed in Mar.4 kg.m 2nd : 180° Finished : 150° (angle torque) Remarks Dodecagon 10.5 M14 x 1.m Remarks M6 M10 M10 M24 x 1.m 1st : 15 kg.m 13.8T 8.5 M12 x 1.m 2nd : 25 kg.m 1st : 6kg.m 3.8T 12.5 kg. 2001 PS-MMA0507-E1A .0 kg.0 kg.8T 8.8T 1.m 2nd : 22 kg.9T Cylinder head bolt M14 x 1.m 1.m 2nd : 90°+90° Finished : 30° (angle torque) hexagon Dodecagon Cylinder head cover bolt Connecting rod bearing cap bolt M8 M16 x 1.4 kg.m Split type Tightening torque for injection pump system Major Parts Injection nozzle holder nut Injection pump bracket Injection pump coupling bolt Injection pump driving gear nut High pressure injection pipe fixing cap nut Injection holder pump delivery valve Screw (Diameter x pitch) Strength (grade) Tightening Torque 1.0 kg.9T 12.9T 10.DE12/T/TI/TIS MAINTENANCE MANUAL APPENDIX Tightening torque for major parts Major Parts Screw (Diameter x pitch) Strength (grade) Tightening Torque 1st : 6kg.0 kg.8T 8.m 2nd : 30 kg.0 kg.m 6.9T 12.0 kg.m 13 ∼ 14 kg.m 1st : 15 kg.9T 8.5 M14 x 1.m 2nd : 30 kg.m 18.2 kg.m Crankshaft main bearing cap bolt Balance weight fixing bolt Flywheel fixing bolt Crankshaft pulley fixing bolt Oil spray nozzle 14.5 - 8.0 kg.8T - 25.5 M14 x 1.5 12T 24. 4 5 7.5 18.5 25 0.5 M20 M20x1.8 (5S) 6.6 6.6 11 12.77 1.5 3.2 4.5 24.4 8.9 8.8 M10 1.28 0.0 16.25 1.5 0.0 M30 18.1 4.35 1.5 2.9 (10K) 12.5 16 18 21 24 27 31 0.75 1.5 2.3 9.7 1.5 M16 M16x1.5 M22 M22x1.5 16.5 6.5 19.9 1.5 22 25 30 34 40 45 0.5 M18 M18x1.0 M38 30.78 1.2 5.75 0.7 0.8 M12 2.6 (5D) 5.28 0.3 6 6.4 4. For example. Special screws should be tightened to 85% or so of the standard value.83 1.4 0.2 2.7 11.0 16.9 (12K) (6G) (8G) 2 Limit value for elasticity (kg/mm ) 20 24 32 30 40 36 48 54 64 90 108 Tightening torque (kg.5 16 18.8 4.1 11.22 0.m) M5 M6 M7 M8 M8x1 M10 M10x1 M12 M12x1.9 4.DE12/T/TI/TIS MAINTENANCE MANUAL Standard bolt tightening torque table Refer to the following table for bolts other then described above Degree of strength 3.2 7 10.5 28 33 37 0.5 17 20.5 11.34 2.35 2.5 2.5 35 42 47 55 61 0.1 2.1 1.9 0.25 1.4 1.5 35 39.3 11.4 20 22 31 33 43 49 60 68 75 85 92 103 Others : 1.63 1 1.31 0.85 1.5 23 0.5 12.16 0.73 1.5 5.3 4.0 35.6 9 9.0 11.4 2.55 0.48 0.2 2.2 7.2 1.4 1. 3.5 10. The above torque rating have been determined to 70% or so of the limit value for bolt elasticity.5 M24 M24x1.5 16 18.6 2.4 2.9 7.5 13.95 3.5 46 52 58 67 0.0 4.8 10 11.6 1.6 (4D) 4.5 M14 M14x1.6 7 7.5 21.2 7.43 0.0 3.5 26 28 36 41 51 58 67 75 82 93 0.5 14.5 4.0 11.1 17.9 2.8 10.5 8.43 0.9 17 21 24.5 26 29 34 38 0.35 6.46 0.0 20.8 9.5 M18 5.5 5.8 1.3 14.15 0.5 11.7 4.8 4.0 M16 4.5 24.1 7.2 27. 2.2 2.2 17 18.7 5 7.5 12 13.1 3.3 2.45 0.5 12.35 3.8 (4S) 5.5 M22 9.8 1.7 3.4 12.0 M14 3.9 2.8 (6S) 6.6 Diameter x pitch (mm) (4A) 4.7 4.30 0.7 19 22.5 5. 2001 PS-MMA0507-E1A .7 3. Tension is calculated by multiplying tensile strength by cross section of thread.1 1.5 8 12 13 18 20 25 28 36 41 49 56 63 74 0.0 M26 13.7 4 6 6.0 ★ : Adopted in DAEWOO engine 167 APPENDIX Printed in Mar.1 5.5 2.5 12. Tightening torque for hollow screw(4-hole) Material SM25C ★ SUM22L STS304 M8 0.7 8 8.3 6.25 0.1 3.55 3. a screw coated with MoS2 should be tightened to 60% or so of the standard value.0 35.8 15.5 18 20.5 31.5 3.0 20.2 4.7 12.8 0.3 6.5 8.5 6.3 3.47 0.6 (6D) 6.5 0.1 3. 113~0.70 0.30~0.3 114.05 4 0~0.55 113.5 3.45 0.023 φ123.03~0.DE12/T/TI/TIS MAINTENANCE MANUAL Maintenance specification table Stand value for assembly Limit for use Group Part Check Inside diameter of cylinder liner for wear Correction Remark Measure unworn portion beneath the rim of upper side φ123~φ123.223 Replace liner 0.30~0.5 0.15 Replace ring or piston Install ring by 120°C Standard gauge inside diameter : φ123 Replace piston if groove width is beyond specified value Measure unworn portion beneath the rim of upper side In case of new valve and seat Replace cyl. head Replace if leaky Water temp.102 0.07~0.35~0.50 0.08 0.060 0~0.5 1.12 ±15g 0. 70°C Correct with a surface grinder Per distortion length for 200mm Clearance between piston and liner Width of piston ring grooves Top ring 2nd ring Oil ring 0.15 0.9 96g 1.5 1.060~3.55 0.887 Engine body Projected portion of Cylinder liner block & The upper surface of liner cylinder block of distortion Hydraulic test for 1 minute (kg/cm2) Valve seat Intake Cylinder depression Exhaust head & Height valve Hydraulic test for 1 minute (kg/cm2) Piston diameter (18mm from the lower side) 0.05~0.30~0.95 ~115 4 φ122.085 - Piston Major moving parts Piston projection from cylinder block upper surface Permissible weight difference of each piston Piston ring Top ring gap 2nd ring Oil ring Piston ring Piston ring groove clearance Top ring 2nd ring Oil ring * mark DE12TIS Limit for use if for standard clearance Direction of ring gap 168 APPENDIX Printed in Mar.040~4.50 * 0. 2001 PS-MMA0507-E1A .3 0~0.873~φ122.152 3.080 4. 01 0.966~φ82.03 0.02 0.860~φ59.025 0.10~0.20 idle gear Between idle gear & 0.5 Replace bearing Measure in the position of crown Crank shaft End play of crankshaft Run-out of crankshaft Balance of crankshaft Tightening torque of journal bearing cap bolt (kg.072~0.050~0.25 0.025~0.05 Limit for use 0.22 ~ 0.m) Outside diameter of cam φ59.13~0.15 hole End play of idle gear 0.12 - After completing of bearing loosen one stud bolt & measure Cam shaft Timing gear Permissible weight difference of each con±18 g rod Tightening torque of con-rod bearing cap bolt 28 (kg.15 or Adjust by a press less if bent Check dynamic 60 or less balance Apply oil to bolt No.3 shaft Between crank gear & 0.142 0.966 0.880 φ59.086~0.116 0.13 Replace oil seal if oil leaking Replace bearing Replace con.DE12/T/TI/TIS MAINTENANCE MANUAL Group Part Check Axial run-out of journal and pin Outside diameter of journal Outside diameter of pin Out of round of journal and pin Permissible radial run out of journal and pin Permissible taper of journal and pin Clearance between crankshaft and bearing Stand value for assembly 0.988 φ81.128 0.-rod Major moving parts Oil seal for wear Clearance between conrod bearing & crank pin End play of con-rod crush Clearance between small end bush & piston pin Connecting Connecting rod bearing rod crush height 0. 2001 PS-MMA0507-E1A .988 φ94.10~0.1 60 30 0.080 0.03 0.4 bearing (holding no.20 camshaft gear Apply oil to bolt φ60 Replace thrust plate Replace thrust collar Replace gear 169 APPENDIX Printed in Mar.27 0.966 φ82.20 0.1 Correction Correct with a grinder Replace crankshaft Replace crankshaft Remark In horizontal and vertical directions φ96 g6 φ83 g6 φ95.966~φ95.119 0. 1 & 7) Measure at 400 rpm No foreign .049 ~ 0.30 Clearance between idle gear shaft and inserting 0.008 0.15~0.050~0.091 0.matters on bearing cap installing surface Measure by tightening metal cap & then loosening one stud bolt Replace with new one.319 0.5 0. use shim 0.52 shaft Clearance between cam 0.m) Journal bearing crush Replace thrust bearing 0.043~0.325 0.167 0.11~0.20 shaft and bush Axial play of camshaft 0. 5 65 Valve * 76.2 170 APPENDIX Printed in Mar.8 * 74.1 Inner Exhaust spring Outer Spring tension 36.84 of exhaust valve stem Clearance Intake 0.25 72 * 82.4 1.0 (against free * 1.2 Replace 0.75 * 1.7 length) Intake Exhaust 0.065 0.1 34mm) kg Straightness 1.8 Apply oil to valve guide & press in * 74.4 37mm) kg Straightness 1.093 0.9 61.4 2.3 1 or more 0.3 - * 45.4~82.8~68.4~82.0 61.DE12/T/TI/TIS MAINTENANCE MANUAL Group Valve system Part Check Stand value for assembly Limit for use Correction Replace valve & guide Replace valve & guide Replace Replace Remark Replace valve guide together when replacing valve Outside diameter φ10.080 0.5 * 85.8~68.5 length) 75.1~39.15 between valve stem and valve Exhaust 0.1 2. head installing hole Clearance between valve Intake guide & valve Exhaust spring seat Free length Intake spring Spring tension (set length: 37mm) kg Straightness (against free length) Free length 0.5 61.5 1.87 of intake valve stem Outside diameter φ10.39 22 22 75.4 * 72 36.4 2.9 or more Valve Perm.5 Free length * 85.020~0.030~0.01 ~ 0.5 61.0 (against free * 1. 2001 PS-MMA0507-E1A .0 72 Replace valve spring * Mark DE12TIS * 82.970 φ10.3 tension (set length: * 74.935~φ10.3 0.950~φ10.18 guide Thickness of valve Intake Exhaust 1. radial Intake run-out between valve stem & Exhaust valve head Clearance between valve guide & cyl.1~50.955 φ10.0 - Replace valve spring Valve clearance (at cold) Adjust Correct or replace if severely pitted on tip of arm and stem Replace bush or shaft Contacting face of valve stem & rocker arm Clearance between rocker arm shaft & rocker arm bush 0.9 (set length: * 45.03 0.0 * 74.5 0.03 0.9 Spring 61.045~0. 978~φ23.3 element (kg/cm2 ) By-pass valve for full oil Valve 4.DE12/T/TI/TIS MAINTENANCE MANUAL Rocker arm shaft for wear Permissible taper of push rod φ23.939~φ27.7 valve (kg/cm2 ) By-pass valve for filter 1. permissible oil temperature °C Oil Permissible temp.965 - Limit for use 0.5 ~ 1.8 Clean or replace Replace valve 171 APPENDIX Printed in Mar.040~0.944~φ19.068 hole Clearance between drive 0.082 gear bushing & cover hole Outside diameter φ16.15~0.5 0.4 (idling) kg/cm2 Max.25 intermediate gear Oil pressure control 4.035~0.5 pump (kg/cm2 ) Control valve for spray 1.950~φ16.8 nozzle (kg/cm2 ) Oil Oil filter element for filter damage Temperature above this not allowable Replace gear or cover - Replace bushing or cover Replace gear Replace bushing φ17e7 φ28e7 0.959 φ23.077 φ19.960 of drive gear bushing Between crank gear & oil 0.3 ~ 4.15~0.3 - Replace Replace Group Part Check Clearance between tappet & cylinder block Outside diameter of tappet Contacting face of tappet & cam Oil pressure (normal speed) kg/cm2 Stand value for assembly 0.15 - Correction Replace tappet Replace tappet Replace if excessively worn of deformed Correct oil leakage and clearance between each part Use suggested oil Remark Valve system Tappet Oil pressure 4.0 ~ 4.032~0.8 Adjust backlash 0.8 ~ 2. 2001 PS-MMA0507-E1A .105 of oil pump gear Clearance between gear shaft & oil pump over 0.8 filter (kg/cm2 ) opening pressure By-pass valve2for oil 5~6 cooler (kg/cm ) Relief valve for oil 8.25 pump drive gear Backlash Between oil pump drive gear & 0.055~0.5 or less 3. oil temperature in short time °C Axial play 0.75 0.8~1.5 ~ 11.6 105 120 - Lubricating system Oil pressure 0.968 of gear shaft Oil Outside diameter pump φ27. 6 DE12/T/TI : 3. bad packing other Fuel filter element for damage Injection pressure of injection Fuel nozzle (kg/cm2) system Operating pressure of overflow valve (kg/cm2) Height of projected nozzle on the cylinder head (mm) Misalignment between injection pump coupling and coupling (mm) Running-in the engine Inspection at completion Cylinder DE12/T : 220 1.6 90~95 103 83 95 or lower - 95 103 - Replace if defective Stroke : min.5 - 0.Water temp.100rpm .5 With pump bracket Retighten head bolt after running in DE12TI/TIS 1st :160 .4~2. nozzle tube or seal ring Adjust by shim Refer to supplement “running-in” Overhaul the engine Correct at 200rpm or more (20°C) DE12TIS : 2.) °C Permissible temperature in a short time °C Thermostat opening temp.2 - Approx.Back pressure : 1 kg/cm 0. & the looseness. 350 Replace if contacted impeller & pump body Temperature above this not allowable Cooling water temp Thermostat Clearance between pump impeller & pump body Operating temperature (permissible temp. 8mm Correct or replace Full operating temp.DE12/T/TI/TIS MAINTENANCE MANUAL Group Part Check Radiator & water pump for corrosion.4~3.5 24 or more - Clean or replace Adjust by shim Replace valve Replace cylinder head. 2001 PS-MMA0507-E1A .0 - Radiator Cooling system Water pump Pressure valve for opening pressure (kg/cm2 ) Negative pressure valve for opening pressure (kg/cm2 ) Delivery volume l/min . °C (under atmospheric pressure) 0.2 or less 24 ~ 28 ±10% or less against average Cylinder compression pressure of cylinder (kg/cm2) Compression pressure difference of each cylinder pressure 172 APPENDIX Printed in Mar. °C Fuel pipe. 2nd : 220 0. injection pipe & nozzle holder for Piping damage. damage & improper connecting Test for leakage (air pressure) (kg/cm2 ) Stand value for assembly - Limit for use - Correction Correct or replace Submerge in water and replace if air bubbles found Remark 1.3~0.Engine speed 2. cracks. 24°C 2 .
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