Daewoo ST Series Operating instructions

Daewoo ST Series Operating instructions
FOREWORD
This manual is designed to serve as an instruction for the Operation & Maintenance of marine
propulsion engines (L136/T/TI/086TI) and marine auxiliary engines (AD136/T/TI/086TI), combined in
one book.
The first half is explained for operation and the latter half is described for maintenance like
disassembling, inspecting and re-assembling etc in order to help an understanding for the
maintenance procedure more easily.
To keep the best performance and the durability of engine 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
Adjustment
Installation
Cleaning
Disassembly
Pay close attention-Important
Reassembly
Tighten to specified torque
Align the marks
Use special tools of manufatur’s
Directional Indication
Lubricate with oil
Inspection
Lubricate with grease
Measurement
Some figures of this manual may be different from the actual appearance of the engine
because of explaining them with the representative figure among these models.
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 manual instruction may be changed without prior notice for
some quality improvement. Thank you.
Sep. 2003
DOOSAN Infracore Co., Ltd.
CONTENTS
Operation Parts
1. Specification ......................................................................................................................... 1
1.1. Engine Specification
1.3. Engine Performance Curve
1.2. Engine Aspects
1.4. Engine Model & Serial Number
2. Safety Regulations .............................................................................................................. 8
2.1. General Notes
2.4. Regulations Designed to Prevent Pollution
2.2. Regulations Designed to Prevent
Accidents with Injury to Persons
2.5. Notes on Safety in Handling Used Engine Oil
2.3. Regulations Designed to Prevent
Damage to Engine and Premature Wear
3. Commissioning and Operation ..................................................................................... 12
3.1. Inspections Before Operation
3.5. Check After Initial 50 Hours Operation
3.2. Starting
3.6. Operation in Winter Time
3.3. Engine Break-in
3.7. Tuning the Engine
3.4. Inspection After Starting
4. Maintenance and Care ..................................................................................................... 21
4.1. General Instructions
4.6. Fuel System
4.2. Periodical Inspection & Maintenance
4.7. Electric System
4.3. Cooling System
4.8. Cylinder
4.4. Lubrication System
4.9. Engine Preservation Points for a Long Time
4.5. Intake & Exhaust System
4.10. Management for Sunken Engine
5. Main Accessory Parts ...................................................................................................... 43
5.1. Reduction Gear
5.3. Propeller Selection
5.2. Front Power Take-Off (F.P.T.O)
5.4. Electric System
Maintenance Parts
6. Disassembly and Assembly of Major Components ................................................. 50
6.1. Disassembly
6.3. Engine Re-assembly
6.2. Inspection
6.4. Break-in After Maintenance
7. Main Parts Maintenance ................................................................................................ 105
7.1. Lubricating System
7.3. Fuel System
7.2. Cooling System
7.4. Turbocharger
8. Trouble Shooting ............................................................................................................. 166
9. Special Tool List................................................................................................................ 172
10. Tightening Torque........................................................................................................... 174
11. Maintenance Specification Table for Major Parts .................................................. 176
• Part & After service center
• Applications for Doosan Engine
1. Specification
1.1. Engine Specification
1.1.1. L136/T/TI
Model
Spec.
Units
L136
L136T
4 cycle, in line,
direct- injection,
water cooled
naturally aspirated
Engine type
Rating output (B.H.P)
Displacement
PS(kW)/rpm
L136TL
160(118)/2,200
200(147)/2,200
240(177)/2,500
mm
Valve clearance at cold
mm
In. : 0.3 , Ex. : 0.3
Low idling rpm
rpm
725 ± 25
No load max. rpm
rpm
6-
111 x 139
below 2,400
Mean effective press. (Initial )
kg/cm
Mean piston speed
m/sec.
2
Compression ratio
8.07
below 2,750
below 2,400
10.71
11.66
11.58
10.19
10.14
10.19
17.6
Max. firing pressure of cylinder
kg/cm2
Comp. pressure (at 200 rpm)
kg/cm
16.7
80
117
128
106
28 ( Initial condition)
2
Governor type of injection pump
Inj. nozzle opening pressure
230(169)/2,200
8,071
Cyl. No. – bore( ) x stroke
Injection timing (B.T.D.C)
4 cycle, in line,
direct- injection,
water cooled
with turbo charger
& inter-cooler
4 cycle, in line, direct- injection,
water cooled with turbo charger
cc
Fuel consumption
L136TI
Mechanical all speed (R.S.V)
g/PS.h
165
155
172
162
liter/h
32
37
50
45
18° ± 1°
deg.
kg/cm
14° ± 1°
214 + 8
2
Starting system
Electric Starting by starter motor
Starter motor capacity
V- kW
24 V – 4.5
Alternator capacity
V- A
24 V – 50
Battery
V- Ah
24V – 150
Cooling system
Indirect cooling by sea water with heat exchanger
Cooling water capacity
lit
Max. : 27 , Min. : 25
Fresh water pump type
Centrifugal type, driven by V- belt
Sea water pump type
Rubber impeller type driven by gear
Lub. Oil
(Engine)
Pan capacity
lit
Max : 23, Min : 17 ( Engine total : 25)
Pressure
kg/cm2
Full : 3.5, Idle: 1.2
Direction of
revolution
Crankshaft
Counter clockwise viewed from stern side
Propeller
Clockwise viewed from stern side
Engine size
(L x W x H)
Without M.G
mm
1,182 x 770 x 925
1182 x 766 x 925
1,182 x 825 x 925
With M.G
mm
1,546 x 770 x 937
1,541 x 766 x 963
1,552 x 825 x 1,027
Engine
dry weight
Without M.G
kg
735
745
773
With M.G
kg
920
935
994
-1-
1.1.2. L086TI
Model
Spec.
L086TI
Units
L086TIH
L086TIM
L086TIL
4 cycle, in line, direct- injection, water cooled
Engine type
with wet-turbo charger & inter-cooler
Rating output (B.H.P)
Displacement
PS(kW)/rpm
285(210)/2,100
300(221)/2,300
cc
360(265)/2,500
8,071
Cylinder No. - bore( ) x stroke
mm
Valve clearance at cold
mm
In. : 0.3, Ex. : 0.3
Low idling rpm
rpm
750 ± 25
No load max. rpm
rpm
6-
111 x 139
below 2,310
below 2,530
below 2,750
Mean effective press. (Initial )
kg/cm
15.14
14.55
16.06
Mean piston speed
m/sec.
9.73
10.66
11.58
2
Compression ratio
16.7
Max. firing pressure of cylinder
kg/cm2
Comp. pressure (at 200 rpm)
kg/cm
130
Injection timing (B.T.D.C)
Inj. nozzle opening pressure
130
Mechanical all speed (R.S.V)
g/PS.h
152
163
170
liter/h
52
62
74
deg.
15° ± 1°
kg/cm2
214 + 8
Starting system
Electric Starting by starter motor
Starter motor capacity
V- kW
24 V - 4.5
Alternator capacity
V- A
24 V - 50
Battery
V- Ah
24V - 150
Cooling system
Indirect sea water cooling with heat exchanger
Cooling water capacity
lit
Max. : 25 , Min. : 23
Fresh water pump type
Centrifugal type, driven by V- belt
Sea water pump type
Lub. Oil
(Engine)
Pan capacity
Direction
of
revolution
Crankshaft
Engine size
(L x W x H)
Engine
dry weight
135
above 28 (Initial condition)
2
Governor type of
injection pump
Fuel consumption
15.3
Pressure
Rubber impeller type driven by gear
lit
kg/cm
Max : 23, Min : 17 (Engine total : 25)
Full : 3.5, Idle: 1.2
2
Counter clockwise viewed from stern side
Propeller
Clockwise viewed from stern side
Without M.G
mm
1,182 x 825 x 962
With M.G
mm
1,557 x 825 x 1,062
Without M.G
kg
790
With M.G
kg
1,015
Note : L086TIL model is not available right now but shows only the development target in
future.
-2-
1.1.3. AD136 / T / TI / 086TI
Model
Spec.
Units
AD136
AD136T
AD136TI
4 cycle, in line,
4 cycle, in line,
4 cycle, in line,
4 cycle, in line,
direct- injection,
direct- injection, direct- injection, direct- injection,
water cooled with water cooled with
water cooled
water cooled with turbo charger & wet-turbo charger
turbo charger
naturally aspirated
inter-cooler
& inter-cooler
Engine type
50 Hz
Rating output
(B.H.P)
PS(kW)
/ rpm
60 Hz
Displacement
105(77) / 1,500
(AD136F)
145(107) / 1,500
(AD136TF)
157(115) / 1,500
(AD136TIF)
205(151) / 1,500
(AD086TIF)
126(93) / 1,800
(AD136S)
170(125) / 1,800
(AD136TS)
188(138) / 1,800
(AD136TIS)
253(186) / 1,800
(AD086TIS)
cc
8,071
Cylinder No. - bore( ) x stroke
mm
Valve clearance at cold
mm
0.3 / 0.3
Low idling rpm
rpm
725 ± 25
No load max. rpm
(50Hz / 60Hz)
rpm
6-
111 x 139
Mechanical governor : 1575 (52.5 Hz) / 1890(63Hz),
Electric governor
Mean effective press. (Initial )
kg/cm
Mean piston speed
m/sec.
2
Compression ratio
7.81 / 7.81
: 1575 (52.5 Hz) / 1890(63Hz),
10.78 / 10.53
11.65 / 11.65
kg/cm
Comp. Press. (at 200 rpm)
kg/cm
2
16.7
74.4 / 79.5
105 / 117.3
109.1 / 127.5
109.1 / 127.5
About 28 (Initial condition)
2
Governor type of inj. pump
Fuel consumption
15.24 / 15.67
6.95 / 8.34
17.6
Max. firing press. of cylinder
Electric Governor
g/PS.h
160 / 160
153 / 155
153 / 153
150 / 151
liter/h
20 / 24
27 / 32
29 / 34
37 / 46
14° ± 1°
15° ± 1°
Injection timing (B.T.D.C)
deg.
Inj. nozzle opening press.
kg/cm
18° ± 1°
224
2
Starting system
Electric Starting by starter motor
Starter motor capacity
V- kW
24 V - 4.5
Alternator capacity
V- A
24 V - 50
Battery
V- Ah
24V - 150
Indirect cooling by sea water with heat exchanger
Cooling system
Cooling water capacity
Max. : 25, Min. : 23
lit
Centrifugal type, driven by V- belt
Fresh water pump type
Rubber impeller type driven by gear
Sea water pump type
Lub. Oil
(Engine)
AD086TI
Pan capacity
lit
Max : 23, Min : 17 (Engine total : 25)
Pressure
kg/cm2
Full : 3.5, Idle: 1.2
Counter clockwise viewed from stern side
Revolution of Crankshaft
Engine only size (L x W x H)
Engine only (Dry weight)
mm
1,182x770x925
1,182x766x925
1,182x825x925
1,182x825x962
kg
735
745
773
790
-3-
1.2. Engine Aspects
1.2.1. Engine Sectional Drawing
26
25
20
8
28
19
7
18
3
2
27
4
22
14
16
5
6
1
17
15
9
13
12 21
23
11
10
24
EC5OM100
1. Cylinder block
11. Camshaft
21. Oil pump
2. Cylinder head
12. Vibration damper
22. Oil cooler
3. Cylinder head cover
13. Camshaft pulley
23. Oil pan
4. Cylinder liner
14. Piston
24. Oil suction pipe
5. Flywheel housing
15. Connecting rod
25. Water pump
6. Flywheel
16. Piston pin
26. Sea water pump
7. Rocker arm
17. Piston cooling spray nozzle
27. Exhaust manifold
8. Push rod
18. Turbocharger
28. Intake manifold
9. Tappet
19. Multi-hole injection nozzle
10. Crankshaft
20. Valve
-4-
1.2.2. Engine Assembly
6
5
3
14
7
15
27
26
8
13
2
21
9
22
12
19
11
10
1
20
23
24
25
4
16
17
18
EC5OM099
1. Crank pulley
10. Oil pan
19. Thermostat housing
2. Expansion tank
11. Injection pump ass’y
20. Breather ass’y
3. Fuel filter
12. Oil guide tube & level gauge
21. Exhaust manifold
4. Oil cooler cover
13. Water pump
22. Oil filler cap
5. Intake manifold
14. Fresh water filler cap
23. Exhaust outlet pipe
6. Intercooler
15. Sea water pump
24. Turbocharger(wet)
7. Oil drain pump
16. Heat exchange ass’y
25. Clutch oil press. gauge
8. Flywheel housing
17. Starter
26. Marine gear oil cooler
9. Oil filter
18. Marine gear ass’y
27. Sea water outlet pipe
-5-
1.3. Engine Performance Curve
1.3.1. L136 / L136T / L136TI /L136TL
100
Fuel Consumption
1000
1500
2000
170
160
150
Full Load
e
ang
nR
ratio
Ope
Propulsion Curve
200
100
2500
1000
1500
2000
300
Full Load
200
e
ang
nR
ratio
Ope
100
400
300
200
Full Load
100
ratio
Ope
Propulsion Curve
170
160
150
Fuel Consumption
Engine Speed (r.p.m)
400
Propulsion Curve
170
160
150
Fuel Consumption
2500
1000
Engine Speed (r.p.m)
1500
2000
e
ang
nR
2500
1000
Engine Speed (r.p.m)
170
160
150
Fuel Consumption
2000
1500
(g/ps.h)
Full Load
ange
tion R
Opera
Propulsion Curve
300
Output (PS)
200
400
L136TL
(g/ps.h)
300
Output (PS)
400
L136TI
(g/ps.h)
Output (PS)
L136T
(g/ps.h)
Output (PS)
L136
2500
Engine Speed (r.p.m)
EC5OM136
1.3.2. L086TI
Heavy Duty
Medium Duty
Full Load
200
Op
100
e
nR
ratio
ang
e
Full Load
300
nge
Ra
tion
a
r
e
Op
200
100
Propulsion Curve
1500
2000
Engine Speed (r.p.m)
Full Load
300
170
160
150
2500
170
160
150
1000
1500
2000
Engine Speed (r.p.m)
2500
Ra
Op
100
Fuel Consumption
e
ng
ion
t
era
200
Propulsion Curve
Propulsion Curve
Fuel Consumption
1000
400
(g/ps.h)
300
400
170
160
150
Fuel Consumption
1000
1500
2000
(g/ps.h)
400
500
Output (PS)
Output (PS)
500
(g/ps.h)
Output (PS)
500
Light Duty
2500
Engine Speed (r.p.m)
EC5OM137
-6-
1.4. Engine Model & Serial Number
The engine serial number is inscribed on
the engine as illustrated. This number is
required when requesting warranty and
ordering parts. It is also referred to as
engine model and serial number because
of their location.
Note : The
engine
model
Name Plate
name
(L136/T/TI/086TI) is described in
Engine Plate
EC5OM138
the name plate on the cylinder
block.
• Engine serial No. (Example : L086TI)
EBPKM300001
Serial No.
Production Year(2003)
Engine Model Suffix
-7-
2. Safety Regulations
2.1. General Notes
Day-to-day use of power engines and the service products necessary for running them presents
no problems if the persons occupied with their operation, maintenance and care are given
suitable training and think as they work.
This summary is a compilation of the most important regulations. These are broken down into
main sections which contain the information necessary for preventing injury to persons, damage
to property and pollution. In addition to these regulations those dictated by the type of engine
and its site are to be observed also.
IMPORTANT : If, despite all precautions, an accident occurs, in particular through contact
with caustic acids, fuel penetrating the skin, scalding from oil, antifreeze being
splashed in the eyes etc., consult a doctor immediately.
2.2. Regulations Designed to Prevent Accidents with Injury to Persons
2.2.1. During commissioning, starting and operation
Before putting the engine into operation for the first time, read the operating instructions
carefully and familiarize yourself with the “critical” points, If you are unsure, ask your
DAEWOO representative.
• For reasons of safety we recommend you attach a notice to the door of the engine room
prohibiting the access of unauthorized persons and that you draw the attention of the
operating personal to the fact that they are responsible for the safety of persons who enter
the engine room.
• The engine must be started and operated only by authorized personnel. Ensure that the
engine
cannot
be
started
by
unauthorized persons.
• When the engine is running, do not
get too close to the rotating parts (All
pulleys, Inj. Pump drive & propeller
shafts, FPTO etc).
Wear the close-fitting clothing as
possible.
EC2OM009
-8-
• Do
not
touch
the
engine
hot
parts(Exh. Manifold & turbocharger
connection pipes, Inter cooler & heat
exchanger connection pipes..etc) with
bare hands when it is warm from
operation risk of burns.
• Exhaust gases are toxic. Comply with
the installation instructions for the
installation of DAEWOO marine diesel
EC2OM010
engines which are to be operated in
enclosed spaces. Ensure that there is
adequate ventilation and air extraction.
• Keep vicinity of engine, ladders and stairways free of oil and grease.
Accidents caused by slipping can have serious consequences.
2.2.2. During maintenance and care
• Always carry out maintenance work when the engine is switched off. If the engine has to be
maintained while it is running, e.g. changing the elements of change-over filters, remember
that there is a risk of scalding. Do not get too close to rotating parts.
• Change the oil when the engine is warm from operation.
CAUTION : There is a risk of burns and scalding. Do not touch oil drain plug or oil filter
with bare hands.
• Take into account the amount of oil in the sump. Use a vessel of sufficient size to ensure
that the oil will not overflow.
• Open the coolant circuit only when the
engine has cooled down.
CAUTION :
When remove the pressure of the filler
cap while the engine is still hot, cover
the cap with a cloth, then turn it left
slowly
to
release
internal
steam
pressure. This will prevent a person
EC5OM135
from scalding by hot steam spouted out.
• Neither tighten up nor open pipes and
hoses (lube oil circuit, coolant circuit and any additional hydraulic oil circuit) during the
operation. The fluid which flow out can cause injury.
• Fuel is inflammable. Do not smoke or use naked lights in its vicinity. The tank must be filled
only when the engine is switched off.
-9-
• When using compressed air, e.g. for cleaning the heat exchanger, wear goggles.
• Keep service products (anti-freeze) only in containers which can not be confused with drinks
containers.
• Comply with the manufacturer’s instructions when handling batteries.
CAUTION :Accumulator acid is toxic and caustic. Battery gases are explosive.
2.2.3. When carrying out checking, setting and repair work
• Checking, setting and repair work must be carried out by authorized personnel only.
• Use only tools which are in satisfactory condition. Slip caused by the worn open-end wrenc
could lead to Injury.
• When the engine is hanging on a crane, no one must be allowed to stand or pass under
it.Keep lifting gear in good condition.
• When checking injectors, do not put your hands under the jet of fuel.
Do not inhale at atomized fuel.
• When working on the electrical system disconnect the battery earth cable first.
After repair engine parts, connect it up again last in prevent short circuits.
2.3. Regulations Designed to Prevent Damage to Engine and Premature Wear
(1) Never demand more of the engine than it was designed to yield for its intended purpose.
Detailed information on this can be found in the sales literature. The injection pump must not
be adjusted without prior written permission of DAEWOO.
(2) If faults occur, find the cause immediately and have it eliminate in order to prevent more
serious of damage.
(3) Use only genuine DAEWOO spare parts. DAEWOO will accept no responsibility for damage
resulting from the installation of other parts which are supposedly “just as good”.
(4) In addition to the above, note the following points.
• Never
let the engine run when dry, i.e. without lube oil, fuel or coolant. Use only
DAEWOO-approved service products. (engine oil, anti-freeze and anticorrosion agent)
• Pay attention to cleanliness. The diesel fuel must be free of water. See “4.6. Fuel System”.
• Have the engine maintained at the specified intervals.
• Do not switch off the engine immediately when it is warm, but let it run without load for
about 5 minutes so that temperature equalization can take place.
• Never put cold coolant into an overheated engine.
• Do not add so much engine oil that the oil level rises above the max. marking on the
dipstick.
Do not exceed the maximum permissible tilt of the engine. Serious damage to the engine
may result if these instructions are not adhered to.
• Always ensure that the testing and monitoring equipment (for battery charge, oil pressure,
and coolant temperature) function satisfactorily.
• Do not let the sea water pump run dry. If there is a risk of frost, drain the water when the
engine switched off.
- 10 -
2.4. Regulations Designed to Prevent Pollution
2.4.1. Engine oil, filter element, fuel filter
• Take old oil only to an oil collection point. Take strict precautions to ensure that oil does not
get into the drains or into the ground and sea.
• The drinking water supply may be contaminated.
• Oil and fuel filter cartridges are classed as dangerous waste and must be treated as such.
2.4.2. Coolant
• Treat undiluted anti-corrosion agent and / or antifreeze as dangerous waste.
• When disposing of spent coolant comply with the regulations of the relevant local authorities.
2.5. Notes on Safety in Handling Used Engine Oil
Prolonged or repeated contact between the skin and any kind of engine oil decreases the skin.
Drying, irritation or inflammation of the skin may therefore occur. Used engine oil also contains
dangerous substances which have caused skin cancer in animal experiments. If the basic rules
of hygiene and health and safety at work are observed, health risks are not to the expected as
a result of handling used engine oil.
Health precautions
• Avoid prolonged or repeated skin contact with used engine oil.
• Protect your skin by means of suitable agents (creams etc.) or wear protective gloves.
• Clean skin which has been in contact with engine oil.
- Wash thoroughly with soap and water. A nailbrush is an effective aid.
- Certain products make it easier to clean your hands.
- Do not use petrol, diesel fuel, gas oil, thinners or solvents as washing agents.
• After washing apply a fatty skin cream to the skin.
• Change oil-soaked clothing and shoes.
• Do not put oily rags into your pockets.
Ensure that used engine oil is disposed of properly.
- Engine oil can endanger the water supply For this reason do not let engine oil get into the ground, waterways, the drains or the sewers.
Violations are punishable. Collect and dispose of used engine oil carefully.
For information on collection points please contact the seller, the supplier or the local
authorities.
- 11 -
3. Commissioning and Operation
3.1. Inspections Before Operation
3.1.1. Lubricating oil
• The notches in dipstick must indicate
the oil level between max. and min.
permissible.
• The measurement of the oil level must
be done on a even water line and in
10 minutes after engine operating.
• Examining
the
viscosity
and
thecontamination of the oil smeared at
the dipstick, replace the engine oil if
EA4O4001
necessary.
Caution : If the installation angle of the engine exceeds 6 degrees, please remark the
maximum and minimum level of the oil dipstick by engraving on the lube oil
capacity of the engine. (Refer to 4.4. “Lubrication System”)
3.1.2. Cooling water
Checking the level of the cooling water
in tank.
Check the opening pressure of the
pressure
valve
using
cap
tester.
Pressure Cap
Replace the filler cap assembly if the
measured valve does not reach the
specified limit.
(Opening pressure of valve : 0.5 ~ 0.9
Expansion Tank
kg/cm )
2
EA7O3004
NOTE : Because it is dangerous to
open the pressure cap quickly when coolant is hot, after covering the cap with a cloth
and then lower the inside pressure of the tank by opening slowly at first, open it up.
- 12 -
3.1.3. Sea water pump
The rotating direction of the pump impeller determines the location of the pump’s intake and
discharge ports.
OUT
IN
IN
OUT
EA7O3005
EA7O3005
• Over-tightened belt or gear load will reduce the bearing life of the sea water pump.
• Do not run sea water pump at dry for more than 20 seconds.
• Make sure that all valves / cocks in the sea water circuit are opened before run.
• If there is a risk of freezing weather, drain the water by loosening bolts of end cover.
• Temperature range : 5 °C (41 °F) ~ 60 °C (140 °F)
3.1.4. Intake and Exhaust Line
Check the condition of intake and exhaust piping lines, and air filter element. If piping lines or
air filter is fouled or worn, clean or replace it.
3.1.5. Fuel Line
Check the leaking of fuel line by opening the fuel valve.
The contamination of fuel causes the clogging of the nozzle or the sticking of the components
of injection pump. Therefore the cleanness of the fuel system should be maintained at any
time.
3.1.6. Bottom of the Engine Room
The bottom of engine room would be as clean and dry as possible.
Check the bilge to prevent water accumulation.
If water accumulation is unavoidable, do not allow the bilge water to reach the bottom of the
engine. To install a bilge pump with an automatic control switch is a good solution.
Caution : Excessive bilge water can cause engine damage like corrosion, rust and
malfunction of engine parts.
- 13 -
3.1.7. Gauge Panel
Check the all gauges of the panel whether the function is in normal or not.
• L136
1
4
5
7
1
10
2
8
9
ENGINE SPEED
10
ENG OIL PRESS
CHARGE
WATER TEMP
6
PRE HEAT
WATER TEMP
5A
OFF
HEAT
2A
ACC
START
ENG STOP
START SWITCH
EB1M3001
1
Case, Gauge
5
Gauge, Water Temp
8
Connector
2
Panel, Gauge
6
Key Switch Ass’y
9
Button, Engine Stop
4
Meter, Tacho
7
Hour Meter
10
Fuse Holder
• L136T/TI/086TI
4
6
2
3
11
5
1
CHARGE
WATER TEMP
ENG. OIL PRSS
7
8
OVER SPEED
9
10
EC5OM007
1
Key Switch
5
Engine Stop Button
9
Oil Press. Warning Lamp
2
Engine Oil Pressure Gauge
6
Hour Meter
10
Over Speed Warning Lamp
3
Tacho-Meter
7
Battery Warning Lamp
11
Fuse
4
Water Temp. Gauge
8
Water Temp. Warning Lamp
Before operating your engine, familiarize yourself with the instruments supplied with your boat.
- 14 -
3.1.8. Engine Stop & Warning Devices
L136/T/TI/086TI gauge panel is equipped with warning lamps and an audible alarm to alert the
operator as follows.
1) Engine Stop Device (Stop solenoid)
Engine stop solenoid is operated with warning lamps and buzzer sound at the same time as
follows.
• When the engine oil pressure is less than 0.5 kg/cm
• When the engine water temperature is more than 100 °C.(212 °F)
2
2) Engine Warning Lamps
Engine warning lamp is turned on with buzzer sound at the same time as follows.
• When the engine oil pressure is less than 0.5 kg/cm
• When the engine water temperature is more than 100 °C.
• When the battery is not charged.
2
The alarm horn will sound when the ignition is turned on and continue to sound until the key
switch is shifted into “OFF” position or minimum oil pressure is obtained. This provides a
functional test of warning system.
Should engine coolant overheat occurs, the alarm horn will sound and the engine is stopped
by stop solenoid at the same time automatically. Proceed as follows:
• First, quickly observe the water temperature gauge for engine coolant overheat and / or
needle oscillation indicating low coolant.
• If the temperature gauge indicates engine coolant overheat range, put the control lever back
to the idle speed position IMMEDIATELY and shift the reduction gear control lever into the
NETURAL position. Do not restart engine until the cause for the alarm has been found and
corrected. Refer to “Overheating” in “8. Trouble Shooting” Chart.
• If the temperature gauge indicates high coolant temperature, check lack of coolant to fill
expansion tank or thermal sensor malfunction.
• If the cause for the alarm cannot be found, contact your DAEWOO dealer.
- 15 -
3.2. Starting
3.2.1. Operation 1
After checking the warning lamps of the gauge panel and the NEUTRAL position of reduction
gear control lever, turn the key switch to the START position to crank the engine, at once.
Behavior - When the key switch is placed in the START position.
3.2.2. Operation 2
After the engine is cranked, convert the key switch to the ACC position quickly.
Behavior - As the engine is cranked, don’t fix the key switch too long (over 5 seconds) in the
START position. If you do so, the starter may be malfunction.
If you fail the engine starting at first, restart the engine after waiting for 30 seconds at least to
prevent the circuit malfunction of the starter.
3.3. Engine Break-in
All DAEWOO marine engines have been run for a short period of time as a final test at the
factory. During the first 20 hours of operation, you must follow the Engine Break-In procedure
to ensure maximum performance and long engine life.
Note : Failure to follow the Engine Break-in procedure may result in serious engine
damage and will avoid the engine warranty.
During the break-in period, be particularly observe as follows :
• Check engine oil level frequently. Maintain oil level in the safe range, between the “min.” and
“max.” marks on dipstick.
• Watch the oil pressure warning lamp. If the lamp blinks whenever the boat attitude (i.e.
turning, climbing on plane, etc.) is changed, it may be the oil pick-up screen not to be
covered with oil. Check oil dipstick and if required, add oil to the oil pan. But do not fill over
maximum level.
Note : Oil pressure will rise as RPM increases, and fall as the engine RPM decreases. In
addition, cold oil will generally show higher oil pressure for any specific RPM than hot
oil. Both of these conditions reflect normal engine operation.
• Watch the engine water temperature gauge and be sure there is proper water circulation. The
water temperature gauge needle may fluctuate if water level in expansion tank is too low.
- 16 -
Initional Break-In of DAEWOO Marine Engines
(Load)
100%
75%
50%
Fast Idle 25%
Idle
0
3 min.
5 5 2
2
30 5
30 min.
5 52
30 5
30 5 10 5
30 min.
5
30
30
30
30 min.
3 2
Repeat again
Repeat again
Up to 2 hours
Up to Next 8 hours
Repeat again
Repeat again
And then Next 10 hours
During 20 hours
Last additional 30 hours
Total 50 hours Initial Break-In of DAEWOO marine Engines
Running Time
EC5OM126
3.3.1. Initial two hours of break-in
For the first five to ten minutes of operation, operate engine at a fast idle (below 1,500 rpm).
During the remaining first two hours of operation, accelerate to bring boat onto plane quickly and
bring throttle back to maintain a planing attitude. During this period, vary the engine speed
frequently by accelerating to approximately three-fourths throttle (1700 ~ 1800 rpm) for two to
three minutes, then back to minimum planing speed (700 ~ 750 rpm).
After the engine has reached operating temperature, momentarily reduce engine speed, then
increase engine speed, to assist the break-in of rings and bearings. Maintain planing boat attitude
to avoid excessive engine load.
Note : Do not run engine at any constant rpm for prolonged periods of time for this initial
two hours of break-in.
3.3.2. Next 8 Hours
During the next 8 hours, continue to operate at approximately three-fourths throttle or less
(Minimum planning speed). Occasionally reduce throttle to idle speed for a cooling period. During
this 8 hours of operation, it is permissible to operate at full throttle for periods of less than two
minutes only 2 times.
Note : Do not run engine at a constant rpm for prolonged periods of time during the breakin period.
- 17 -
3.3.3. Final 10 hours
During the final 10 hours of break-in, it is permissible to operate at full throttle for five to ten
minutes at a time. After warming engine to operating temperature, momentarily reduce then
increase engine speed. Continue to operate at approximately three-fourths throttle. Occasionally
reduce engine speed to idle to provide cooling periods.
Note : Do not run engine at a constant rpm for prolonged periods of time during the breakin period.
3.3.4. Operating after break-in 20 hours
When starting a cold engine, always allow the engine to warm up gradually. Never run the engine
at full throttle until the engine is thoroughly warmed up.
And you’d better run the engine at three-fourths throttle (about 1800 ~ 1900 rpm) until additional
30 hours (after finishing break-in 20 hours) as possible.
Be sure to check the oil level frequently during initial 50 hours of operation since the oil
consumption will be high until the piston rings are properly seated.
When the engine operation become to reach 50 hours in total including the break-in period 20
hours, replace the engine oil and oil filter to new ones. Refer to “4.4. Lubricating System”.
NOTE : When engine is overheated, do not stop the engine immediately.
Lower the engine load and run the engine to be a lower rpm as possible.
- 18 -
3.4. Inspection After Starting
During operation the oil pressure in the engine lubrication system must be monitored. If the
monitoring devices register a drop in the lube oil pressure, switch off the engine immediately.And
the charge warning lamp of the alternator should go out when the engine is running.
• Do not disconnect the battery or pole terminals or the cables.
• If, during operation, the battery charge lamp suddenly lights up, stop the engine immediately
and remedy the fault in the electrical system.
• Engine should be stopped if the color, the noise or the odor of exhaust gas is not normal.
• Confirm the following things through warning lamps and gauge panel.
3.4.1. Pressure of lubricating oil
The normal pressure comes up to 1 kg/cm2 (1.0 bar) at idling and 3 ~ 5 kg/cm2 (3.0 ~ 4.9 bar) at
rated speed. If the pressure fluctuates at idling or does not reach up to the expected level at high
speed, shut down the engine immediately and check the oil level and the oil line leakage.
3.4.2. Temperature of cooling water
The cooling water temperature should be 71 ~ 85 °C in normal operating conditions. Abnormally
high cooling water temperature could cause the overheating of engine and the sticking of cylinder
components. And excessively low cooling water temperature increases the fuel consumption,
accelerates the wears of cylinder liners and shortens the engine life-time.
3.5. Check After Initial 50 Hours Operation
To insure your continued boating enjoyment, you should check as follows:
• Change engine oil and oil filter cartridge.
• Change fuel filter cartridge.
• Check coolant level.
• Check the tension of all drive belts.
• Check engine mounting screws for tightness.
• Check for any deficiencies, malfunctions, signs of abuse, etc. Correction of any problems at
this time will prevent the worsening of a minor problem and help ensure a trouble free
boating season.
Note : This time is a good opportune to discuss with your dealer about your engine etc which
may have arisen after the first 50 hours of operation and establish a routine preventive
maintenance schedule like “4.2. Periodical Inspection & Maintenance”.
- 19 -
3.6. Operation in Winter Time
Pay special attention to the freezing of cooling water and the viscosity of lubricating oil.
3.6.1. Prevention against the freeze of cooling water
When not using anti-freeze, completely discharge the whole cooling water after engine running.
The freeze of cooling water causes the fatal damages of the engine. Because the anti-freeze is
used to prevent coolant from freeze and corrosion, it is always to be filled with the anti-freeze 35
~ 40 % of the engine whole coolant.
3.6.2. Prevention against excessive cooling
Drop of thermal efficiency caused by excessive cooling increases fuel consumption. Therefore
prevent the engine from excessive cooling. If the temperature of coolant does not reach to normal
condition (71 ~ 85 °C) after continuous operation, examine the thermostat or the other cooling
lines.
3.6.3. Lubricating oil
As cold weather leads to the rise of oil viscosity, engine speed becomes unstable after starting.
Therefore the lubricating oil for winter (SAE 15W40 or 10W40) should be used to prevent this
unstableness. Refer to “4.4. Lubricating System”.
3.7. Tuning the Engine
The purpose of an engine tune-up is to restore power and performance that’s been lost through
wear, corrosion or deterioration of one or more parts or components. In the normal operation of
an engine, these changes can take place gradually at a number of points, so that it’s seldom
advisable to attempt an improvement in performance by correction of one or two items only.
Time will be saved and more lasting results will be obtained by following definition and thorough
procedure of analysis and correction of all items affecting power and performance.
Economical, trouble-free operation can better be ensured if a complete tune-up is performed
once every year, preferably in spring. Components that affect power and performance to be
checked are:
• Components affecting fuel injection ;
Nozzle, delivery valve, fuel filter, fuel water separator, etc.
• Components affecting intake & exhaust ;
Air filter, inter-cooler, turbo-charger, silencer, good ventilation of engine room, etc.
• Components affecting lubrication & cooling ;
Air & oil filter, anti- freeze, heat exchanger, rubber impeller, sea water filter, kingston valve,
misalignment of propeller, stableness of bed frame, bent propeller blade, etc.
- 20 -
4. Maintenance and Care
4.1. General Instructions
1. Before performing service operation, disconnect the grounding cable from the battery for
reducing the chance of cable damage and burning due to short-circuiting.
2. Use covers to prevent the disassembled parts and components from damage or pollution.
3. Engine oil and anti-freeze solution must be handled with care. They can cause damage for
painted parts.
4. The use of proper tools or specified special tools is important to perform the efficient and
reliable maintenance operation.
5. Use genuine DAEWOO parts necessarily.
6. Used cotter pins, gaskets, O-rings, oil seals, lock washer and self-lock nuts should be
discarded. New ones should be used for re-assembled parts. If these are reused, normal
performance can not be maintained.
7. To facilitate reassembling, keep disassembled parts neatly in groups. Fixing bolts and nuts
for reassembled parts should be reused at the original position. They are varied in hardness
or length because they are designed depending on their application.
8. Clean the disassembled parts prior to inspection or re-assembly. By using compressed air,
make oil ports and etc. of them free from any foreign material.
9. Lubricate the surface of rotating and sliding parts with oil or grease before installation.
10. If necessary, use sealant onto gaskets to prevent leakage.
11. Carefully obey all specified torque to tighten bolts and nuts
12. When maintenance is completed, make a final check to be sure it has been done properly.
- 21 -
4.2. Periodical Inspection & Maintenance
In order to insure maximum, trouble-free engine performance at all times, regular inspection,
adjustment and maintenance are vital before occurring any problems.
• Daily inspections in below figure should be checked every day.
• The following maintenance details should be executed thoroughly at regular internals.
Inspection
Daily
Every
50 hrs
Every
100 hrs
Every
250 hrs
Every
500 hrs
Every
600 hrs
Every
1,000 hrs
Coolant level check and refill
Cooling
Contamination of the coolant
check and the quantity of the
anti-freeze
1 Year
change
Heat-exchanger and water
cooling line cleaning
(Change O-Ring & Gasket)
1,200hr
V-belt check and adjustment
2,000hrs
change
Check thermostat and clean
or exchange for excessive
corrosion
1 years
Impeller of sea water pump
check
2,000hr
change
System
Oil level check
Lubrication oil exchange
Lubrication
System
Oil filter cartridge replacement
1st
1st
Marine gear oil exchange
1st
Air filter element cleaning &
change
Clean
Change
Inter-cooler cleaning
Turbocharger cleaning
2,000hrs
Exhaust gas check
Intake
Exhaust Priming pump strainer cleaning
Fuel
Fuel tank check & cleaning
System Water separator cleaning
Fuel filter exchange
Electrical
System
1st
Fuel Injection timing check
1 year
Fuel Injection nozzle check
1 year
Warning lamps check
Battery charging check
Wiring harness check
Cylinder compression
pressure check
needed
Cylinder
In./ Ex. valve clearance
adjustment
- 22 -
4.3. Cooling System
4.3.1. Coolant level check and refill
• Replenish the deficient coolant in the expansion tank every day before running. The coolant
must be changed at intervals of 1,200 hours operation or six months whichever comes first.
If the coolant is being fouled greatly, it will lead engine overheat or coolant blow off from the
expansion tank.
• Clean fresh water should be used for engine coolant.
• Additional agent (35 ~ 40% anti-freeze and 3 ~ 5% anti-corrosion agent) should be mixed
with fresh water for engine coolant to prevent the cooling system problem like freezing,
corrosion and etc.
CAUTION : Suitable mixture of anti-freeze and anti-corrosion agent can protect the engine
corrosion from deteriorating and raises a boiling point, but by using unsuitable
mixture engine components like water pump impeller and water jacket of cylinder
block may be occurred a malfunction by any bad corrosion damage or cavitation.
(1) Coolant replenishment
Let the plug in the highest level of the water lines or the upper plug of wet turbocharger
open, and fill the coolant about three forth of the expansion tank slowly until the air bubbles
in water do not come out through the plug hole. Then reassemble the plug.
After filling the coolant, run the engine at the idle rpm for around 5 minutes and you will
find out the engine coolant level becomes lower than before cause of escaping the air
bubbles in water. Then stop the engine and replenish additional coolant properly.
(2) Coolant change
• Open
the
pressure
cap
of
expansion to remove the air
pressure.
• Loosen two drain plugs. One is
lower side of the oil cooler and
another is upper side of the
starter as figure.
• After
drain reassemble the plug
Drain plug
and replenish the coolant as same
EC5OM127
as “(1) Coolant replenishment”.
CAUTION : When remove the pressure of the filler cap while the engine is still hot, cover the
cap with a cloth, then turn it left slowly to release internal steam pressure. This
will prevent a person from scalding by hot steam spouted out from the filler cap.
- 23 -
4.3.2. Contamination check of the coolant and the quantity of the anti-freeze
We recommend the engine coolant for DAEWOO marine engines should be mixture of fresh
water and additional agent (35 ~ 40% anti-freeze and 3 ~ 5% anti-corrosion agent).
Check the quantity of the anti-freeze every 600 hours. From time to time, refill the anti-freeze
as much as required.
You can check the quantity of anti-freeze and anti-corrosion agent by using a FLEETGUARD
test kit simply as follow. (Fleetguard CC2602M : DHI No. ; 60.99901-0038)
1) Contamination check
• How to use test kit (Striped pad)
(1) Collect half of a coolant sample cup from a drain plug at the lower side of the oil cooler
or cylinder block. Coolant must be between 10°C and 55°C when tested. Room
temperature is preferred.
Do not collect the coolant from the expansion tank or overflow system.
The collected sample is less contaminated, so it can not be substituted for the quality of
whole coolant.
(2) Shake the bottle filled with sample coolant to mix well and take out one strip from bottle
of the test kit. Then dip the strip in coolant sample for 3~5 seconds, take it out and shake
it briskly to remove excess liquid.
Do not touch the pads on the end of the strip. Discard the kit if unused strips have
turned brown for the nitrite test pad.
(3) Wait for 45 seconds after taking the strip out in the bottle of the sample coolant, then
compare the color of the pads with the standard color chart of the test kit label and record
the result as follows.
Caution : All three pad readings must be completed no later than 75 seconds after
dipping strip.
Do not touch the stripe with fingers.
• How to judge the strip
strip
c)
b)
a)
a) Compare FREEZEPOINT (end pad) to chart and record result.
b) Next compare MOLYDATE (middle pad) to chart and record result.
c) Finally compare NITRITE test to chart and record result.
- 24 -
(1) Compare the end pad “a)” color of the strip
% GLYCOL / FREEZEPOINT (℃) (End Pad)
25%
33%
40%
50%
60%
with color blocks of a row at the upper part
of the standard color chart (below of the
letter “GLYCOL/FREEZE POINT”). Same
-12°-15°
-15°-18°
-18° -21°
-21°-23°
-23°-29°
-29° -34°
-34°-43°
-43°-51℃
-51°
-12°
color in the block of the row means the
content
of
anti-freeze
in
the
SCA Units per Litre
coolant.
(Normal range is between 33% and 50%.)
Row 6
(2) Compare the middle pad “b)” color of the
Row 5
strip with the color that the column block
Row 4
color of MOLYDATE at the left side of the
table intersects the row block color of
Row 3
0.0 0.4 0.7 0.9 1.0 1.1 1.3 1.5
TEST
0.0 0.4 0.6 0.7 0.9 0.9 1.1 1.3
0.0 0.4 0.5 0.5 0.6 0.7 1.0 1.2
SERVICE
0.0 0.3 0.4 0.4 0.6 0.7 0.9 1.1
0.0 0.2 0.3 0.4 0.5 0.6 0.8 1.0
NITRITE at the bottom (pad “c)” color of the
Row 2
strip) on the table “SCA Units per Litre”.
0.0 0.2 0.2 0.2 0.4 0.5 0.7 0.9
Row 1
(Normal range of “SCA Units per Litre” is
PRE CHARGE
0.0 0.1 0.2 0.2 0.3 0.4 0.6 0.9
between 0.3 and 0.8 : “green color area”)
Row 0
MOLYBDATE
(MIDDLE PAD)
A
B
C
D
E
F
G
H
NITRITE
EA7O5013
During the comparison, if uncertain about color match, pick the lower numbered block.
(example: if the color of NITRITE pad is between standard color “D” and “F”, then use column
E.)
(3) If the value of “SCA Units per Litre” is less than 0.3, refill the DCA4 liquid (anti-corrosion agent) a
little, But larger than 0.8, Drain some amount of engine coolant and replenish the fresh water
instead. The content of the anti-freeze and anti-corrosion agent can be regulated by this way.
Every year coolant must be replaced. It is essential the coolant should be mixture of
fresh water, proper anti-freeze and anti-corrosion agent.
- 25 -
2) Quantity of anti-freeze
The anti-freeze, 35 ~ 40% of the whole coolant, is always to be used to prevent the cooling
system from the corrosion. And in winter the amount of anti-freeze shown in the following
table should be used in accordance with the ambient temperature.
As the individual freezing points corresponding to the proportions of antifreeze in the table
are subject to change slightly according to the kind of antifreeze, you must follow the
specifications provided by the antifreeze manufacturer.
Ambient
Temperature (˚C)
Cooling water (%)
Anti-freeze (%)
Over -10
85
15
-10
80
20
-15
73
27
-20
67
33
-25
60
40
-30
56
44
-40
50
50
Any coolant loss due to engine operation must be replenished. But adding fresh water for
coolant tends to lower the content of anti-freeze. Always replenish the coolant with a
mixture of antifreeze and water, and keep the proper content of antifreeze (35 ~ 40%)
4.3.3. Heat exchanger and water cooling line cleaning
(1) Heat exchanger cleaning
If the heat exchanger tubes are clogged by small pieces or polluted by corrosion, the volume
of supplied sea water will be reduced gradually. This would be cause of engine overheating.
• Disassemble both left and right side covers of the heat exchanger.
• Remove the clogged small pieces and clean the heat-exchanger tubes.
When the heat-exchanger tubes do cleaning, clean outside and inner side of tubes by using
a small wire brush and pressurized water.
(2) Fresh water cooling line cleaning
If the cooling circuits are fouled with water scales or sludge particles, the cooling efficiency will
be lowered.
The poor condition of the cooling system might be normally due to use of unsuitable antifreezing agents so periodically clean the circuit interior with a cleaner.
Cooling system cleaning interval : Every 1,200 hours
- 26 -
4.3.4. V-belt check and adjustment
(1) Visual check
Check the belt for cracks, oil, overheating and wear.
(2) Tension check
By the finger-pressure, the belt is
pressed by 10 ~ 15mm between the
10mm
water pump pulley and the alternator
pulley in normal condition.
Water pump
For the adjustment of the tension,
loosen the adjusting bolts which support
Alternator
the alternator, adjust the tension and
tighten the bolts again.
(3) V-belt change
Change the belt if necessary after every
Crank pulley
2,000 hours of operation.
EB1O3006
If, in the case of a multiple belt drive,
wear or differing tensions are found,
always replace the complete set of the
belts.
Note : Always apply to DAEWOO genuine parts every replacement.
4.3.5. Thermostat check
The
thermostat
maintains
a
constant
To heat exchanger
temperature of coolant (71 ~ 85 °C) and
improves thermal efficiency of the engine
by preventing heat loss.
Namely, when the temperature of coolant is
lower than 85 °C, the thermostat valve is
closed to make the coolant bypass to
From cooling
water pump
directly enter the water pump. When the
coolant temperature rises to open wide the
EAMC002I
thermostat valve, the bypass circuit is
closed and the water passage to the heat
exchanger is opened so that the coolant is
forced to flow into the heat exchanger.
Item
Type
Specifications
Wax-pallet type
Open at
71 °C
Open wide at
85 °C
Valve lift
To bypass
tube
Bypass
valve
8 mm or more
- 27 -
• Inspection
(1) Check the wax pallet and spring for
damage.
(2) Put the thermostat in a container of
water, then heat the water slowly
Bar
and check temperature with a
Thermometer
thermometer. If the valve lift is 0.1
mm
(starting
to
open)
at
temperature of 71 °C and 8 mm or
Wood plate
more (opening wide) at temperature
of 85 °C, the thermostat is normal.
EFM2055I
• Thermostat replacement
(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. Such relatively slow reaction is mainly due to the
large heat capacity of the wax pellet type thermostat. Therefore, to avoid a sharp rise of
coolant temperature, it is essential to idle the engine sufficiently before running it. In cold
weather, do not run the engine at overload or overspeed it immediately after starting off.
(2) When draining out or replenishing coolant, do it slowly so that air is bled sufficiently from
the entire cooling system.
(3) Replacing thermostat.
If the thermostat is detected defective, replace with a new one.
Check the thermostat and clean or exchange for excessive corrosion every 1 year.
4.3.6. Impeller of sea water pump check
The sea water pump is a rubber impeller type driven by gear. Every time the engine starts you
should always check whether the kingston valve on the bottom of boat is opened or not.
If the engine is run in a dry impeller condition for more than 20 seconds, the rubber impeller
is burned and cracked by high revolution of sea water pump.
- 28 -
• Impeller disassembly
(1) Remove end cover screws, end cover
and o-ring.
(2) Grasp the hub of impeller with water
pump pliers and withdraw it by twisting to
the rotating direction of the sea water
pump body or remove it using two drivers
like upper figure.
(3) Detach the cam unscrewed a bolt and
clean the sealant of cam and body bore.
EB4O401L
(4) Remove the wear-plate.
EB4O402L
• Impeller assembly
(1) Install wear-plate in body bore, aligning
slot in wear-plate with dowel pin in body.
(2) Apply a thin coat of sealant to cam screw
threads and top side of cam and install in
body with cam screw.
(3) Lubricate impeller bore and end surfaces
of impeller with light coat of water pump
grease and start the impeller in bore with
a rotary motion until shaft key engage,
EA4O5014
then push it into the bore side by twisting
into rotating direction.
Caution : When you assemble the rubber impeller, do not use hammer to prevent
the mechanical damage.
(4) Install O-ring and end cover and secure with end cover screws.
(5) After assembled the impeller open the kingston valve and check the leakage of sea water
pump on running the engine.
- 29 -
4.4. Lubrication System
4.4.1. Oil level check
• The notches in dipstick must indicate
the oil level between high and low
permissible when the vessel is in the
water and with its normal trim.
• The oil level should be checked with
the engine horizontal and only after it
has been shut down for about 10
MAX
minutes.
• Examining
the
viscosity
and
MIN
the
EA6O5001
contamination of the oil smeared at
the dipstick, replace the engine oil if
necessary.
CAUTION : Do not add so much engine
oil that the oil level rises
above
the
maximum
marking on the dipstick.
Over filling causes excessive
blow-by gas and will result in
damage to the engine.
EB0O7002
• How to re-mark the oil dipstick
Since the inclination angle of marine
engine may vary greatly as vessels,
the high and low oil levels on the
dipstick should be also changed when
the engine inclination angle is over 6
degree.
Dipstick should be re-marked by
engraving on the lube oil capacity of
each engine. Be sure to check and
EB0O7003
mark the oil levels between High and
Low
when
the
vessel
is
commissioning at first. Please note
that stamping or notching will weaken the dipstick and the tip of the dipstick may break off
in the oil pan.
The capacity of lube oil can be referred to “1.1. Engine Specification”.
- 30 -
4.4.2. Lubrication oil exchange
Engine oil and the oil filter are important factors affecting engine life. They affect ease of starting,
fuel economy, combustion chamber deposits and engine wear.
The first engine oil change should be after 50 hours of operation and next exchange will be
performed every 250 hours. At the end of the break-in period (50 hours), change the engine oil
and replace the oil filter cartridge to new one.
(1) Oil drainage
• While the oil is still hot, discharge the
sump oil or marine gear sump oil by
rotating oil drain pump manually.
Oil drain pump
EC5OM128
• Refill
new engine oil to the oil filler
neck on the head cover in accordance
with the oil capacity of the engine. Be
careful about the mixing of dust or
contaminator during the supplement
of the engine oil.
Then confirm that the oil level gauge
indicates the vicinity of its maximum
level.
•
EA9O4002
For a few minutes, operate the engine
at idling in order to circulate oil
through lubrication system.
• Thereafter shut down the engine. After waiting for about 10 minutes, measure the quantity
of oil and refill the additional oil if necessary.
• Recommendation for lubrication oil
Initial factory filling is high quality break-in oil (API Service CH-4 grade). During the break-in
period (50 hours), check the oil level frequently. Somewhat higher oil consumption is normal
until piston rings are seated. The oil level should be maintained in the safe range between
the Min. and Max. mark on the dipstick. To obtain the best engine performance and engine
life, Engine oil is specified by API Service, letter designations and SAE viscosity numbers. If
the specified engine oil is not available, use a reputable brand of engine oil labeled for API
Service CH-4 and SAE viscosity 15W40 or 10W40.
Refer to oil identification symbol on the container.
- 31 -
Engine oil viscosity - ambient temperature
SAE 20, 20W
Single
grade
SAE 30
SAE 10W
Ambient -30 C
temp
(-20 F)
SAE 40, 50
-15 C
(-0 F)
-0 C
(-32 F)
Multi
grade
15 C
(60 F)
25 C 30 C
(80 F) (90 F)
SAE 10W - 30
SAE 15W - 40
SAE 10W - 40, 20W - 40, 20W - 50
SAE 5W - 20
EA4M1008
4.4.3. Oil filter cartridge replacement
Every time oil exchanges, replace the oil
filter cartridge.
• Drain engine oil by loosening the drain
plug on the filter head.
CAUTION : Don’t forget tightening the
drain
plug
after
having
drained engine oil.
• Remove
the oil filter by turning it
EB1O5002
counter-clockwise with a filter wrench.
• Wipe, clean the fitting face of the body
contacting with the oil filter so that new
oil filter cartridge can be seated properly.
• Lightly oil the O-ring and turn the oil filter until sealing face is fitted against the O-ring And
then turn it in addition by 3/4 ~1 turns further with hand or the filter wrench.
NOTE : It is strongly advisable to use DAEWOO genuine oil filter cartridge for replacement.
4.4.4. Marine gear oil change
Always apply to API Service SAE #30 for reduction gear oil Change the reduction gear oil at
100 hours of operation at first and next exchange will be performed every 600 hours.
- 32 -
4.4.5. Cylinder compression pressure
check
• Stop the engine after warming up, and
take out nozzle holder assembly.
• Install
the special tool (compression
gauge adapter) at the nozzle holder
hole, and connect the compression
pressure gauge there.
Standard value
Limit value
Difference between
each cylinder
24 ~ 28kg/cm2
24kg/cm2 or less
EB4O403L
Within ± 10 %
Test Condition
* Cooling
water temperature 20°C, Engine rotation 200rpm (about 10 revolutions)
4.5. Intake & Exhaust System
4.5.1. Valve clearance adjustment
Usually should check the valve clearance of intake & exhaust every 1,000 hours after engine
operation. Refer to “6.3.24. Valve clearance adjustment” details.
The valve clearances are to be adjusted at the times of the following situations.
• After initial 50 hours operation.
• When the engine is overhauled and the cylinder heads are disassembled.
• When severe noise comes from valve train.
• When the engine is not normally operated, even though there is no trouble in the fuel
system.
- 33 -
4.5.2. Air filter element cleaning &
change
The
engine
life
and
performance
depends on the intake air condition
greatly.
A
fouled
air
filter
element
results
decreased intake air amount that leads
decreased engine output and finally
may cause an engine malfunction.
Further, a damaged air filer element
results wear on the cylinder component
or the valve mechanism etc. leading
increased engine oil consumption and
decreased engine output, finally leads to
shorten the engine life.
EA7O5006
EA7O5006
The air filter element should be cleaned
periodically as follow.
• Cleaning of the air filter element : Every 100 hours
• Exchange of the air filter element : Every 600 hours
Replace the air cleaner if deformed, broken or cracked.
(1) Air filter element cleaning
• Wash the polluted element in warm
water non-household detergent.
• Rinse the element with clean water
• Dry it thoroughly with natural air or
electric fan.
Don’t use a flame or compressed air
for dry.
It makes damages to the element.
EA3M1024
(2) Air filter element check
• Confirm inside of the element clean
and dry.
• Replace the new element if tears, rips or damages are found.
- 34 -
4.5.3. Inter-cooler cleaning
Inter-cooler depends on the intake air
conditiongreatly. The fouled air pollutes
and clogs the air fins of the inter cooler.
As a result of this, theengine output is
decreased and the engine malfunction
may
be
occurred.
Therefore
alwayscheck weather the intake air
systems like air filter element are worn
or polluted.
EC5OM106
The inter-cooler has to be removed from
theengine for cleaning.
• How to inter-cooler cleaning
In order to maintain the heat transfer efficiency of the inter-cooler, it is necessary to clean it
at regular intervals. For this purpose, dismantle the inter-cooler. In almost all cases, it will
suffice to clean the individual parts in a hot alkaline solution, e.g. a 3 to 5% P3-FD solution.
If hard and firmly adhering scale deposits continue to exist, a second treatment should be
made with a descaling agent which will not corrode the cooler core. Use new gaskets when
reassembling the inter-cooler.
Be sure to clean the sealing surfaces carefully before installing the gaskets.
Observe the specified pressure when making the hydraulic test.
Test gauge pressure
water side
400 kPa (4 bar)
charge air side
300 kPa (3 bar)
Cleaning of inter cooler : Every 1,000 hours.
4.5.4. Turbocharger cleaning
• Turbocharger should be cleaned every 2,000 hours. The only points to be observed are the
oil pipes which should be checked at every oil change for leakage and restrictions. Inspect
the condition of turbocharger like oil leaks, and unusual turbo sounds periodically.
• Air cleaner element should be checked and cleaned periodically to prevent foreign matters
from entering the inside of the engine.
• Should check and measure the pressure of intake air and exhaust gas periodically. If there
is air leakage, should repair the problem at once not to occur the engine power loss and over
heating.
• In
case of operating in highly dust or oil-laden atmospheres, cleaning of the air
compressorimpeller may be necessary from time to time. To this end, remove compressor
casing (Caution: Do not skew it!) and clean in a non-acid solvent, if necessary use a plastic
scraper.
If the air compressor should be badly fouled, it is recommended that the wheel be allowed
to soak in a vessel with solvent and to clean it then with a stiff non-steel brush. In doing so,
- 35 -
take care to see that only the compressor wheel is immersed and that the turbocharger is
supported on the bearing casing and not on the wheel.
4.5.5. Exhaust gas check
Exhaust gas depends on much or less of it shows whether combustion condition of the engine
is good or not. If exhaust gas is any abnormal condition like excessive smoke, white smoke,
black smoke, the engine should be serviced maintenance from specialist.
4.6. Fuel System
As fuel injection pumps and injection nozzles consist of very complicated and precise
components, the contamination of fuel causes the clogging of the nozzle or the sticking of the
injection pump components. Therefore, the cleanness of the fuel system should be maintained
at any time.
If the engine is equipped with a fuel water separator, drain off any water that has accumulated.
Water in fuel can seriously affect engine performance and may cause engine damage.
4.6.1. Priming pump strainer cleaning
Clean the priming pump strainer every
100 hours operation. The strainer is
incorporated in the priming pump inlet
side joint bolt. Clean the strainer with the
compressed air and rinse it in the fuel
oil.
Strainer(Inner)
EA7O5009
4.6.2. Fuel tank check & cleaning
Fill the tank with recommended fuel and should reduce water condensation of the fuel tank as
possible. Also it is important for the engine performance to keep the fuel cool.
Make sure fuel supply valves (if used) are opened before run.
In marine environment, the most likely fuel contaminants are water and microbial growth
(black “slime”). Generally, this type of contamination is the result of poor fuel handling
practices.
Black “slime” requires water in the fuel to form and grow, so the best prevention is to keep
water condensation to a minimum in storage tanks.
If diesel fuel which contains moisture is used, injection system and cylinder liners, pistons will
be damaged. Drain moisture and accumulated sediment from drainage device of storage tank
regularly. You’d better change the element of the water separator or fuel filter cartridge several
times until fuel of the suction line is cleaned.
- 36 -
NOTICE : A galvanized steel tank should never be used for fuel storage, because fuel oil
reacts chemically with the zinc coating to form powdery flakes which can quickly
clog the fuel filters and damage the fuel pump and injection nozzles.
• How to select fuel oil
Fuel quality is an important factor in obtaining satisfactory engine performance, long engine life,
and acceptable exhaust emission levels. DAEWOO engines are designed to operate on most
diesel fuels marketed today. In general, fuels meeting the properties of ASTM designation D975
(grades 1-D and 2-D) have provided satisfactory performance.
The ASTM 975 specification, however, does not in itself adequately define the fuel characteristics
needed for assurance of fuel quality.
The properties listed in the fuel oil selection chart below have provided optimum engine
performance. Grade 2-D fuel is normally available for marine service. Grade 1-D fuel should not be
used in pleasure craft engines, except in an emergency.
<Fuel Oil Selection Chart>
General Fuel
Classification
ASTM
Test
No. 1
ASTM 1-D
No. 2
ASTM 2-D
DIN 51601
Gravity, °API
D 287
40 ~ 44
33 ~ 37
0.815 ~ 0.855
Flash Point
Min. °F (°C)
D 93
100 (38)
125 (52)
131 (55)
Viscosity, Kinematic
CST 100 °F (40 °C )
D 445
1.3 ~ 2.4
1.9 ~ 4.1
1.8 ~ 10
D 2500
See Note 1)
See Note 1)
See Note 1)
D 129
0.5
0.5
0.15
D 524
0.15
0.35
0.1
D 2274
1.5
1.5
D 482
0.01
0.01
D 613
45
45
IMP, Typical #)
350(177)
375(191)
10% Typical
#)
385(196)
430(221)
50% Typical
#)
45(218)
510(256)
500 (260) Max.
625(329) Max.
550(288) Max.`
675(357) Max.
0.05
0.05
#)
Cloud Point °F
#)
Sulfur Content
wt%, Max.
Carbon Residue
on 10%, wt%, Max.
Accelerated Stability
Total Insolubles
mg/100 ml, Max.
#)
Ash, wt%, Max.
Cetane Number, Min.
Distillation
+)
> 45
D 86
Temperature, °F(°C)
90%
+)
End Point
#)
680(360)
Water & Sediment
%, Max.
#)
D 1796
Not specified In ASTM D 975
+)
Differs from ASTM D 975
- 37 -
0.05
Note : The cloud point should be 6 °C (10 °F) below the lowest expected fuel temperature to
prevent clogging of fuel filter by crystals.
4.6.3. Water separator cleaning
DAEWOO recommends the fuel water separator to install between fuel tank and fuel injection
pump strongly.
Condensation formed in a partially filled tank promotes the growth of microbial organisms that
can clog fuel filters and restrict fuel flow and cause the engine power decrease before.
Drain the accumulated moisture of the water separator every 100 hours to prevent engine
damage.
4.6.4. Fuel filter exchange
• Loosen
the fuel filter by turning it
counter-clockwise
with
the
filter
wrench. Discard the used filter a
designated place.
• Wipe the filter fitting face clean.
• Supply fuel to the new filter and apply
engine oil to the O-ring face lightly.
• Turn the new filter until the filter O-ring
is fitted against the sealing face.
•
EA7O5007
And then turn the filter cartridge about
3/4 ~1 turn with hands.
Fuel system bleeding
Whenever fuel filter is changed or the
engine is stopped by cause of the fuel
lack, the air of fuel line must be removed
as follows.
Bleed the fuel by manually operating the
priming pump with fuel filter outlet joint
Priming Pump
bolt and injection pump bleeder screw
loosened.
• Press the feed pump cap repetitively
EA7O5010
until the fuel without bubbles comes
out from the bleeding plug screw.
• After the whole air is pulled out, close
the plug screws of the filter and the pump.
• Confirm the resistance of fuel delivery by repetition pressing of the feed pump cap, Pressure
and turn the priming pump cap simultaneously to close it.
- 38 -
4.6.5. Fuel injection timing check (by authorized specialist personnel)
Check the fuel injection timing every year. Refer to details in “6.3.27. Injection pump & timing “
Caution :
• Check
the fuel injection pump housing for cracks or breaks, and replace if
damaged.
• Check whether the lead seal for idling control and speed control levers have been
removed or not.
• No alterations must be made to the injection pump. If the lead seal is damaged
the warranty on the engine will become null and void.
• We strongly recommend that any faults developing in the injection pump should
be taken care of by authorized specialist personnel.
4.6.6. Injection Nozzle check (by authorized specialist personnel)
Check the fuel injection nozzle every year or increasing the smoke excessively.
Refer to details in “7.3.3. Fuel injection nozzle”.
4.7. Electric System
4.7.1. Warning lamps check
Check the lamps of the gauge panel carefully whether the lamp is switch on or not while the
engine is running. The oil warning lamp should be switched on below 0.5 bar of the oil
pressure and the water temp warning lamp should be switched off under 95 ° C of water
temperature (normal condition).
4.7.2. Battery charge check
Always check whether the battery capacity is sufficient or not before sailing far away from
harbor.
4.7.3. Wiring harness check
Check the engine wiring is loosened, shorted or worn every 600 hours.
- 39 -
4.8. Cylinder
4.8.1. Valve clearance adjustment
Usually should check the valve clearance of intake & exhaust every 1,000 hours after engine
operation. Refer to "6.3.26. Valve clearance adjustment" details.
The valve clearances should be adjusted at the times of the following situations.
• After initial 50 hours operation.
• When the engine is overhauled and the cylinder heads are disassembled.
• When severe noise comes from valve train.
- When the engine is not normally operated, even though there is no trouble in the fuel
system.
4.8.2. Cylinder compression pressure
check
• Stop the engine after warming up, and
take out nozzle holder assembly.
• Install
the special tool (compression
gauge adapter) at the nozzle holder
hole, and connect the compression
pressure gauge there.
Standard value
Limit value
24 ~ 28kg/cm2
24kg/cm2 or less
EB4O403L
Difference between
each cylinder
Within ± 10 %
Test Condition
* Cooling
water temperature 20°C, Engine rotation 200rpm (about 10 revolutions)
- 40 -
4.9. Engine Preservation Points for a Long Time
Preserved engine for a long time should be prevented from corrosion or entering faulty matters.
Especially the external and internal major components of the engine are likely to corrode.
Please take care of the engine to maintain its good performance as follows.
• Drain the engine coolant completely and fill flesh water into the engine. Then run it sufficiently
until washing out the engine coolant line.
Finally drain the water, and refill new coolant (flesh water with 35 ~ 40% anti-freeze).
• Run the engine until the temperature of engine coolant is reached to normal condition (71 ~
85 °C), after then stop the engine.
• Drain engine oil by removing the drain plug of the oil pan or using the oil drain pump. Then
refill new engine oil up to “MAX” mark line and change oil filter cartridge to new one.
Prior to changing the oil, run the engine for 10 minutes. Drain engine oil while the engine is
still hot. It is helpful to drain the faulty matters attached in the bottom of the oil pan.
• Close the valve or the cock of the fuel tank securely. Then detach the fuel filter and the water
separator to clean them or replace with a new one.
• Run the engine about 5 minutes in order to circulate the new fuel through the all fuel lines
completely.
• Disassemble the air filter to clean. If the element is fouled or worn severely, replace it with
a
new one.
• Drain the reduction gear oil completely, then clean the strainer that is assembled in the
reduction gear.
Refill the specified oil (SAE #30, above API CC grade) up to the “MAX” level.
• While the engine is running at idle rpm for 5 minutes, shift the control lever position of the
reduction gear in turn (eg. “Neutral” - “Forward”- “Neutral” - “Reverse”) to circulate the oil
completely.
• Put the engine throttle lever at the idle position then reduction gear and FPTO lever at “switch
off” position (Neutral & OFF).
• Drain the engine coolant completely and let the drain plugs removed.
• Close the kingston valve of the sea water line tightly. To avoid damage cause of freezing,
drain the water of the heat exchanger, inter cooler, reduction gear oil cooler completely and
keep the plugs opened.
Finally don’t forget to detach the sea water pump impeller and preserve it at a dark place.
• First of all, disconnect the battery wire (negative pole), then detach the other cables.
Clean battery and all cables. After that replenish the distilled water for battery. (for refill type)
DAEWOO battery is maintenance free type, so there is no need to refill the water.
To protect corrosion, apply the grease on the wire terminals of the battery.
• Loosen the V-belt(s) to release the pulley bearing from loaded tension and insert some pieces
of paper between V-belt(s) and the pulley grooves.
• At least run the engine at idle rpm or a little more for 10 minutes once 10 days in order to
lubricate all lubrication system and charge the batteries of the engine.
• The engine not used for a long time should be checked the condition regularly.
Apply the grease on the engine parts to keep from rust.
- 41 -
4.10. Management for Sunken Engine
If the engine is sunk in sea water, remove the moisture of all engine parts as soon as possible
and ask after service of your DAEWOO dealer at once.
All parts of the engine should be disassembled to remove the salty moisture. After this, engine
oil should be applied onto the parts at once. Finally check whether the components of the
engine are dried, eroded away or damaged especially components of the fuel system. These
actions must be finished quickly without delay. If not, engine fatal damage may result from
salty corrosion.
Be sure to install the auto bilge pump in the bottom of the engine room. It can be a good
solution to keep the water level below flywheel housing and to prevent overflowing with water.
- 42 -
5. Main Accessory Parts
5.1. Reduction Gear
Refer to “reduction gear manual” provided with engine separately for detail operation and
maintenance of reduction gear.
5.1.1. Construction and operation
The reduction gear is used for high-speed engine and consists of 4 major components such
as input shaft, gear shaft, output shaft, and housing.
The clutch for forward and reverse movements is composed of a hydraulic wet-type and multiplate type. The construction and power line is as follows;
1
2
3
4
5
11
6
7
8
9
10
EFM6006I
<Power line>
Neutral : 1-2-5-4-8
Forward : 1-2-5-3-7-10
Reverse : 1-2-5-4-8-9-6-7-10
1. Rubber block
6. Reverse pinion
2. Spider
7. Output shaft
3. Forward pinion
8. Reverse drive gear
4. Reverse drive gear
9. Gear shaft
5. Input shaft
10. Propeller shaft
- 43 -
5.1.2. Characteristics
The hydraulic-type clutch is composed of forward main body, reverse main body, output shaft,
and selector valve..
The selector valve assembly installed on the external part is a device designed to control
forward, neutral, and reverse movements and also it can be remote-controlled. The oil
pumped up at the pump supplies hydraulic pressure for the clutch assembly, lubricating
portions on gear and bearings, and cooling system. But when assembling this hydraulic type
clutch, use care so that it is aligned with the engine correctly.
5.1.3. Operation
(1) Before operation
• Check the tightening bolts and nuts on the components as a whole for looseness.
• Check the oil level with the oil level gauge.
(Run the engine at idle for a few minutes, then stop it before checking the oil level.)
• Place the control lever in the neutral position before starting the engine.
(2) Starting
• Run the engine at idle for about 10 minutes.
• Check for oil leaks, unusual sound, temperature, etc. during the engine idling.
• While checking the clutch pressure, increase the engine rpm.
(3) Driving and stopping
• Check to see that the specified pressure is obtained when engaging the clutch.
The pressure may drop slightly at low engine rpm, but it does not affect the operation of
the engine.
• When attempting to change gears for forward or reverse movement, first put the engine
rpm at idle.
• The temperature of oil at operation must be 60 ~ 90°C.
• When attempting to stop the engine, be sure to place the control lever in the neutral
position.
- 44 -
(4) Emergency bolt
The emergency bolt is designed to couple the clutch mechanically when the clutch
indicates abnormal condition or slip at clutch coupling operation. The reverse clutch pack
has no emergency bolt. When using the emergency bolt, first loosen the tightening bolts to
remove the control block, tighten the 8mm wrench bolt on the forward disc pack using a
5mm L-shaped wrench, then reassemble the control block in the reverse order. Be sure to
use this emergency bolt literally in case of emergency.
Steel
강
판
스냅
링
Snap
ring
plate
소결판
Sintered
plate
긴급
볼트
Emergency
bolts
피스톤
Piston
판
Back 뒷
plate
EA7O6011 EEO5009I
5.2. Front Power Take-Off (F.P.T.O)
5.2.1. For maximum FPTO power
For front power take-off in line with
Fiexible coupling
crankshaft, it is a standard procedure to
V-pulley
Driveshaft
support driveshaft and V-pulley by two
Engine
pillow blocks by using flexile coupling
for connection to engine.
When the front PTO is installed, be sure
to take deflection reading. Radial runout should be no more than 0.02 mm.
Be sure to limit the front PTO output
within
the
maximum
Crank pulley Pillow blocks
allowable
horsepower as specified for each
model. (Torque represents when there is no propeller load)
Model
Load(kW)
rpm
Model
Load(kW)
rpm
L136
60
1,600
L136TI
88
1,600
L136T
72
1,600
L086TI
105
1,600
- 45 -
EA4O7001
5.2.2. For small cross drive power
The figure is applicable to the drive
arrangement (No supporting bearing on
front side of PTO pulley) in which the
Engine
distance between the end face of the
engine
pulley
and
the
Crank V-pulley, PTO
pulley
MAX. 170mm
(6.7 in) dia.
centerline
through pulley groove is not greater
than 60mm. The distance is indicated
as L in the figure.
L
EA4O7002
Model
L mm
Belt driven side load(kW)
L136
L136T
rpm
35
40
60
L136TI
50
L086TI
62
1,600
5.3. Propeller Selection
Output
Power
Your dealer has chosen a propeller
designed to deliver top performance and
economy under most conditions. To
obtain
the
maximum
percentage
of
A
available horsepower (A), the engine
100%
C
D
90%
80%
70%
60%
50%
RPM at Full Throttle should be in the
40%
specified Full Throttle Operating Rage (B).
30%
B
Refer to Specifications in Performance
RPM
Curve.
EB0O9001
If the engine’s full throttle RPM on normal
load is below the specified on the low side
of the range (C), use a propeller with less pitch to increase the RPM. Should the engine’s full
throttle RPM want to exceed the specified range (D), the engine RPM is limited by the governor.
Use a propeller of higher pitch to stop the limiting by the governor.
Note : Engine damage can result from incorrect propeller selection which:
• (C) Prevents engine RPM from attaining the specified “Full Throttle Operating Range”.
Engine is laboring, install lower pitch propeller.
• (D) Allows engine RPM above the specified “Full Throttle Operating Range”. Engine RPM is
limited by the governor, install a higher pitch propeller.
- 46 -
5.4. Electric System
5.4.1. Alternator
Terminal R
Terminal L
Terminal P
Terminal B
Terminal E
EFM5001I
The alternator is fitted with integral silicon
rectifiers.
mounted
A
on
transistorized
the
alternator
P
regulator
limits
B
the
L
alternator voltage evenly. The alternator
I.C
Regulator
should be operated with the regulator and
R
F
battery connected in circuit to avoid the
Body
damage of the rectifier and regulator.
The alternator is maintenance free, but it
must be protected against dust and above
Circuit Diagram
EA7O3008
all against moisture therefore it must be
mounted a cover for protector properly.
(1) Inspection Point (In case of abnormal charging)
• Voltage measurement between terminal and alternator body during operation.
<Voltage during operation>
<Voltage during stop>
Measuring point
Voltage
Measuring point
Voltage
Terminal B - Body
about DC28V ~ 29V
Terminal B - Body
about DC24V
Terminal L - Body
about DC28V ~ 29V
Terminal L - Body
about DC2V
Terminal R - Body
about DC28V ~ 29V
Terminal R - Body
about DC24V
For the confirmation of wiring state, measurement of voltage should be carried out only at each
terminal during engine stop.
- 47 -
• Inspection points on the voltage regulator
<Resistance value between voltage regulator’s terminals>
Resistance Value
Resistance Value
Terminal
Terminal
(KΩ)
+
-
L
E
about 2
R
E
about 53
F
E
about 50
L
F
about 50
R
L
R
F
(KΩ)
+
-
E
R
about 50
L
R
about 168
F
R
∞
∞
∞
(2) Precautions in use
• Pay attention to dropping the battery voltage capacity when they are left for long time even
without use.
• In cold winter season, for the starting may not be done well sometime, do not try it to be
continuous immediately but try to start again after waiting about 30 seconds.
• Prior to operating the gauge panel, make sure of the polarity of battery once again (In
general, red side means “+” and black one is “-”.)
• Disassembling the gauge panel may be accompanied with a risk of electrical shock, First
detach the cable from the connector at the rear side of the gauge panel without fail, then
disassemble it.
• If metallic foil is used for safety connector instead of the cut-off fuse, excessive current that
can make serious damage might flow into the electric parts of the engine. (Never do this!) If
cutting off of fuse is occurred, solve the problem, then replace it with a new fuse.
• Since battery has a danger of explosion by a heat, it must not be installed at the place where
there generates a lot of heat.
• When engine is in stop, always pull out the key. Then a hazard of fire or wound due to wrong
operation may not happen.
• In case of scrapping the batteries, observe the followings.
NOTE : Do not throw it in the fire to scrap. It should not be thrown away into the places where
are liable to cause the environmental pollution such as stream, river and mountain.
Pack them as far as possible and dispose it as rubbish that is unable to use again.
• DAEWOO will not be responsible to the problems that might be raised by the disassembling
and structural change of this product without consultation.
- 48 -
5.4.2. Starter Motor
The starter motor is installed on the flywheel housing.
When the starter key switch is turned on, the starter motor pinion flies out and engages the ring
gear of the flywheel. Then the main contact is closed, current flows, and the engine is started.
After the engine starts, the pinion automatically returns to its initial position as soon as the starter
key switch is released.
Otherwise, the starter motor may be damaged or burned out.
In case of repairing the engine, dip the
pinion of the starter and ring gear into the
new fuel, then remove the dirty or corrosion
with a brush.
After that, apply the grease on them to
protect the corrosion.
Whenever you clean the starter, always
pay attention not to occur the electric short
due to entering the water.
Starter
motor
always
EB1M5020
should
be
protected from humidity.
B
Precaution : Before the maintenance
W
Motor
S/W
of the electric system,
S
be sure to detach the
SW
M
Key S/W
battery wire (-) to avoid
the electric short.
Circuit Diagram
- 49 -
EA7O3009
6. Disassembly and Assembly of Major Components
6.1. Disassembly
6.1.1. General precautions
• Maintenance operation should be carried out in a bright and clean place.
• Before disassembly, provide racks for arrangement of various tools and disassembled parts.
• Arrange the disassembled parts in the disassembly sequence and use care to prevent any
damage to them.
6.1.2. Cooling water
• Remove
the drain plug from the
cylinder block and under side of oil
cooler, then drain out the cooling
water into a container.
Drain plug
EC5OM129
6.1.3. Engine oil and drain pump
• Drain
out
the
engine
oil
into
a
container using oil drain pump.
• Remove the oil hose from oil pan and
reduction gear.
• Unscrew
the oil drain pump fixing
bolts and disassemble the oil drain
pump.
EC5OM108
6.1.4. V - belt
• Loosen
the tension adjusting nut
installedon the alternator support, and
take off the V -belt.
EC5OM130
- 50 -
6.1.5. Alternator
• Remove
the electric wires and the
alternator
fixing
bolt
and
then
disassemble the cover and alternator.
• Remove the tension adjusting bolt and
bracket.
EC5OM109
6.1.6. Fuel filter
• Remove fuel hoses connected to the
fuel injection pump, take off the filter
housing fixing bolts, then disassemble
the fuel filter.
EC5OM110
6.1.7. Breather
• Loosen
the clamp screw to remove
the rubber hose and the breather after
unscrew.
EB1M3006
6.1.8. Inter cooler
• Remove the cooling water pipe from
inter cooler to marine gear oil cooler.
• Remove
the air pipe connected to
intake manifold and turbocharger.
• Disassemble
the intercooler after
unscrew the mounting bolts on the
heat exchanger.
EC5OM111
- 51 -
6.1.9. Air cleaner
• Remove the air filter element.
• Loosen the clamp, then remove the air
cleaner.
EB1M3008
6.1.10. Turbo charger
Turbo Charger
• Loosen the clamp screw of the rubber
hose connected to the inter cooler,
and take off the intake pipes both
simultaneously.
• Unscrew
the exhaust pipe flange
fixing bolts and the nuts installed on
theturbocharger, then take out the
exhaust pipe.
•
Remove
the
EC5OM131
turbocharger
after
removing the oil supply pipe and
return pipe including both inlet and
outlet cooling water pipes.
6.1.11. Expansion tank
• Remove the reservoir tank and hoses
connected to the expansion tank.
• Loosen
fixing
the expansion tank bracket
bolts
then
remove
the
expansion tank.
EC5OM113
- 52 -
6.1.12. Stop solenoid
• Remove the cable from the fuel stop
lever to the stop solenoid.
• Disassemble the stop solenoid.
EC5OM114
6.1.13. Injection pipe
• Unscrew
the
hollow
screws
to
disassemble the fuel return pipe.
• Remove the nuts installed on the fuel
injection
pump
nozzles,
then
and
the
injection
disassemble
the
injection pipe.
EAMD011I
6.1.14. Intake manifold
• Remove the hoses connected to the
injection pump and fuel filter and
intake manifold.
• Loosen
the intake manifold fixing
bolts, then disassemble the intake
manifold.
EC5OM115
6.1.15. Thermostat
• Release the hose clamps connected
to
the
both
portion
of
the
heat
exchanger and cooling water pipe
• Remove
the
thermostat
housing
assembly, and unscrew the mounting
bolts, then take off two thermostats.
EC5OM116
- 53 -
6.1.16. Heat exchanger
• Loosen the clamp on the rubber hoses
connected to the inter cooler and
cooling
water
pipe
of
the
heat
exchanger, and remove the inter
cooler then take off the rubber hoses.
• After remove the inter cooler, unscrew
the heat exchanger fixing bolts, then
detach the heat exchanger.
EC5OM117
6.1.17. Exhaust manifold
• Remove the cooling water pipes on
the front and upper side and then
exhaust outlet pipe.
• Unscrew the exhaust manifold fixing
bolts, and then detach the exhaust
manifold and gaskets.
Caution : The exhaust manifold is
very heavy.
Be careful to handle it.
EC5OM118
6.1.18. Starter
• Unscrew the starter fixing bolts, then
disassemble the starter.
EC5OM119
6.1.19. Sea water pump
• Release the clamp on the rubber hose
connected to the sea water pipe then
detach the rubber hose.
• Unscrew
the sea water pump fixing
bolts, then remove the sea water
pump.
EC5OM120
- 54 -
6.1.20. Water pump
• Remove
rubber
the expansion tank and
hose
connected
to
the
expansion tank.
• Remove
the water pipe and hoses
connected to the oil cooler.
• Unscrew the water pump fixing bolts
and remove the water pump.
EB1M3017
6.1.21. Injection pump
(A) L086TI
• Remove the oil supply pipe and the
return pipe connected to the fuel
injection pump.
• Unscrew
the bolts connected the
coupling and drive shaft, disassemble
the injection pump mounting bolts,
then detach the injection pump.
Note : After letting No.1 cylinder to
EAMD021I
the ‘OT’ position by turning
the crankshaft, disassemble
the injection pump.
• Unscrew the pump bracket fixing bolts
to detach the bracket from the cylinder
block.
Note : Do not mix the disassembled
shims. They should be
reassembled to the original
position.
EAMD022I
- 55 -
(B) L136/T/TI
• Put the piston (No.1) of the engine to
O.T position, then remove the timing
gear case cover, and engrave a line
on the both flanges as the figure. (This
is only for no engraved line before.)
• Remove the injection pump,
Engrave
표시선Line
EB4O601L
To exchange the injection pump for new
one, put the piston (No.1) of the engine
to O.T position, then mark the line
marking
temporary by using oil paint at the
geared point between injection pump
gear and idle gear separately.
This marking is used to assemble the
injection pump gear to reassemble the
new injection pump. (Refer to 6.3.27.
ENM3032S
(b).)
6.1.22. Oil filter
• Detach
the pipes connected to the
water pump and heat exchanger.
Remove the oil filter cartridge using a
filter wrench.
• Unscrew the oil filter fixing bolts and
detach
the
oil
filter
and
cooler
Oil cooler
assembly from the cylinder block.
EC5OM132
6.1.23. Vibration damper
• Unscrew
the pulley fixing bolts and
disassemble
the
pulley-vibration
damper assembly.
• Unscrew the vibration damper fixing
bolts and detach the damper from the
pulley.
- 56 -
6.1.24. Timing gear case cover
• Disassemble
the oil seal using the
removing jig.
• Unscrew
the cover fixing bolts and
disassemble the cover from the timing
gear case.
EAMD025I
6.1.25. Idle gear
• Unscrew the idle gear fixing bolts and
disassemble the thrust washer and
idle gear.
• Disassemble the idle gear pin using a
rubber hammer to prevent them from
damaging.
ENM3032S
6.1.26. Injection pump drive
• Unscrew
the
drive
shaft
bearing
housing fixing bolts and remove the
injection pump drive assembly like as
the shaft, gear, bearings, and housing
are put together.
EB1M3023
6.1.27. Cylinder head cover
• Unscrew the head cover fixing bolts
and disassemble the cover.
• Keep the bolts in an assembly state so
that the packing and washers may not
be lost, and keep the cover packing as
assembled with the cover.
- 57 -
6.1.28. Rocker arm assembly
• Unscrew the rocker arm bracket bolts
and remove the rocker arm assembly.
• Take off the snap rings to remove the
washers
and
rocker
arm,
then
unscrew the bracket fixing bolts to
take off the bracket and springs.
• Take out the push rods.
EAMD029I
6.1.29. Injection nozzle
• Take off the injection pipes between
the
injection
pump
and
injection
nozzles.
• Remove the nozzle holder assembly
using the nozzle removing jig.
Do not disassemble the injection
nozzle unless coolant or gas comes
out.
EFM1004I
6.1.30. Cylinder head
• Unscrew the cylinder head fixing bolts
and take off the cylinder heads.
• Remove the cylinder head gaskets.
EFM2076I
- 58 -
6.1.31. Valve & stem seal
• Compress
the valve spring retainer
using a jig and take off the valve cotter
pins.
• Disassemble
the valve springs and
retainers.
• Take off the valves.
• Remove and discard the used valve
compress
the
스프링 분해
spring
지그
stem seals in order not to be re-used.
EA0M4007
6.1.32. Oil cooler
• Unscrew
the oil cooler cover fixing
bolts and disassemble the oil cooler
tube assembly from the oil cooler
housing.
Oil cooler
EC5OM132
6.1.33. Oil pan
• Stand
the engine up the flywheel
housing end face towards the bottom
side.
• Release the oil pan fixing bolts, then
disassemble the oil pan.
EAMD034I
6.1.34. Oil pump & oil pipe
• Unscrew the oil suction pipe bracket
bolts, releasing the pipe fixing bolts,
then detach the oil suction pipe
assembly.
• Disassemble the oil pipes connected
the oil pump to the cylinder block.
• Unscrew the oil pump fixing bolts and
disassemble the oil pump.
- 59 -
6.1.35. Relief valve
• Unscrew the relief valve housing fixing
bolts
• Disassemble the relief valve from the
housing.
Relief valve
EB1M3019
6.1.36. Piston and connecting rod
• Disassemble
the
pistons
by
two
cylinders while turning the crankshaft.
• Unscrew
the connecting rod fixing
bolts and take off the pistons and
connecting rods in the direction of
piston upper side.
EAMD037I
• Remove the piston pin and snap rings,
then disconnect the connecting rod
from the piston.
• Disassemble the piston rings using a
ring pliers.
• Arrange
the
disassembled
parts
carefully in order not to interchange
each other and keep them in the
sequence of cylinder number.
- 60 -
6.1.37. Cylinder liner
• Take off the cylinder liner.
EAMD040I
6.1.38. Flywheel
• First
remove two fixing bolts of the
flywheel and install the two dowel pins
in the bolt hole.
• Unscrew the last flywheel fixing bolts,
and then detach the flywheel with
care.
EB1M3020
6.1.39. Oil seal
• Take off the rear oil seal using an oil
seal disassembling jig.
6.1.40. Flywheel housing
• Loosen the housing fixing bolts, then
disassemble the flywheel housing.
EB1M3021
- 61 -
6.1.41. Cam shaft and tappet
• Remove the camshaft gear and thrust
washer.
• Take out the camshaft with care not to
damage it and inner bearings.
• Take out the tappets by hand.
EAMD044I
6.1.42. Crankshaft gear and oil pump idle gear
• Loosen
the socket head bolts and
take out the oil pump idle gear.
• Use a puller of special tool to remove
the crankshaft gear.
6.1.43. Timing gear case
• Unscrew
the case fixing bolts and
disassemble the timing gear case.
EAMD046I
6.1.44. Crankshaft and bearing cap
• Unscrew the main bearing cap fixing
bolts and remove the bearing caps.
• Take off the crankshaft.
• Detach the main bearings.
EAMD047S
- 62 -
6.1.45. Oil spray nozzle
• Unscrew the fixing bolt and remove
the oil spray nozzles.
- 63 -
6.2. Inspection
6.2.1. Cylinder block
1) Clean the cylinder block thoroughly and check a visual inspection for cracks or damage.
2) Replace if cracked or severely damaged, and correct if slightly damaged.
3) Check the oil and water passing lines for restriction or corrosion.
4) Make a hydraulic test to check for any cracks or air leaks.
Hydraulic test : Stop up each outlet port of water and oil passages in the cylinder block,
apply air pressure of about 4 kg/cm2 against the inlet ports, then immerse
the cylinder block in water for about 1 minute to check any leaks. (Water
temperature: 70°C)
6.2.2. Cylinder head
1) Inspection of cracks and damage
• Carefully remove carbon from the lower face of the cylinder head using nonmetallic material
to prevent scratching of the valve seat faces.
• Check the entire cylinder head for very fine cracks or damage invisible to ordinary sight
using a hydraulic tester or a magnetic flaw detector.
2) Distortion at the lower face
• Measure
the amount of distortion
(t)
using a straight edge and a feeler
gauge at six positions as shown in the
B
A
right figure.
• If
C
the measured value exceeds the
D
standard value, retrace the head with
grinding paper of fine grain size to
E
F
correct such defects.
• If
the measured value exceeds the
EA3M2031
maximum allowable limit, replace the
cylinder head.
<Lower face warp and height>
Warp
Thickness : t
(reference)
Standard
Limit
0.2 mm or less
0.3 mm
109.9 ~ 110.1 mm 108.4 mm
EA0M4039
- 64 -
3) Flatness
Measure the flatness of the intake and exhaust manifold face mounted on the cylinder head
using a straight edge and a feeler gauge.
Standard
Limit
0.05 mm
0.2 mm
4) Hydraulic test
Hydraulic test for the cylinder head is same as that for cylinder block.
6.2.3. Valve & valve guide
1) Valve
Clean the valves with clean diesel oil, then inspect them as follows :
• Valve stem outer diameter
Measure the valve stem outer diameter
at 3 positions (top, middle, and bottom).
If the amount of wear is beyond the
limit, replace the valve.
End of stem
Dimension
Description
Intake valve stem
Exhaust valve stem
Standard
Limit
8.95 ~
8.97 mm
8.93mm
8.935 ~
8.955 mm
8.91 mm
EFM2036I
• Valve seat contacting faces
Check the valve seat contacting face for scratch or wear, and correct the faces with fine
grinding paper as necessary. Replace if severely damaged.
• Valve head thickness
Measure the valve head thickness, and
replace the valve if the measured value
is beyond the limit.
Dimension
Description
Standard
Limit
Intake valve
2.7 mm
1 mm or less
Exhaust valve
2.2 mm
1 mm or less
EFM2037I
- 65 -
2) Valve guide
• Install the valve into the valve guide
and measure the clearance between
them by valve movement. If the
clearance is excessive, measure the
valve and replace either the valve or
Measuring
position
the valve guide, whichever worn more.
<Valve stem end play>
EA0M4052
Standard
Limit
0.030 ~ 0.065 mm
0.15 mm
Exhaust valve 0.045 ~ 0.080 mm
0.15 mm
Intake valve
• Install the valve into the cylinder head valve guide, then check and see if it is centered with
the valve seat using a special tool.
3) Valve seat
• Contacting face amount
Measure the contacting face between
the intake valve seat and exhaust valve
seat for valve seat wear, and replace if
the
measured
value
exceeds
the
specified limit.
Depression
EA0M4046
• Install the valve into the valve seat on
the cylinder head, and check the
amount of depression of the valve
from the lower portion of the cylinder
head using a dial gauge.
Valve Depression
Standard
Limit
EDM2032P
Intake &Exhaust 0~0.3 mm 0.55 mm
If the amount of depression is beyond the specified limit, replace the valve seat.
- 66 -
• For removal of the valve seat, apply
arc welding work to two points of valve
Valve seat
insert
seat insert, and pull out the valve seat
insert with inner extractor.
Cylinder head
Welding bead
EA3M2032
• For assembling of a new valve seat, by putting it among the dry ices of an ice box previously
for about 2 hours for the cold shrinkage, and press it in the cylinder head by a special tool.
(bench press)
• Apply the valve lapping compound on the valve head seating face and lap the valve seat by
turning it until it is seated in its position, then wipe out the lapping compound.
Note : Clean the valve and cylinder head with light oil or equivalent after the valve seat
finishing is completed, and make sure that there are no grinding materials remained.
4) Valve spring
• Visual check
Visually check the exterior of the valve
springs for damage, and replace if
necessary.
• Valve Spring Free Length
Use a vernier caliper to measure the
valvespring free length.
If the measured value is less than the
specified limit, the valve spring must
be replaced.
Spring free Length
Standard
Intake valve
64 mm
Exhaust
Inner
60 mm
valve
Outer
71 mm
EJM2049I
- 67 -
•
Valve Spring Inclination
Use a surface plate and a square to
measure the valve spring inclination.If
the
measured
value
exceeds
Inclination
the
specified limit, the valve spring must be
Standard
Limit
1.8 mm
2.7 mm
Valve spring
inclination
Free length
replaced.
Square
EJM2050I
• Valve Spring Tension
Use a spring tester to measure the
valve spring tension if the measured
value is less than the specified limit, the
valve spring must be replaced.
Set Length
Intake
Valve Spring
valve
Tension at 41mm
Spring
force
Limit
Spring tester
70 kg
± 3kg
EA0M4056
Set Length
Exhaust
Inner
38 mm
28.6 kg
±6%
valve
Outer
41 mm
66 kg
±5%
6.2.4. Rocker arm shaft assembly
1) Rocker arm shaft
• Rocker arm shaft run-out
Place the rocker arm shaft on two V
blocks and inspect the shaft for
bending using a dial gauge.
If the amount of this run-out is small,
press the shaft with a bench press to
correct the run-out. Replace the shaft
if the measured value exceeds the
limit.
Limit
0.3 mm
EDM2037I
- 68 -
• Rocker arm shaft diameter
With an outside micrometer, measure
the rocker arm shaft diameter at the
point where the rocker arms have
been installed.
Replace the rocker arm if the amount
of wear is beyond the specified limit.
Standard
23.939 ~
23.96 mm
Limit
23.75 mm
EA8M3002
2) Rocker arm
• Visual check
Visually check the face of the rocker arm in contact with the valve stem end for scores and
step wear. If the wear is small, correct it with an oil stone or grinding paper of fine grain size.
Rocker arm with a considerable amount of step wear should be replaced.
• Diameter of the rocker arm bushing
Measure the inside diameter of the
rocker arm bushing with an inside
micrometer or vernier calipers, and
compare the measured values with
the rocker arm shaft diameter. If the
clearance exceeds the limit, replace
either bushing or shaft, whichever
worn more.
Standard
Limit
0.020 ~ 0.093 mm
0.25 mm
EA0M4059
3) Tappet and push rod
• Clearance
Measure the clearance of the tappet and tappet holes of the cylinder block. If the value is
beyond the specified limit, replace the tappet.
Standard
Limit
0.035 ~ 0.077 mm
0.1 mm
- 69 -
•
Visual check of tappet
Visually check the face of the tappets
in contact with the cam for pitting,
scores or cracks, and replace if
severely damaged. If the amount of
unevenness
(1) 요철
cracks or pitting is small, correct with
Crack
(2)
균열
Normal
(3)
정상
an oilstone or grinding paper.
abnormal
(4)
비정상
EA0M4070
•
Outside diameter
With an outside micrometer, measure
the tappet outside diameter. If the
measured value is beyond the limit,
replace tappets.
Standard
19.944 ~
19.965 mm
EDM2061I
•
Push rod run-out
Use a feeler gauge to measure the
push rod run-out.
Roll the push rod along a smooth flat
surface as shown in the figure.
Limit
0.3 mm or less
Feeler gauge
EA0M4073
- 70 -
6.2.5. Camshaft
1) Cam
• Cam lobe height
Use a micrometer to measure the cam
lobe height and journal diameter.
If the measured number is less than
the specified limit, the camshaft must
replaced.
Items
Cam lobe
Intake
height (C)
Exhaust
Standard
Limit
49.15 mm
48.85 mm
49.32
49.00 mm
I II
A
C
B
D
I II
B
A
EA0M4062
Cam journal
57.86 ~
diameter (A, B)
57.52 mm
57.88 mm
• Cam surface
Inspect the cam surface for scratch or damage.
Slight step wear or damage on the cam surface may be corrected with an oilstone or oiled
grinding paper. But, replace if severely damaged.
2) Camshaft
• Clearance
between
camshaft
journal and camshaft bush
- With
an
measure
outside
the
micrometer,
camshaft
journal
Camshaft bearing
diameter.
- Measure the inside diameter of the
camshaft bush on the cylinder block
using a cylinder bore indicator, and
compare the measured value with
the camshaft outside diameter to
determine the clearance.
EA0M4063
<Clearance>
Standard
Limit
0.12 ~ 0.17 mm
0.24 mm
Replace the bush if the measured value is beyond the specified limit.
- 71 -
• Run-out
Support the camshaft on two V blocks
and check for run-out using a dial
indicator. Correct or replace the cam
shaft if the amount of run-out is
beyond the value indicating need for
servicing.
Standard
Limit
0.05 mm
0.2 mm
EA0M4066
3) Camshaft end play
• Push the thrust plate toward the cam
gear.
• With
a feeler gauge, measure the
clearance between the thrust plate
and camshaft journal.
• If the end play is excessive, replace
the thrust plate.
Standard
Limit
0.28 ~ 0.43 mm
0.6 mm
간극 게이지
Feeler
gauge
EA0M4067
6.2.6. Crank shaft
1) Defect check
• Visually check the crankshaft journal and crank pins for scores or cracks.
• Using a magnetic power and color check, inspect the crankshaft for cracks, and replace the
crankshaft which has cracks.
2) Wear measuring
• With an outside micrometer measure
the diameter of the crankshaft journals
and pins in the directions as shown,
and compare the measured values to
determine the amount of wear.
• If the amount of wear is beyond the
limit, polish the crankshaft and install
undersize bearings. However, if the
amount of wear is within the limit, you
EAMD057I
can correct the wear using an oil
stone or oiled grinding paper of fine
grain size. (Be sure to use grinding paper which has been immersed in oil.)
- 72 -
Standard
Journal
diameter
Pin
diameter
Limit
A
83.966 ~ 83.988
83.000 mm
70.971 ~ 70.990
70.000 mm
B
B
B
B
A
EFM2047I
* Undersize bearings available
Standard
0.25 (Inside diameter is 0.25 mm lesser than the standard size.)
0.50 (Inside diameter is 0.50 mm lesser than the standard size.)
0.75 (Inside diameter is 0.75 mm lesser than the standard size.)
1.00 (Inside diameter is 1.00 mm lesser than the standard size.)
Undersize bearings are available in 4 different sizes as indicated above, and the
crankshaft can be reground to the above sizes.
Note : When regrinding the crankshaft
as described above, the fillet
"R"
section ‘R’ should be finished
correctly. Avoid sharp corners or
"R"
insufficient fillet.
"R"
* Standard values of ‘R’
1
Crank Pin ‘R’
: 4.5
2
Crank journal ‘R’ : 4
Normal
0
-0.2
3) Crankshaft run-out
• Support the crankshaft on V blocks.
• Turn the crankshaft with a dial
indicator placed on the surface plate
and
measure
the
"R"
"R"
Poor
Poor
0
-0.2
amount
of
crankshaft run-out.
Standard
Limit
0.05 mm
0.1 mm
- 73 -
EFM2048I
6.2.7. Crankshaft bearing and con- rod bearing
1) Visual check
Visually check the crankshaft bearing and the connecting rod bearing for scores, uneven
wear or damage.
2) Oil clearance between crankshaft and bearing.
• Main bearing clearance
Install
the
main
bearing
in
the
cylinder block, tighten the bearing
cap
to
specified
torque,
then
measure the inside diameter.
Torque
30 kg.m
Crank journal
Diameter
83.966~83.988 mm
Compare
the
two
values
obtained
through measurement of the main bearing inside diameter with the outside diameter of the
crankshaft journal to determine the oil clearance.
Standard
Limit
0.052 ~ 0.122 mm
0.25 mm
• Connecting rod bearing clearance
(Method 1)
Install the connecting rod bearing in
the
connecting
rod
bearing
cap,
tighten the connecting rod cap bolts to
the specified torque, then measure
the inside diameter.
Torque
18 kg.m
Cranck pin Dia.
70.971 ~ 70.990 mm
- 74 -
Compare
the
two
values
obtained
through measurement of connecting rod
bearing inside diameter with the outside
diameters of the crankshaft pins to
determine the oil clearance.
Standard
Limit
0.049 ~ 0.119 mm
0.20 mm
EAMD060I
If the clearance deviates from the
specified range, polish the crankshaft
journals and pins ground and install undersized bearings.
• Connecting rod bearing clearance (Method 2 : with plastic gauge )
Assemble the crankshaft on the cylinder block and put the plastic gauge on the journal and
pin of crankshaft and then after assembling bearing cap, tighten the bolts at the specific
torque. Again after disassembling the bearing cap by removing the bolts, take out the flatted
plastic gauge and measure the width of plastic gauge by means of plastic gauge measuring
scale. This is the oil clearance.
3) Bearing spread and crush
•
Inspection
Check to see that the bearing requires
a
considerable
amount
of
finger
pressure at re-assembly operation.
OA
OB
스프레드
A-OB
Spread = = OAB
EDM2047I
- 75 -
• Crankshaft bearing crush
Install the bearing and cap in the
cylinder block, retighten the bolts to
specified torque, only unscrew out
one bolt completely, then measure the
clearance between the bearing cap
and cylinder block using a feeler
gauge.
Standard
0.19 ~ 0.22 mm
EA6M063I
• Connecting rod bearing crush
Install the bearing and cap in the
connecting rod big end, retighten the
bolts to specified torque, only unscrew
out one bolt completely, then measure
the clearance between the bearing
cap and the connecting rod big end
using a feeler gauge.
Standard
0.3 ~ 0.5 mm
EA6M064I
4) Crank shaft end play
• Assemble the crankshaft to the cylinder
block.
• With a dial gauge, measure crankshaft
end play.
Standard
Limit
0.15 ~ 0.325 mm
0.5 mm
- 76 -
6.2.8. Piston
1) Visual check
Visually check the pistons for cracks, scuff or wear, paying particular attention to the ring
groove.
2) Clearance between the piston and
cylinder liner
• With an outside micrometer, measure
the piston outside diameter at a point
Position of measuring
outside diameter
13mm away from the lower end of
piston skirt at right angle against
direction of the piston pin hole.
Standard
110.801 ~
110.959 mm
13
EC5OM133
• Using a cylinder bore gauge, measure
cylinder liner inside diameter at 3
2
points (Contacting face of the cylinder
1st, 2nd, and oil rings on B.D.C) in a
direction
at
an
angle
of
45°
separately. Take the mean value
except
the
largest
and
smallest
values.
Standard
Limit
111 ~ 111.022 mm
111.222 mm
EAMD067I
• The clearance is computed by subtracting the piston outside diameter from the cylinder liner
inside diameter. Replace either piston or cylinder liner, whichever damaged more, if the
clearance is beyond the specified limit.
<Clearance between piston and liner>
Standard
0.041 ~ 0.221mm
- 77 -
6.2.9. Piston rings
1) Visual check
Replace the piston rings with new ones if detected worn or broken when the engine is
overhauled.
2) Piston ring gap
• Insert the piston ring into the upper portion of the cylinder liner bore and then it should be
positioned at a right angle against the cylinder liner wall surface.
• Measure
the piston ring gap with a
feeler gauge.
Standard
Limit
Top ring
0.40 ~ 0.65 mm
1.5 mm
2nd ring
0.40 ~ 0.65 mm
1.5 mm
Oil ring
0.30 ~ 0.60 mm
1.5 mm
Replace piston rings with new ones if
the gap is beyond the limit
3) Piston ring side clearance
• Fit the compression rings and oil ring
in the piston ring grooves.
• With
Feeler gauge
a feeler gauge, measure side
clearance of each ring, and replace
either
the
measured
ring
value
or
piston
is
if
the
beyond
the
specified limit.
Standard
Top ring
Limit
EA0M4032
Tapered Type
2nd ring 0.07 ~ 0.102 mm 0.15 mm
Oil ring
0.05 ~ 0.085 mm 0.15 mm
4) Piston ring tension
With a tension tester, measure piston ring tension. Replace the piston ring if the measured
value is beyond the limit.
Standard
Top ring
2.58 ~ 3.88 kg
2nd ring
1.81 ~ 2.71 kg
Oil ring
3.57 ~ 5.03 kg
- 78 -
6.2.10. Piston pin
1) Wear
Measure the amount of wear on the
piston pin at the points as shown. If
the measured values are beyond the
limit (0.005 mm or greater), replace
the pin.
Standard
Limit
41.944 ~ 42.000 mm
41.940 mm or less
EA0M4031
2) Clearance
Measure the clearance between the
piston pin and connecting rod bush,
and replace either of them, whichever
damaged more, if the measured
value is beyond the limit.
Standard
Limit
0.009 ~ 0.015 mm
0.08 mm
EA3M2047
3) Condition check
Check the insertion condition of the piston and piston pin. If it is possible to force the pin
into the piston heated by piston heater, the piston is normal.
When replacing the piston, be sure to replace the piston pin together.
- 79 -
6.2.11. Connecting rod
1) Distortion
Check the connecting rod for distortion. As shown in the figure below, install the connecting
rod to the connecting rod tester, and check for distortion using a feeler gauge. If the
connecting rod is found distorted, never re-use it but replace with a new one.
2) Holes alignment (parallelism)
Measure
the
alignment
of
the
connecting rod small bushing hole
and the connecting rod big end hole.
At this time also, use both connecting
rod tester and feeler gauge.
Standard
Limit
0.05 mm
0.1 mm or less
Feeler gauge
EA0M4034
3) Wear
• Assemble the connecting rod to the crankshaft and measure connecting rod big end side
clearance using a feeler gauge.
• Assemble the connecting rod to the piston and measure connecting rod small end side
clearance.
• If the measured values are beyond the limit, replace the connecting rod.
Limit
0.5 mm
- 80 -
6.3. Engine Re-assembly
6.3.1. General precautions
• Clean all the disassembled parts, particularly oil and water ports, using compressed air,
then check that they are free from restrictions.I
• Arrange the general and special tools in order to engine assembly operation.
• To lubricate each sliding part, prepare the clean engine oil.
• Prepare maintenance materials such as sealant, gaskets, and etc.
• Discard used gaskets, seal rings, and consumable parts, and replace with new ones.
• Apply only the specified torque for bolts in the specified tightening order and avoid overtightening.
• Be sure to check that all the engine parts operate smoothly after being reassembled.
• Check the bolts for looseness after preliminary re-assembly.
• After completing the engine re-assembly operation, check if there is missing parts or shortage of parts.
•
Keep your hands clean during the maintenance.
6.3.2. Cylinder block
• Cover the floor of the workshop with wood plate or thick paper to prevent damage to the
cylinder head and place the head face of the cylinder block towards downward.
6.3.3. Oil spray nozzle
• Tighten and assemble the oil spray
nozzle with fixing bolts using the
spray nozzle jig.
EDM3053I
6.3.4. Tappet and cam shaft
• Under cool a new bush with dry ice for about 2 hours and press it into position in the cylinder block using a bench press. After the pressing operation, measure the inside diameter of
the cam bush to check if it is not deformed.
- 81 -
• Apply engine oil to the entire face of
the tappets and slide them into the
tappet holes on the cylinder block.
• Wet
the cam bush inside diameter
and camshaft with oil, and carefully
assemble them while turning the
camshaft.
• Check
to see that the camshaft
rotates smoothly.
EDM2060I
6.3.5. Crankshaft
• Install
the main bearing machined
Key키groove
홈
with two holes in the cylinder block so
Oil
port구멍과
and passage
오일
통로
that the key is aligned with the key
groove, then apply oil to the bearing
surface.
EA0M4083
• Heat the crankshaft gear for at least
10 minutes to 120° C
then apply
,
sealant (Loctite # 641) to the inside
wall of the heated crankshaft gear
evenly before inserting it to the end of
crankshaft.
EA8M3014
- 82 -
• Semi-tighten a bolt at both sides of
the crankshaft, apply engine oil to
journals and pins, then assemble the
crankshaft with the cylinder block by
tightening the fixing bolts.
EAMD075S
• Install the oiled thrust washers with
the oil groove facing outward of the
bearing.
• Install the bearing and thrust washers
to the bearing cap and apply oil to the
bearing and thrust washers.
EAMD077I
• Install the bearing cap by matching
the cylinder block number compare
with the bearing cap number.
7
6
5
4
3
2
1
EAMD078I
- 83 -
• Apply oil to the entire part of the bearing cap bolts, then tighten in tightening sequence to specified torque.
30 kg.m
Torque
EAMD079I
• After semi-tightening both bolts evenly, tighten them diagonally specified torque using a
torque wrench as follows.
<Tightening order>
(1) First stage
: Coat engine oil over the bolts.
(2) Second stage : Temporary assemble the bolts about 1 ~ 2 threads
(3) Third stage
: With impact wrench, tighten up to about 15 kg.m
(4) Fourth stage
: With torque wrench, tighten up to about 25 kg.m
(5) Fifth stage
: By means of torque wrench, tighten finally in the specified torque. (30
kg.m).
•
•
Tighten the bearing cap in the sequence of its number 4-3-5-2-6-1-7.
Check to see that the assembled crankshaft turns smoothly.
6.3.6. Flywheel housing
• Temporarily install the guide bar on
the cylinder block.
• Apply gasket to the cylinder block.
• Using the dowel pin and guide bar,
install the flywheel housing and tighten the fixing bolts in a diagonal
sequence to specified torque.
Torque
8 kg.m
EB1M3021
- 84 -
6.3.7. 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, then assemble the oil
seal using an oil seal fitting jig.
6.3.8. Flywheel
• Install a guide bar into a bolt hole on
the crank shaft, and lift the flywheel to
align the dowel pin with the pin hole
on the flywheel for temporary assembly operation.
• Install
bolts in the remaining holes,
take out the guide bar, then install a
bolt in the hole where the guide bar
had been inserted.
EB1M3020
• Tighten the fixing bolts using a torque
wrench in a diagonal sequence to
specified torque.
Torque
21.5 kg.m
4
8
6
1
2
5
7
3
EAMD097I
6.3.9. Timing gear case
• Mount the gasket using dowel pin on
the cylinder block.
• Install the timing gear case by aligning the dowel pin with the dowel pin
hole on the timing gear case.
EAMD082I
- 85 -
6.3.10. Injection pump drive gear
• Mount the gasket by aligning the bolt
holes with the pin holes on the bearing housing.
• Tighten up the fixing bolts in the direction of fuel injection pump.
EB1M3023
6.3.11. Timing gear
• Install the oil pump idle gear into the
No.7 bearing cap.
• Install
a thrust washer over the
Idle gear pin
camshaft and assemble the cam gear
by aligning it with camshaft key
groove.
Torque
2.2 kg.m
EAMD083I
• After the oil port on the idle gear pin
Idle gear pin
towards the cylinder block, install the
idle gear pin.
EA8M3004
• Install the idle gear by coinciding the
Mark "2"
marks impressed on the crank gear,
cam gear, fuel injection pump drive
Fuel injection
pump drive gear
gear, and idle gear each other.
• Install a thrust washer on the idle gear
Cam gear
1
2
2
2
1
1
Idle gear
and tighten to specified torque.
Mark "1"
Torque
6.2 kg.m
Mark "0"
Crank
gear
EA8M3005
- 86 -
• Check and adjust the amount of backlash between gears using a feeler gauge.
Items
Standard
Limit
Cam gear & idle gear
0.16 ~ 0.28 mm
0.35 mm
Crank gear & idle gear 0.16 ~ 0.28 mm
0.35 mm
Injection pump &
idle gear
0.16 ~ 0.28 mm
0.35 mm
6.3.12. Timing gear case cover
• Install
the dowel pin on the timing
gear case.
• Mount a gasket by aligning the fixing
bolt holes with those on the gasket.
• Align the dowel pin with the cover pin
hole, then install the cover with light
tap.
• Tighten the fixing bolts beginning with
the oil pan fitting face.
6.3.13. Front oil seal
• Apply lubricating oil to the outside of
the oil seal and timing gear case
inside diameter and fit it over the
crankshaft, then assemble the oil seal
using an oil seal fitting jig.
Oil seal fitting jig
EAMD086I
6.3.14. Cylinder liner
• Stand the cylinder block so that the
flywheel faces downward.
• Thoroughly clean the liner flange fitting surface and bore inside with compressed air to prevent the entry of foreign substances.
• After
the cleaning operation, make
the cylinder liner dried up and push it
into the cylinder block by hand.
•
EAMD087I
Wet the liner inside diameter with
engine oil.
- 87 -
6.3.15. Piston and connecting rod
• Use a piston heater to heat the piston
approximately 100 °C ~ 212 °F for 5
minutes.
• Align the piston pin hole with the connecting rod small end bush oiled and
press the piston pin (by lightly tapping
with a rubber hammer) to assemble
the connecting rod into the piston.
EAMD088I
• Noticing
the direction of the piston,
make the longer side (machined with
key groove on the bearing) of the connecting rod big end and the mark of
‘
‘ impressed on the inside of the
1 06
piston face each other in opposite
directions. On the piston head surface, the longer side of the connecting rod big end is in opposite direction
EAMD089I
from the valve seat surface.
• Install the snap rings and check to see that it is securely assembled.
•
Install the piston ring in the piston using piston ring pliers.
- 88 -
• Identify
the mark “Y” on the piston
ring end to prevent assembling the
bottom of the piston ring is being
interchanged
with
its
top
faced
marked “Y”.
Note : Be sure to make the piston ring
end marked face(“Y”) upward.
"Y" marked from piston ring
manulacturing company
EAMD090I
• Adjust
the angle among individual
45
piston ring gaps to 90° and fit a piston
2nd ring gap
assembling jig onto the piston, Use
(0.35~0.50mm)
O
45
O
Top ring gap
(0.30~0.45mm)
care not to match the ring gaps with
the piston pin direction.
90
• Install the bearing by aligning it with
the connecting rod key groove and
O
Piston pin
apply oil to the bearing and piston.
Oil ring gap
Piston
(0.30~0.50mm)
EA8M3006
• Make a position the valve seating surface toward the tappet hole and insert
the piston with hand.
Tappet hole
Use care not to damage the cylinder
liner and piston, and slightly lift and
Valve seating
insert the piston into the cylinder so
that the ring may not be damaged by
the fillet of the liner.
• Install the bearing in the connecting
EAMD092I
rod cap and apply oil.
• Make sure that the manufacture serial
number impressed on the connecting
rod cap and the connecting rod big
end is identical, and install the connecting rod cap by aligning it with
dowel pin.
• Wet the fixing bolts with oil, semi-tighten them by hand, tighten them to
specified
torque
using
a
torque
wrench as follows.
- 89 -
<Tightening order>
(1) First stage
: Coat engine oil over bolts
(2) Second stage : Temporary screw the bolt about 1 ~ 2 threads
(3) Third stage
: With torque wrench, tighten at about 10 kg.m
(4) Fourth stage
(5) Fifth stage
: With torque wrench, tighten up to about 15 kg.m
: Finally, tighten in the specified torque 18kg.m with torque wrench .
18 kg.m
Torque
• Move the bearing cap with hand, and
release and reassemble it if no movement is detected.
EAMD094I
6.3.16. Relief valve
•
Assemble the relief valve.
EAMD036I
6.3.17. Oil pump and oil pipe
• Install a dowel pin in the No.7 bearing
cap, then assemble the oil pump with
specified torque.
Torque
4.4 kg.m
• Assemble the oil suction pipe with the
delivery pipe, then install the bracket
on the bearing cap.
- 90 -
6.3.18. Oil pan
• Mount
gasket and put the oil pan
thereon.
• Align the bolt holes with gasket holes
to prevent damage to the gasket and
tighten bolts to specified torque.
Torque
2.2 kg.m
EAMD034I
6.3.19. Vibration damper and pulley
• Assemble the vibration damper on the
Crankshaft pulley.
• Install the crankshaft pulley assembly
on the crankshaft, then tighten the
bolts and thrust washers.
Torque
13.4 kg.m
6.3.20. Cylinder head
• Install the injection nozzle fixing stud
bolts and water pipe fixing stud bolts.
• 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.
TOP
• Install head gasket, with ‘TOP’ mark
facing upward, on the cylinder block
by aligning the holes with dowel pins.
EB1M3025
- 91 -
• Check the inside of combustion chamber for foreign substances, and carefully mount the cylinder head on the
cylinder block by aligning the dowel
pin in the pin hole. Be careful not to
damage the head gasket. If the dowel
pin is not in alignment, lift the cylinder
head again and then remount it.
EAMD102I
• Coat the head bolts with engine oil,
then tighten them in proper sequence
to the specified torque according to
bolt tightening order. (refer to the fig-
5
3
2
7
5
3
2
7
5
3
2
7
8
1
4
6
8
1
4
6
8
1
4
6
ure)
EDM2097I
<Cylinder Head Bolts>
Type 1
Type 2
TY
12.9T
TY
10.9T
M14x1.5x146
M14x1.5x146
24.5 kg.m
6 kg.m +180˚+150˚
Specification
Torque
However, before tightening bolts, align the side face of 3 cylinder heads with parallel. They
should be adjusted in a straight line exactly.
<Tightening order of bolts by steps>
(1) First stage
: Coat the bolts with engine oil.
(2) Second stage : Tighten 1 ~ 2 threads with hands.
(3) Third stage
: Tighten at about 6 kg.m with a wrench.
(4) Fourth stage
: Tighten at rotating angle method 180° with a wrench.
(5) Fifth stage
: Finally, tighten at rotating angle method 150° with a torque wrench .
However, all bolts are tightened simultaneously by above steps as possible.
• Coat the push rod with engine oil and insert it into the push rod hole.
- 92 -
6.3.21. Intake and exhaust valves
• Identify
the marks of “IN” and “EX”
impressed on the valve head before
assembling the valve in the head.
• With
a valve stem seal fitting jig,
assemble the valve guide and stem
seal.
• After
installing valve springs and
spring retainer, press the retainer with
a jig, then install cotter pin.
• Tap the valve stem lightly with a rubber hammer to check that the valve is
assembled correctly.
compressor
the spring
EA0M4007
6.3.22. Rocker arm assembly
• Apply lubricating oil to the rocker arm
bush and shaft, and assemble the
intermediate bracket with the rocker
arm using fixing bolts.
4.4 kg.m
Torque
EB1M3026
• Semi-install
the
valve
clearance
adjusting bolts onto the rocker arm.
• Install the spring, rocker arm, bracket,
rocker arm, spring, washer, and snap
ring in the described sequence.
• Install the rocker arm and bracket in
the same direction.
EA8M3008
- 93 -
6.3.23. Injection nozzle
• Install the dust seal with its round portion facing downward.
• Mount a seal ring on its position of the
cylinder head and then assemble the
nozzle holder.
• Be sure to follow the specified torque.
EB1M3024
7.0 kg.m
Torque
6.3.24. Valve clearance adjustment
• Cylinder No. 1 begins from the rear side where the flywheel is mounted but cylinder No. 6
begins from the front side of the engine on the contrary.
Flywheel
Intaek Valve
1
Exhaust Valve
2
3
Cylinder No.
4
5
Crank Pulley
6
EA7M2002
Step 1 :
• After letting the cylinder No.6 in the overlap TDC position by turning the crankshaft, adjust
the valves corresponding to “
” of following figure. At this time cylinder No. 1 should be at
the ignition TDC position.
Step 2 :
• After adjusting upper valves turn the crank pulley 360° to adjust the other valve clearance
until the cylinder No. 1 comes to overlap TDC position.
At this time cylinder No. 6 should be at the ignition TDC position(O.T).
• Adjust the valve corresponding to “
” of upper figure.
After reconfirming the valve clearances, retighten it if necessary.
• Loosen the lock nuts of the rocker arm adjusting screws and push the specified feeler gauge
and adjusting the valve clearance with adjusting screw respectively.
Model
Intake Valve
Exhaust Valve
L136/T/TI/086TI
AD136/T/TI/086TI
0.3 mm
0.3 mm
- 94 -
• Adjust valve clearance with a feeler
gauge and tighten the fixing nuts to
specified torque.
4.4 kg.m
Torque
EA0O4014
6.3.25. Injection pipe
• Semi-assemble the nuts at both ends
of the fuel injection pipe and tighten
them up one by one to specified
torque.
2.9 ~ 3.2 kg.m
Torque
• Tighten the hollow screws to assemble the fuel return pipe.
• Assemble the fuel return hose on the
fuel injection pump.
6.3.26. Cylinder head cover
• Assemble
the new packing in the
cylinder head cover, install the cover
on the cylinder head, then tighten the
fixing bolts in sequence to specified
torque.
Torque
1.5 kg.m
• Assemble the breather hose and the
breather assembly.
• Assemble the oil filler cap in the cylinder head cover.
EA9O4002
- 95 -
6.3.27. Injection pump & injection timing
(1) Fuel injection pump
(A) L086TI, AD086TI
• Install the injection pump bracket in
the cylinder block.
• After measuring the amount of runout with an alignment setting jig,
disassemble the bracket, adjust the
shims, then reassemble it.
Run out
• Mount
0.2 mm or less
the top/bottom adjusting
shims in the bracket and then
EAMD107I
mount the fuel injection pump.
• Tighten the fixing bolts in a diagonal
sequence to specified torque.
Torque
4.4 kg.m
(B) L136/T/TI, AD136/T/TI
• Reassemble the injection pump by
using the engraved line as the figure.
Engrave Line
표시선
EB4O601L
To assemble the new injection pump,
align the center of the hexagonal
socket plug on the front side of the
injection pump with the upper bolt
hole of the injection pump flange.
EB1M9090
- 96 -
Then assemble the injection pump gear
by aligning with the oil paint marking
lines as figure.
marking
ENM3032S
(2) Injection timing
• Turn the crank shaft until cylinder No.
6 is placed in the overlap TDC and
Timing
check hole
then turn again the flywheel clockwise
until the notch mark corresponding to
the injection timing degree its model is
aligned with hole center(
) in the fly-
wheel as right figure.
<Fuel injection timing>
Refer to “ 1. Engine specification ” for
each model.
Flywheel
ring gear
Injection timing
notch mark
EB1M3028
EB1M3028
- 97 -
(A) L086TI, AD086TI
• After letting the cylinder No. 6 at overlap TDC position, adjust the injection
timing degree of the engine.
• After that, turn the injection pump until
the notch mark of the pump indicator
plate mounted is aligned with the
notch mark of the drive shaft flange as
right figure.
• Tighten
the coupling housing fixing
EQM3089S
bolts and nuts to specified torque.
6.0 kg.m
Torque
• Tighten
the coupling housing fixing
bolts and nuts to specified torque.
Torque
7.5 ~ 8.5 kg.m
• Install the oil delivery pipe and return
pipe.
• At the same time, install the oil delivery pipe which feeds oil to the sea
EAMD021I
water pump.
(B) How to check the fuel injection timing exactiy
• To
confirm the fuel injection pump
timing, put the cylinder No. 6 in the
overlap
TDC
position. And
Holder
홀
더
then
remove the seat, spring and delivery
valve from No. 1 plunger of the injec-
시
트
Seat
tion pump to check whether the fuel
A
ejection or not from the injection pipe
visually.
Delivery
딜리버리
Valve
밸브
• Assemble the holder and pipe except
seat, spring and delivery valve (“A”
parts).
Holder Torque
Spring
4 ~ 4.5 kg.m
- 98 -
EA3M1017
• Turn the crank pulley clockwise slowly
on pumping the priming pump to be
continues simultaneously and you can
see the point that fuel falls down by
one drop per every 5 or 6 seconds
from the fuel pipe No. 1. This point is
the very fuel injection timing degree.
EA9M3016
• After confirming the fuel injection timing, reassemble the holder and inner
Holder
홀
더
parts including seat, spring and delivery valve.
시
트
Seat
4 ~ 4.5 kg.m
Holder Torque
A
Spring
Delivery
딜리버리
Valve
밸브
• Connect the No. 1 fuel injection pipe
and tighten as specified torque.
EA3M1017
Fuel pipe nut Torque 3 ~ 3.5 kg.m
Caution : Do not too tighten the delivery valve holder to prevent the rack mal function of the
fuel injection pump.
In case of exchanging the injection pump, be sure to fill the engine oil in the governor before engine starting.
<Oil capacity of injection pump>
L136/T/TI
AD136/T/TI
L086TI
AD086TI
0.5 LIt.
0.7 Lit.
6.3.28. Oil cooler & oil filter
• After assembling the oil cooler onto
the oil cooler housing, tighten the
mounting
bolts
of
the
oil
cooler
assembly in the cylinder block inserting a new gasket.
•
Oil filter
Lightly oil the O-ring and turn the oil fil-
Oil cooler
ter cartridge until its O-ring is contacted against the sealing face of the oil
filter head. And then turn the oil filter
EC5OM134
cartridge 3/4~1 turn more with hands
or a filter wrench.
- 99 -
• Connect the cooling water pipes to the water pump and the heat exchanger.
6.3.29. Water pump
• Mount a new gasket.
• Install the water pump on the cylinder
block and tighten the assembling bolts
with specified torque.
2.2 kg.m
Torque
• Connect cooling water pipe and the
expansion tank each other.
EB1M3017
6.3.30. Sea water pump
• Mount a new gasket.
• Install the sea water pump on the timing gear case cover and tighten the
assembling
bolts
with
specified
torque.
Torque
4.4 kg.m
EC5OM120
6.3.31. Heat exchanger
• Install the heat exchanger on the flywheel housing, and tighten the fixing
bolts with specified torque.
Torque
4.4 kg.m
EC5OM117
- 100 -
6.3.32. Thermostat
• Install the thermostat.
• Fit the new gasket on the thermostat
housing, then assemble the thermostat housing with mounting bolts.
• Assemble
the hose clamps in both
sides of the heat exchanger and cooling water pipe
EC5OM116
6.3.33 Exhaust manifold
• Assemble the exhaust manifold with
steel gasket in order to be installed in
the small hole between two holes of
the gasket upward and be sure to
check the squared port of the gasket
whether the square port of the cylinder
head is aligned before assembling.
• Tighten the fixing bolts with specified
torque.
EC5OM125
M10 (Upper row)
4.4 kg.m
M12 Lower row)
8.0 kg.m
Torque
6.3.34. Intake manifold
• Assemble the intake manifold including the gasket.
• Connect
the air hose to the boost
compensator of the fuel injection
pump.
EC5OM115
- 101 -
6.3.35. Stop solenoid (L086TI)
• Assemble the brackets on the injection pump body.
• Install the stop solenoid and tighten
the fixing bolts.
• Connect the tie rod to fuel feed pump
and stop solenoid.
EC5OM114
6.3.36. Injection pipe
• Semi-assemble nuts at both ends of
the fuel high pressure pipe and tighten
them up one by one to specified
torque.
Torque
3.0 kg.m
• Tighten the hollow screws to assemble the fuel return pipe.
• Assemble the fuel return hose to the
EAMD120I
fuel injection pump.
6.3.37. Starter
• Assemble the starter in position on the
flywheel housing.
Torque
8.0 kg.m
EC5OM119
6.3.38. Intercooler
• After
sub-assembling the air inlet &
outlet pipe and sea water inlet & outlet cooling water pipe in the heat
exchanger separately assemble the
intercooler assembly on the bracket of
the heat exchanger
• Insert the hoses each pipe and clamp
the hoses separately.
EC5OM111
- 102 -
6.3.39. Turbocharger
• Insert a new gasket on the exhaust
outlet pipe and mount the turbocharger.
• Install the oil supply & return pipe.
• Clamp the rubber hose connected to
the air inlet pipe of the inter cooler,
and assemble the cooling water inlet
& outlet pipe.
EC5OM130
6.3.40. Air cleaner
• Assemble the air cleaner and tighten
the bolt and nut of clamp properly
• Finally install the air filter element.
EB1M3008
6.3.41. Expansion tank and Reservoir
tank
• Assemble
the expansion tank and
rubber hose for by-pass pipe, and
then tighten the clamp.
• Finally
assemble the reservoir tank
using holder and connect the hose
between the expansion tank and
reservoir tank.
EC5OM113
6.3.42. Fuel filter
• Assemble the fuel filter on the right of
intake manifold as figure.
• Assemble the fuel feed hose according to the direction of the arrow
impressed on the fuel filter head so
that fuel can be fed in the sequence of
FUEL FEED PUMP R FUEL FILTER
R FUEL INJECTION PUMP.
EC5OM110
- 103 -
6.3.43. Alternator
• Install the alternator mounting bracket.
• Assemble the alternator and protector.
EC5OM109
6.3.44. V - Belt
• Install the V-belt on the crank pulley
and alternator.
• Adjust
the V-belt tension using the
tension adjusting bolt.
EB1M3003
6.4. Break-in After Maintenance
Because the sliding parts of a new or an overhauled engine are not lapped enough, the oil film
can be destroyed easily by overload or over-speed and the engine life time may be shorten.
Therefore the operator must follow the things of “3.3 Engine Break-in” by all means.
- 104 -
7. Main Parts Maintenance
7.1. Lubricating System
Lubricating oil pumped by the gear oil pump in the oil pan is filtrated in the oil filter through oil
cooler.
This filtrated oil passed on the main oil gallery of the cylinder block where is distributed to
lubricate the various sliding parts, fuel injection pump, and turbo-charger etc also in order to
ensure normal engine performance.
7.1.1. Specifications
Item
Specifications
Lubricating system
Forced pressure circulation
Oil pump type
Gear type
Relief valve opening pressure
10 ± 1.5 kg/cm2
Bypass for oil cooler Opening pressure
5+1 kg/cm2
Adjusting valve for spray nozzle Opening pressure
1.5 ~ 1.8 kg/cm2
Oil filter type
Full flow
Bypass for filter element
Cartridge Type
Valve opening pressure
1.8 ~ 2.3 kg/cm2
Bypass for entire oil filter Valve opening pressure
4.0 ~ 4.8 kg/cm2
7.1.2. Oil pump
• Disassembly
(1) Disassembly of oil pump drive gear
a) Unscrew
the
screw
and
disassemble the oil relief valve.
b) Unfold the washer for the oil
pump drive gear fixing nut and
remove the nut.
c) Disassemble the drive gear.
EAMC004I
- 105 -
(2) Remove the oil pump cover fixing
nuts and disassemble the oil
pump cover.
The oil pump cover is fixed with
the two dowel pins.
(3) Disassemble the drive and driven
gear.
EAMC005I
• Inspection and correction
(1) With steel ruler and feeler gauge,
measure the axial end play of the
oil pump gear. Replace if the
measured value is beyond the
limit.
Limit
0.025 ~ 0.089 mm
EAMC006I
(2) With a feeler gauge, measure the
amount of backlash between the
oil pump drive gear and driven
gear. Replace if the measured
value is beyond the limit.
Limit
(3) Measuring
0.050 ~ 0.64 mm
clearance
between
EAMC007I
drive shaft and bushing
a. Measure the outside diameter of
the drive shaft and driven shaft, and replace if the measured values are less than the
limit.
Limit
16.95 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 between oil pump shaft and bush>
Standard
0.032 ~ 0.077 mm
- 106 -
•
Re-assembly
(1) For re-assembly, reverse the disassembly sequence.
7.2. Cooling System
7.2.1. Cooling water pump
• Loosen the bolt (8) and remove the pulley (12).
• Unscrew the socket bolt (7) and detach the housing cover (5).
• After heating on the impeller (3) a little remove the impeller using a special jig.
• Detach the mechanical seal (4).
• Heat on the hub (9) little by little and then remove the hub using a removing jig.
• After detach the snap ring (11) remove the unit bearing shaft.
• Follow the re-assembly on contrary to order of disassembly.
• Exchange the oil seal (4) to a new one.
• If the used impeller is re-assembled, keep the clearance between the pump housing and
impeller not to be more than 0.35 mm.
<Water pump assembly>
12
11
10
9
7
8
6
5
4
3
2
1
EB1M4005
EB1M4005
1. Water Pump Housing
5. Housing Cover
2. Unit bearing & Shaft
6. Gasket
10. Hub
3. Impeller
7. Socket Bolt
11. Snap Ring
4. Mechanical Seal
8. Hex Bolt
12. Pulley
- 107 -
9. Spring Washer
7.3. Fuel System
7.3.1. Injection pump
The components relating to the injection pump should be serviced at regular intervals as the
plunger and delivery valve may be worn after a given length of time for use and cause the
deterioration of the engine.
Make sure that servicing should be performed at the professional maintenance shop as
authorized by Bosch or Zexel Company.
For adjustment of fuel injection volume, refer to the ‘Specifications of fuel injection pump’
described on the following pages.
1) L136, AD136
(1) Main Specification
Fuel Injection Pump : 65.11101-7269A
Governor Type
: RSV
Model Type
: PES6AD
Cam Lift
: 11 mm
Fuel Feed Pump
: 105210-4830
Injection Timing
: BTDC 18° ±1°
Injection Order
: 1-5-3-6-2-4
Rotating Direction
: Clockwise (Viewed at driving gear side)
(2) Calibration Data
(A) Test condition
for injection pump
Nozzle & Holder Ass’y
105780-8140
Injection pipe(ID ,OD ,L)
-
Test oil
(B) Engine standard
parts
Opening pressure :175kg/cm2
8.0 x
ISO4113
Nozzle & holder Ass’y
Temperature :40 ± 5 ˚C
65.10101-7050
Nozzle (5 x
-
Injection pipe (ID, OD, L)
2.0 - 600 mm
0.36)
214 + 8 kg/cm2
-
6x
2.2 - 650 mm
Rack diagram and setting valve at each point
Refer to (3) Rack Diagram
Check
point
Rack
Pump
position speed
Injection Q`ty on RIG
(mm3 / 1,000st)
(A) Test condition
Press.
Max. Var.
(mmHg)
(mm)
(rpm)
A
10.5
1100
88.5 ± 2
± 2.5
Full
B
7.7
~
~
370
11.5 ± 2
± 25
Idle
100
(135)
-
-
C
for inj. Pump
Bet. Cyl. (%)
Balance Weight
740g
Lever ratio (min/max)
Governor spring
k = 7.2 kg/mm
Plunger
1 : 1.2
9.5 , 20 + 45 lead
Idle spring
k = 1.9 kg/mm
Delivery valve retraction volume
70 mm3/st, t=0.11
Idle sub spring
k = 3.0 kg/mm
Delivery valve opening pressure
23.1 kg/cm2
Start spring
k = 0.01 kg/mm Delivery valve spring
Max. discharge pressure
k = 3.4 kg/mm2 Feed pump
- 108 -
k = 1.63 kg/mm
105210-5280
(KP-FP/KE-ADS)
(3) Rack Diagram
Idling serve
아이들링
서브spring
스프링
Rack position (MM)
14
14
or more
14
또는than
14이상
C
Stroke start
스트로크
스타트
Governor
spring
가버너
스프링
셋트set
아이들링
Idling serve
서브Spring
스프링setting
셋팅
10.5
7.7
6.9
6.9
0
B
370 486 ±5
+30
1100 +20
1215
1215 또는
or LESS
이하
1165 ±5
Pump speed (RPM)
EB7O7015
- 109 -
2) L136T, AD136T
(1) Main Specification
Fuel Injection Pump : 65.11101-7271A
Model Type
: PES6AD
Governor Type
: RSV
Fuel Feed Pump
: 105210-4830
Cam Lift
: 11 mm
Injection Timing
: BTDC 18° ±1°
Injection Order
: 1-5-3-6-2-4
Rotating Direction
: Clockwise (Viewed at driving gear side)
(2) Calibration Data
(A) Test condition
for injection pump
Nozzle & Holder Ass’y
105780-8140
Injection pipe(ID ,OD ,L)
-
Test oil
(B) Engine standard
parts
Opening pressure :175kg/cm2
8.0 x
ISO4113
Nozzle & holder Ass’y
Temperature :40 ± 5 ˚C
65.10101-7050
Nozzle (5 x
-
Injection pipe (ID, OD, L)
2.0 - 600 mm
0.36)
214 + 8 kg/cm2
-
6x
2.2 - 650 mm
Rack diagram and setting valve at each point
Refer to (3) Rack Diagram
Check
point
Rack
Pump
position speed
Injection Q`ty on RIG
(mm3 / 1,000st)
(A) Test condition
Press.
Max. Var.
(mmHg)
(mm)
(rpm)
A
10.5
1100
113.5 ± 2
± 2.5
Full
B
7.9
~
~
370
11.5 ± 2
± 25
Idle
100
-
-
-
C
for inj. Pump
Bet. Cyl. (%)
Balance Weight
740g
Lever ratio (min/max)
Governor spring
k = 7.2 kg/mm
Plunger
1 : 1.2
9.5 , 20 + 45 lead
Idle spring
k = 1.9 kg/mm
Delivery valve retraction volume
70 mm3/st, t=0.11
Idle sub spring
k = 3.0 kg/mm
Delivery valve opening pressure
23.1 kg/cm2
Start spring
k = 0.01 kg/mm Delivery valve spring
Max. discharge pressure
k = 3.4 kg/mm2 Feed pump
- 110 -
k = 1.63 kg/mm
105210-5280
(KP-FP/KE-ADS)
(3) Rack Diagram
14
또는
14이상
or more than 14
C
±1.0mm
부스터 보점
스타트 : 1.0
Booster
compensating
start
: 1.0 ± 1.0 mm
Rack position (MM)
A
Governor
spring
setting
가버너
스프링
셋팅
11.2 ±5
10.5
C
(7.7)
Idling
serve
Spring
setting
아이들링
서브
스프링
셋팅
B
Q = 17±1.3 ㎟/st
R2 (7.0)
R1 -0.1
0
370
485
400
1100 +30
+20
1190 ±5
1165 ±5
Pump speed (RPM)
EB7O7016
- 111 -
3) L136TI, AD136TI
(1) Main Specification
Fuel Injection Pump : 65.11101-7341
Model Type
: PES6AD
Governor Type
: RSV
Fuel Feed Pump
: 105210-5610
Cam Lift
: 12 mm
Injection Timing
: BTDC 14° ±1°
Injection Order
: 1-5-3-6-2-4
Rotating Direction
: Clockwise (Viewed at driving gear side)
(2) Calibration Data
(A) Test condition
for injection pump
Nozzle & Holder Ass’y
105160-4370
Injection pipe(ID ,OD ,L)
-
Test oil
(B) Engine standard
parts
Opening pressure : 175kg/cm2
8.0 x
Calibration oil
Temperature :40 ± 5 ˚C
105160-4370
Nozzle & holder Ass’y
Nozzle (5 x
Calibration oil
Injection pipe (ID, OD, L)
6x
2.0 - 600 mm
0.36)
214 + 8 kg/cm2
2.0 - 650 mm
6x
2.0 - 650 mm
Rack diagram and setting valve at each point
Refer to (3) Rack Diagram
Check
point
R1=12.5
Rack
Pump
position speed
(mm)
(rpm)
A
12.5
1100
B
C
(12.5)
~
~ 7.8
D
R1-1.5
E
more 14
Injection Q`ty on RIG
(mm3 / 1,000st)
(A) Test condition
for inj. Pump
Max. Var.
Bet. Cyl. (%)
Boost
Press.
(mmHg)
121 ± 2
-
750
(123.5)
-
370
10 ± 1.5
-
-
600
(89.5)
-
-
100
(155)
-
-
More
500
Balance Weight
740g
Lever ratio (min/max)
Governor spring
k = 7.2 kg/mm
Plunger
1 : 1.2
9.5 , 20 + 45 lead
Idle spring
k = 1.9 kg/mm
Delivery valve retraction volume
70 mm3/st
Idle sub spring
k = 2.5 kg/mm
Delivery valve opening pressure
23.1 kg/cm2
Start spring
k = 0.01 kg/mm Delivery valve spring
k = 1.63 kg/mm
Max. discharge pressure
k = 3.4 kg/mm2 Feed pump
105210-5610
- 112 -
(3) Rack Diagram
or more14.0
than이상
14
E
Rack position (MM)
C
±0.1 mm
Booster보정
compensating
: 1.5
부스터
스타트 : 1.5stroke
13.1±0.1
12.5
B
±0.1
mm
A
D
Idle serve,
spring
set셋트
아이들링
스브,
스프링
10.0±0.1
C
7.8
6.25±0.1
6.00±0.2
0
480
370
1180
1140
400
1225
Pump speed (RPM)
EB7O7018
- 113 -
4) L086TIH, AD086TI
(1) Main Specification
Fuel Injection Pump : 65.11101-7311
Model Type
: PE6P120/720RS3S
Governor Type
: RSV 200/1300
Plunger
: 134153-1420
Delivery Valve
: 134110-1420
Fuel Feed Pump
: 105237-5470
Cam Lift
: 12 mm
Injection Timing
: BTDC 15° ±1°
Injection Order
: 1-5-3-6-2-4
Rotating Direction
: Clockwise (Viewed at driving gear side)
(2) Calibration data
(A) Test condition
Nozzle & Holder Ass’y
105780-8140
for injection pump Injection pipe(ID ,OD ,L)
-
Test oil
(B) Engine standard
parts
8.0 x
ISO4113
3.0 - 600 mm
Temperature :40 ± 5 ˚C
65.10101-7450
Nozzle & holder Ass’y
LRC6703709
Injection pipe (ID, OD, L)
Opening pressure :175kg/cm2
Nozzle (5 x
0.36)
214 + 8 kg/cm2
65.10301-6049A
65.10301-6052A
6.35 x
2.2 - 650 mm
Rack diagram and setting valve at each point
Refer to (3) Rack Diagram
Injection Q`ty on RIG
Press.
Rack
Pump
A
12.2
1050
169.5 ± 2.0
±2
980≤
B
(6.7)
315
10.0 ± 1.3
± 15
-
C
12.2
500
(177)
-
980≤
D
10.0
500
(103) ± 3
-
-
-
-
Check
point
(mm / 1,000st)
(mmHg)
position speed
(A) Test condition (B) Engine
(mm) (rpm)
standard parts
for inj. pump
3
Boost pressure dependent full - load stop (boost compensator spring operation point)
Refer to (4) Boost pressure
Injection Q’ty on RIG
Press.
Rack
Pump
position
(mm)
speed
(rpm)
(A) Test condition
(B) Engine
for inj. pump
standard parts
P1
10.0
500
177
-
150
P2
12.2
500
103
-
880
-
-
-
-
-
-
Check
point
(mm3 / 1,000st)
(mmHg)
Weight
Weight = 740kg Lever ratio(min/max)
Governor spring
k = 7.2 kg/mm
Plunger
Idle spring
k = 1.9 kg/mm
Delivery valve retraction volume
100 mm3/st, t=0.09
Idle sub spring
k = 1.2 kg/mm
Delivery opening pressure
18.5 kg/cm2
Start spring
k = 0.01 kg/mm Delivery valve spring
Boost compensator spring
k = 1.0 kg/mm
Feed pump
- 114 -
Min. speed 1 : 1.2
Max. speed 1 : 1.2
12 , 30 lead
k = 0.87 kg/mm
105237-5470
(NP-FP/KD-PS)
(3) Rack diagram
14
C
A
RACK POSITION, mm
12
랙
10
위
8
치
6
D
B
(mm)
4
2
0
INJECTION
PUMP
SPEED, rpm
분사펌프
속도(rpm)
EB1M4001
(4) Boost compensator pressure
13.0
RACK POSITION, mm
P2
12.0
랙
위
11.0
치
P1
(mm)
10.0
9.0
0
200
400
600
800
1000
BOOST
PRESSURE, mmHg
부양 압력(mmHg)
EB1M4002
- 115 -
5) L086TIM
(1) Main Specification
Fuel Injection Pump : 65.11101-7311
Model Type
: PE6P120/720RS3S
Governor Type
: RSV 200/1300
Plunger
: 134153-1420
Delivery Valve
: 134110-1420
Fuel Feed Pump
: 105237-5470
Cam Lift
: 12 mm
Injection Timing
: BTDC 15° ±1°
Injection Order
: 1-5-3-6-2-4
Rotating Direction
: Clockwise (Viewed at driving gear side)
(2) Calibration data
(A) Test condition
Nozzle & Holder Ass’y
105780-8140
for injection pump Injection pipe(ID ,OD ,L)
-
Test oil
(B) Engine standard
parts
8.0 x
ISO4113
3.0 - 600 mm
Temperature :40 ± 5 ˚C
65.10101-7450
Nozzle & holder Ass’y
LRC6703709
Injection pipe (ID, OD, L)
Opening pressure :175kg/cm2
Nozzle (5 x
0.36)
214 + 8 kg/cm2
65.10301-6049A
6.35 x
65.10301-6052A
2.2 - 650 mm
Rack diagram and setting valve at each point
Refer to (3) Rack Diagram
Injection Q`ty on RIG
Press.
Rack
Pump
A
12.4
1150
178.7 ± 5.0
Max. Power
-
B
8.1
700
19.1 ± 1.0
-
-
C
12.4
500
182.2 ± 3.0
-
-
D
10.0
500
99.5 ± 3.0
-
-
E
W/Cap
100
225.3 ± 3.0
-
-
Check
point
(mm / 1,000st)
(mmHg)
position speed
(A) Test condition (B) Engine
(mm) (rpm)
standard parts
for inj. pump
3
Boost pressure dependent full - load stop (boost compensator spring operation point)
Refer to (4) Boost pressure
Injection Q’ty on RIG
Pump
point
position
(mm)
speed
(rpm)
P1
12.4
500
178.7 ± 5.0
-
1,020
P2
10.0
500
99.5 ± 3.0
-
150
-
-
-
-
-
-
Check
Weight
Press.
Rack
(mm / 1,000st)
(mmHg)
3
(A) Test condition (B) Engine
for inj. pump
Weight = 740kg Lever ratio(min/max)
standard parts
Min. speed 1 : 1.2
Max. speed 1 : 1.2
Governor spring
k = 7.2 kg/mm
Plunger
Idle spring
k = 1.9 kg/mm
Delivery valve retraction volume
100 mm3/st, t=0.09
Idle sub spring
k = 1.2 kg/mm
Delivery valve opening pressure
18.5 kg/cm2
Start spring
k = 0.01 kg/mm Delivery valve spring
Boost compensator spring
k = 1.0 kg/mm
Feed pump
- 116 -
12 , 30 lead
k = 0.87 kg/mm
105237-5470
(NP-FP/KD-PS)
(3) Rack diagram
E
14
C
A
RACK POSITION (mm)
12
랙
10
위
8
치
6
D
B
(mm)
4
2
0
200
400
600
800
1000
1200
1400
분사펌프
속도(rpm)
PUMP SPEED
(rpm)
EB1O4001
(4) Boost compensator pressure
14
RACK POSITION (mm)
P1
12
랙
위
P2
10
치
(mm)
8
6
0
200
400
600
800
1000
1200
부양PRESSURE
압력 (mmHg)
BOOST
(mmHg)
EB1O4002
- 117 -
7.3.2. Electric governor system
1) AD136 / T / TI
Governor system for fuel injection pump consists of “Integral Actuator” and “ Speed Control
Unit”.
(1) ACAD176 Series Electric Actuator
• Introduction
The ACD176 SERIES electric actuator is designed to mount directly on a Bosch “A” size
fuel injection pump, with a left hand rack, in place of the mechanical governor. When the
ACE176 is installed on the fuel pump, an optimum performance, long life fuel control
system results. An external fuel shut off lever is available to manually override the
actuator’s control. Also provided is an adjustable internal maximum fuel limit
The ACD176 can control fuel pumps of up to 6 cylinders.
The actuator was designed with two isolated chambers. The upper chamber is wet with
oil and contains the connection to the fuel rack and an optional manual shut off
mechanism.
The sealed lower chamber contains the electromagnetic components.
This design eliminates the possibility of magnetic pa other oil contaminants interfering
with the operation eletric actuator. Unreliable devices such as bell sliding seals are not
used so that no maintenance is The designed ieft of the actuator is typically longer of the
engine.
Available actuator models : ACD176-12 (12V w/o manual shutoff)
ACD176-24 (24V w/o manual shutoff)
ACD176A-12 (12V w/ manual shutoff)
ACD176A-24 (24V w/ manual shutoff)
The 176 SERIES actuator can also be supplied with tion sensor that allows the actuator
to be used in a agement system. Contact GAC for assistance.
• Specifications
Performance
Force ........... (see Figure 1) ............................................................ 6.2 lb. (27.5 N)
Operating Stroke............................................................................ 0.80 in. (21 mm)
Response Time (10 ~ 90 %, 2 - 19 mm) .................................................. 35 msec.
Electrical Power Input
Operating Voltage ............................................................................. 12 or 24V DC
Nominal Operating Curren ...........12V DC version ......................................... 4.0 A
24V DC version ......................................... 2.0 A
Maximum Current ........................12V DC version ......................................... 5.8 A
24V DC version ......................................... 3.1 A
- 118 -
Environmental
Operating Temperature ....................................................... -40 to +95 °C (-40 to +200 °F)
Relative Humidity ............................................................................................. up to 100 %
Vibration .................................................................................................. 20 g, 20 - 500 Hz
Shock ....................................................................................................... 20 g @ 11 msec.
Physical
Dimensions ..................................................................................................... See Figure 2
Weight ....................................................................................................... 4.75 lb. (1.9 kg.)
Mounting ................................................................... Requires camshaft bearing retainer it
BOSCH P/N 1415522036
• Installation
Perparing the fuel injection pump
If the fuel injection pump is equipped with a mechanical governor, it must be removed. GAC
recommends that this modicication be performed by a qualified fuel injection service facility. The
following procedure lists the general steps required to remove the mechanical governor.
Note :
Be prepared to collect the oil that will be released from the mechanical governor.
1. Remove the rear housing from the mechanical governor and disconnect the governor linkage
from the fuel rack. Remove the flyweight assembly. A specical tool is required.
2. Remove the intermediate governor housing. This leaves only the rack and camshaft protruding
from the pump.
3. Install the camshaft bearing retainer plate to provide support to the bearing formerly held by the
governor housing.
This plate must have countersunk holes for the mounting screws.
Installing the actuator
All hardware needed to attach the actuator to the pump is located in kit KT288 supplied with the
actuator.
1. The mounting surface on the pump must be clean. Attach the link(1) to the left-hand side of the
fuel rack with a M5 X 10 mm screw(2) that includes a patch of locking adgesive.
Tighten the screw to 3 - 4 NM so that the pump and torque to 5 - 6 NM.
2. Remove the two lower screws of the bearing retainer plate and replace them with the retainers(3).
Attach the retainers with their shorter end threaded into the pump and torque to 5 - 6 NM.
3. Temporarily place the actuator over the rack and retainers and onto the pump face. Check that
the actuator contacts both the pump face and shoulders of the retainers. If necessary, use M6
spring washers to shim the retainers. The upper and lower mounting points of the actuator must
be equally supported. Remove the actuator from the pump.
- 119 -
4. Remove both of the actuator covers. DO NOT remove or loosen the lever(16) from the actuator
shaft. Place the o-ring seal(4) into the groove on the mounting face of the actuator. Apply a small
amount of grease to the o-ring to hold it in place.
5. Swing the armature out of the actuator so that the lever(16) is out of the way. Guide the actuator
over the rack and onto the lower mounting retainer studs. Attach the top of the actuator to the
pump with the M8 X 16 mm socket head screw(5), lock washer(6), and flat washer(7). Use M6
hex nuts(8) and spring washers(9) to secure the portion of the actuator. Torque the screw to 6 8 NM and nuts to 5 - 6 NM.
6. Pull on the rack so that it is as far out of the pump as possible. Check that it moves freely. Place
the return spring(10) over the rack. Place the spring retainer / shut off plate assembly(11, 12) and
the M10 locking nut(13) over the threads on the rack link(1). The flats on the shut off plate(12)
must engage the flats on the link(1). Tighten the nut to 6 - 8 NM and insure that the shut off plate
is vertical and secure.
7. Test the engagement of the shut off mechanism with the rack linkage. Swing the lever back into
the actuator. Push on the armature to insure that the rack linkage operates smoothly and returns
immediately when released. Reattach the lower actuator cover(23) and tighten the screws(20) to
4 - 6 NM.
8. Loosen the fixation screw(17) so that the bearing(18) can be adjusted in its slot. Adjust the
bearing so that it pushes the rack0.5 - 0.7 mm away from its stop position. Hold the bearing in this
position and tighten the screw(17) to 4 - ? NM. The rack is now adjusted so that premature wear
of the gear segments is avoided. Confirm that the operating lever screw(19) is tightened to 12 13 NM. Inspect the assembly to make sure all screws are tight.
9. Ther lever has a maximum fuel adjustment set screw(14). This screw is used to restrict the fuel
rack from 1 to 14.5 mm.
Caution :
Setting fuel levels above 14.5 mm can cause the screw to hit the back cover, which can
restrict minimum fuel. This can lead to a dangerous condition. Do not operate the engine this
way. Fuel levels above 14.5 mm require a shorter stop screw, M6 X 25mm.
With the fuel pump operating on the engine, the maximum fuel setting can be set to prvide specific
horsepower. Once this setting is made tighten the lock nut(15) on the stop screw to 5 - 6 NM.
10. Move the manual shut off lever to the stop position and insure that the fuel is completely shutoff
and the engie stops.
11. With the engine shut down, install the upper chamber cover with the four scew(20, 21) and lock
washers. Note that when installed, the cover must not hit the internal lever or its stop screw.
Tighten the screws to 2 - 3 NM. Check for any oil leaks. Lock wire the screws for tamper
resistance.
Caution :
The engine should be equipped with an independent shut down device to prevent overspeed
whic can cause equipment damage or personal injury.
- 120 -
Caution :
Adjusting the fuel pump is an essential part for performance and endurance of engine,
therefore operation and maintenance should be performed only by specialized engineer.
Figure 1 ACD176 Fuel Rack Force vs. Stroke
WIRNING
The ACD176 actuator is pre-wired for 12 or 24V
DC operation. Use the included cable harness to
connect the actuator to the speed control unit.
The cable may be lengthened as necessary to fit
the specific application. Use the comparable
size wire to extend the cable harness. DO NOT
use an ACD176 on a 32V system, contact the
factory for assistance.
Figure 2 ACTUATOR OUTLINE
EA4O9001
- 121 -
EA4O9101
- 122 -
2) AD086TI
Governor system for fuel injection pump consists of “Integral Actuator” and “Speed Control Unit”.
(1) Integral Actuator
Adjust linkage length so that
when fastened to the operating
lever the fuel rack is approx.
0.5-1.0mm away from its extreme
stop position
Emergency
mechanjcal stop
Upper chamber
Engine oil lubricated
Linkage length L
Extreme stop position
of fuel rack
Injection
pump
Operating lever
Fuel rack
Electromechanical chamber
Completety enclosed, and
seated
Operating lever
The G.A.C actuator concept
Fastest responsotime
Maintenance free
Linear
Fuel
stopplate
<Side View>
Stop nut
Max. fuel
stop screw
Fixation screw
<Top View>
• Functions of Actuator’s component
1. Emergency stop lever
It is emergency stop lever operated by manual at emergency.
2. Upper control chamber
The cover for controlling the inside is installed.
3. Electro control chamber
Operating lever is started by the electric signal generated in it.
4. Adjusting screw
As it is a part of controlling the max. fuel amount if the length which comes outside is long
the torque decreases or if the length is short the torque increases.
5. Fuel stop plate
It is the plate which prevents fuel from increasing by stopping the proceeding of adjusting
screw.
6. Operating lever
It is a connecting lever for operating the fuel rack.
7. Fuel lever
It is connected with link lever, controls fuel amount of the fuel injection pump.
Caution :
Adjusting the fuel pump is an essential part for performance and endurance of engine,
therefore operation and maintenance should be performed only by specialized engineer.
- 123 -
No.
Description
Q’ty
Remark
No.
Description
Q’ty
Remark
1
Stop lever(emergency)
1
20
actuator spring
1
2
pump gasket
1
21
gasket,lower cover
1
3
washer
4
22
lower cover
1
4
allen screw
4
7 ~ 9 N.m
23
washer
8
5
ball link
2
*
24
allen screw
6
6
stop nut
2
3.5 ~ 4.0 N.m
25
receptacle
1
7
operating lever
1
26
sealing screw
2
8
oil seal
1
27
gasket, upper cover
1
9
counter nut
1
28
flat washer
2
10
stop screw
1
29
screw, ball link
2
*
11
connector screw
4
30
connecting rod
1
*
12
mounting bar
1
31
nut
2
*
13
flat washer
2
32
stop plate
1
*
14
lock washer
2
33
top cover
1
15
nut
2
34
manual stop
device complete
1
16
flat washer
2
*
linkage complete
comprise pos.
5,6,28,29,30,31,32
1
17
lock washer
2
35
fixing screw
1
12.5±13.0N.m
18
nut
2
36
stop nut
1
12.5±13.0 N.m
19
threaded bolt
(part of bearing kit)
2
4.5 ~ 6.0 N.m
17 ~ 21 N.m
7 ~ 9 N.m
- 124 -
2.0 ± 3.0 N.m
3.5 ± 4.5 N.m
(2) Speed control unit for governor system (All)
a) Introduction
Series speed control unit is an all electronic device designed to control engine speed with
fast and precise response to transient load changes. This closed loop control, when
connected to a proportional electric actuator and supplied with a magnetic speed sensor
signal, will control a wide variety of engines in an isochronous or droop mode.
The speed control unit are the engine STARTING FUEL and SPEED RAMPING
adjustments. The use of these features will minimize engine exhaust smoke experienced
prior to attaining engine operating speed.
Other features include adjustable droop and idle operation, inputs for accessories used in
multi-engine or special applications, protection against reverse battery voltage, transient
voltages, accidental short circuit of the actuator and fail safe design in the event of loss of
speed sensor signal or battery supply.
GAC actuator model
Speed control unit model
AD136/T/TI
AD086TI
ACD 176A-24
ACE 175
DWC-2000
ESD55500
b) Description
Engine speed information for the speed control unit is usually received from a magnetic pickup sensor Any other signal generating device may be used provided the generated
frequency is proportional to engine speed and meets the voltage input and frequency range
specification. The speed sensor is typically mounted in close proximity to an engine driven
ferrous gear, usually the engine ring gear. As the teeth of the gear pass the magnetic sensor,
a signal is generated which is proportional to engine speed.
Signal strength must be within the range of the input amplifier. An amplitude of 0.5 to 120 volts
RMS is required to allow the unit to function within its design specifications. The speed signal
is applied to Terminals C and D of the speed control unit. Between these terminals there is
an input impedance of over 33,000 ohms. Terminal D is internally connected to Terminal E,
battery negative. Only one end of the cable should be connected.
When a speed sensor signal is received by the controller, the signal is amplified and shaped
by an internal circuit to provide an analog speed signal. If the speed sensor monitor does not
detect a speed sensor signal, the output circuit of the speed control unit will turn off all current
to the actuator.
A summing circuit receives the speed sensor signal along with the speed adjust set point
input. The speed range has a ratio of 8:1 and is adjusted with a 25 turn potentiometer. The
output from the summing circuit is the input to the dynamic control section of the speed control
unit. The dynamic control circuit, of which the gain and stability adjustments are part, has a
control function that will provide isochronous and stable performance for most engine types
and fuel systems.
The speed control unit circuit is influenced by the gain and stability performance adjustments.
The governor system sensitivity is increased with clockwise rotation of the gain adjustment.
The gain adjustment has a range of 33:1.
- 125 -
The stability adjustment, when advanced clockwise, increases the time rate of response of the
governor system to match the various time constants of a wide variety of engines. The speed
control unit is a PID device, the “D”, derivative portion can be varied when required. (See
Instability section.)
During the engine cranking cycle, STARTING FUEL can be adjusted from an almost closed,
to a nearly full fuel position.
Once the engine has started, the speed control point is determined, first by the IDLE speed
set point and the SPEED RAMPING circuit. After engine speed ramping has been completed,
the engine will be at its governed operating speed.
At the desired governed engine speed, the actuator will be energized with sufficient current to
maintain the desired engine speed, independent of load (isochronous operation).
The output circuit provides switching current at a frequency of about 500Hz to drive the
actuator Since the switching frequency is well beyond the natural frequency of the actuator,
there is no visible motion of the actuator output shaft.
Switching the output transistors reduces its internal power dissipation for efficient power
control. The output circuit can provide current of unto 10amps continuous at 25?C for 12 and
24VDC battery systems. The actuator responds to the average current to position the engine
fuel control lever.
In standard operation, the speed control unit performance is isochronous. Droop governing
can be selected by connecting terminals K and L and the percent of droop governing can be
varied with the droop adjustment control . The droop range can be increased by connecting
Terminals G and H.
The speed control unit has several performance and protection features which enhance the
governor system. A speed anticipation circuit minimizes speed overshoot on engine start-up
or when large increments of load are applied to the engine.
Engine idle speed can be remotely selected and is adjustable. Accessory inputs to achieve
variable speed operation and multi-engine control can be accepted by the speed control unit
from GAC load sharing modules, automatic synchronizers.
- 126 -
c) Specification
PERFORMANCE
Isochronous Operation/steady State Stability
± 0.25% or better
Speed Range/Governor
1 K ± 7.5 KHz continuous
Speed Drift with Temperature
± 1% Maximum
Idle Adjust CW
60% of set speed
Idle Adjust CCW
Less than 1,200 Hz.
Droop Range
1 ± 5 % regulation*
Droop Adj. Max. (K-L Jumpered)
400 Hz ± 75 Hz per 1.0 A change
Droop Adj. Min. (K-L Jumpered)
15 Hz ± 6 Hz. per 1.0 A change
Speed Trim Range
± 200 HZ
Remote Variable Speed Range
Terminal Sensitivity
500 ± 7.5 Hz or any part thereof
J
100 Hz ± 15 Hz/Volt @ 5.0 K Impedance
L
735 Hz ± 60 Hz/Volt @ 65 K Impedance
N
148 Hz ± 10 Hz/Vo1t @ 1 Meg. Impedance
P
10 VDC Supply @ 20 ma Max.
Speed switch adjustment range
1,000 ~ 10,000 Hz
ENVIRONMENTAL
- 40 ° to 180 °F (- 40 ° to + 85 °C)
Ambient Operating Temperature Range
Relative Humidity
up to 95 %
All Surface Finishes
Fungus Proof and Corrosion Resistant
INPUT POWER
Supply
12 or 24 VDC Battery Systems
(Transient and Reverse Voltage Protected)**
Polarity
Negative Ground (Case Isolated)
Power Consumption
50 mA continuous plus actuator current
Actuator Current Range @ 77 ?F (25 ?C) -
Min.2.5 Amps/ Max. 10 Amps continuous ***
(Inductive Load)
Speed Sensor Signal
0.5 ~ 120 Volts RMS
Speed switch relay contacts (N.O. and N.C.)
10 Amps
RELIABILITY
Vibration
1G @ 20 ~ 100 Hz
Testing
100% Functionally Tested
PHYSICAL
Dimensions
See Outline
Weight
1.8 lbs (820 grams)
Mounting
Any Position, Vertical Preferred
Note :
* Droop is based on a speed sensor frequency of 4,000 Hz and an actuator current.
Change of 1 amp from no load to full load. Applications with higher speed sensor signals will
experience less percentage of droop. Applications with more actuator current change will
experience higher percentages of droop. See droop description for specific details on
operation of droop ranges.
** Protected against reverse voltage by a series diode. A 15 Amp. fuse must be Installed in the
positive battery lead.
*** Protected against short circuit to actuator (shuts off current to actuator), unit automatically
turns back on when shorts is removed.
- 127 -
d-1) Wiring Diagram and Outline (AD034TI, AD136/T/TI)
6.25
154
9.5
15
1
2
3
4
5
6
7
8
Over
Speed
Run
9
Crank
Overspeed
Run
Crank
Speed
D1
139
ON
OFF
Stability
Starting
Fuel
GHANA CONTROL
MADE IN KOREA
Speed
Ramping
D2
ON
OFF
Idle
Idle
Speed Trim
Actuator
B C
D
E
F G
Droop
Droop
Battery
+
AUX 10V
H
J
K
L
M
N
P
15
A
Test
Gain
GOVERNOR CONTROLLER
MODEL : DWC-2000
INPUT : DC24V
PARTS No. : 65.11220-7006
SERIAL No. :
Pick-Up
Reset
10V POWER
AUX.
ACTUATOR
ADD JUMPER FOR 12V
BATTERY ORACTUATOR
CURRENTS ABOVE 5A
GND
CLOSE FOR DROOP
MAGNETIC
PICK UP
CW
BATTERY
32
FUSE
15A MAX.
OPTIONALACTUATOR
CABLE SHIELDING TO
MEET CE DIRECTIVE
CLOSE FOR IDLE
SPEED TRIM
CONTROL - 5K
- 128 -
d-2) Wiring Diagram and Outline (AD086TI)
6.00 (152)
5.25 (133)
O 0.27 (7)
C2
ON
SOFT COUPLING
OFF
C1 OFF
LEAD CIRCUIT
ON
OVERSPEED
OVERNORS
MERICA
GA
C
1 2 3
RESET TEST
OVERSPEED
ORP
SPEED CONTROL UNIT
SPEED
MODEL : ESD5550
S/N
GAIN
STABILITY
6.00 (152)
6.05 (165)
MADE IN AGAWAM, MA U.S.A
STARTING
FUEL
SPEED
RAMPING
CAUTION
PICK-UP
E3
DEAD TIME
COMPENSATION
JUMPER
DROOP
ENGINE SPEED CONTROL
COMPONENT WHEN INSTALLING
OR SERVICING REFER TO
PRODUCT PUBLICATION
ACTUATOR
E2
E1
_
+
BATTERY
IDLE
AUX
10V
OUTPUT
A B C D E F G H J K L M N P
OPTIONAL ACTUATOR
CABLE SHELDING TO
MEET CE DIRECTIVE
ACCESSORY POWER
SUPPLY
ACCESSORY INPUT
*
ADD JUMPER FOR 12V
BATTERY OR ACTUATOR
CURRENTS ABOVE 5A
GROUND REFERENCE
ACTUATOR
CW
MAGNETIC
PICK-UP
_
+
BATTERY
1.03 (26)
CLOSE FORDROOP
SPED TRIM
CONTROL - 5K
S1
CLOSE FOR IDLE
FUSE 15A
Note :
•
If wire leads are longer than 3 meters (10 ft), a shielded cable should be used. Ground
shield at one end only.
• The speed control unit is rugged enough to be placed in a control cabinet or engine
mounted enclosure with other dedicated control equipment. If water, mist, or condensation
may come in contact with the controller, it should be mounted vertically. This will allow the
fluid to drain away from the speed control unit.
• Extremely heat should be avoided.
- 129 -
Caution :
An overspeed shutdown device, independent of the governor system, should be provided to
prevent loss of engine control which may cause personal injury or equipment damage. Do not
rely exclusively on the governor system electric actuator to prevent overspeed. A secondary
shutoff device, such as a fuel solenoid must be used.
e) Functions of the Control unit
1. STARTING FUEL : When starting engine at first, it controls the amount of starting fuel. If you
turn it clockwise, the amount of fuel increases.
2. SPEED RAMPING : It controls time to be taken for the max. speed. If you turn it counter
clockwise, the time to be reached the rating speed is reduced.
3. IDLE
: Adjust the idle speed of the engine. If the engine rotates clockwise, the
speed of the engine increases.
4. GAIN
: It makes fluctuant rate of speed which generated from engine stable.
5. STABILITY
: It makes fluctuant rate of speed according to the engine mounting stable.
6. SPEED
: Adjust the engine speed. If engine rotates clockwise, engine speed
increases.
7. OVER SPEED
: Adjust engine over speed. If engine rotates clockwise, engine speed
increases.
8. DROOP SPEED
: It is used in parallel operation of generator.
9. RESET
: It is used for initializing the over speed controller.
10. TEST
: It is used for confirming and setting the over speed.
11. A, B TERMINAL
: They are connected with actuator of the injection pump.
12. C, D TERMINAL
: They are connected with magnetic pickup sensor, shield wire should be
used. Don’t use magnetic pickup sensor connected with them for other
purpose.
13. E, F TERMINAL
: They are connected with battery (E
- polar, F
14. G,M TERMINAL
: They are terminals for maintaining the idle speed.
15. K, L TERMINAL
: They are terminals for droop.
+ polar)
16. H, J, N, P TERMINAL : They are subsidiary terminals.
f) Wiring
Basic electrical connections are illustrated above. Actuator and battery connections to Terminals A,
B, E, and F should be #16AWG (1.3 mm2) or larger.
Long cables require an increased wire size to minimize voltage drops.
The battery positive (+) input, Terminal F, should be fused for 15 amps as illustrated.
Magnetic speed sensor connections to Terminals C and D MUST BE TWISTED AND/OR
SHIELDED for their entire length. The speed sensor cable shield should only be connected to
terminal D. The shield should be insulated to insure no other part of the shield comes in contact
with engine ground, otherwise stray speed signals may be introduced to the speed control unit. With
the engine stopped,
adjust the gap between the magnetic speed sensor and the ring gear teeth. The gap should not be
any smaller than 0.020 in, (0.45 mm). Usually, backing out the speed sensor 3/4 turn after touching
the ring gear tooth will achieve a satisfactory air gap. The magnetic speed sensor voltage should
be at least 1 VAC RMS during cranking.
- 130 -
g) Adjustments (Used new controller)
1. Before Starting Engine
1
The GAIN and STABILITY adjustments are set to mid position.
2
STARTING FUEL : FULL CW (Maximum Fuel)
3
SPEED RAMPING : FULL CCW (Fastest)
4
IDLE : FULL CW (Idle speed increase position)
5
Place the engine in idle by connecting Terminals M & G.
2. After Starting Engine
When starting engine at first, actuator activates forward “maximum fuel” position. After starting
engine, adjust to maintain idle speed. The speed control unit governed speed setting is factory
set at approximately engine idle speed. (1000 Hz, speed sensor signal)
1
Adjust STARTING FUEL and SPEED RAMPING depending on engine running status.
2
If the engine is unstable after starting, turn the GAIN and STABILITY adjustments
counterclockwise until the engine is stable.
3
After disconnecting Terminals M & G, turn SPEED to adjust maximum engine speed.
4
After connecting Terminals turn IDLE to set idle speed at 750 rpm. Then disconnect Terminal
M & G, to recheck and readjust maximum engine speed.
3. Governor Speeding Setting
The governed speed set point is increased by clockwise rotation of the SPEED adjustment
control. Remote speed adjustment can be obtained with an optional 5K
Speed Trim Control
4. Governor Performance
Once the engine is at operating speed and at no load, the following governor performance
adjustment can be made.
1
Rotate the GAIN adjustment clockwise until instability develops.
Gradually move the adjustment counterclockwise until stability returns.
Move the adjustment one division further counterclockwise to insure
stable performance.
2
Rotate the STABILITY adjustment clockwise until instability develops.
Gradually move the adjustment counterclockwise until stability returns.
Move the adjustment one division further to insure stable performance.
3
Gain and stability adjustments may require minor changes after engine load is applied.
Normally, adjustments made at no load achieve satisfactory performance. A strip chart
recorder can be used to further optimize the adjustments.
Note :
If instability cannot be corrected or further performance improvements are required, refer to
the section on SYSTEM TROUBLESHOOTING.
- 131 -
5. Starting Fuel Adjustment
The engine’s exhaust smoke at start-up can be minimized by completing the
following adjustments.
1
Place the engine in idle by connecting Terminals M & G.
2
Adjust the IDLE speed for as low a speed setting as the application allows.
3
Adjust the STARTING FUEL CCW until the engine speed begins to fall, Increase the
STARTING FUEL slightly so that the idle speed is returned to the desired level.
4
Stop the engine.
One of two methods of operation for the ESD5550 may now be selected.
Method 1) : Start the engine and accelerate directly to the operating speed (Generator Sets, etc.)
1
Remove the connection between Terminals M & G. Start the engine and adjust the
SPEED RAMPING for the least smoke on acceleration from idle to rated speed.
2
If the starting smoke is excessive, the STARTING FUEL may need to be adjusted
slightly CCW. If the starting time is too long, the STARTING FUEL may need to be
adjusted slightly CW.
Method 2) : Start the engine and control at an idle speed for a period of time prior to accelerating
to the operating speed. This method separates the starting process so that each may
be optimized for the lowest smoke emissions.
1
Replace the connection between Terminals M & G with a switch, usually an oil
pressure switch. Start the engine. If the starting smoke is excessive, the
STARTING FUEL may need to be adjusted slightly CCW. If the starting time is too
long, the STARTING FUEL may need to be adjusted slightly CW.
2
When the switch opens, adjust the SPEED RAMPING for the least amount of
smoke when accelerating from idle speed to rated speed.
6. Idle Speed Setting
If the IDLE speed setting was not adjusted as detailed in “Starting Fuel Adjustment” section, then
place the optional external selector switch in the IDLE position. The idle speed set point is
increased by clockwise rotation of the IDLE adjustment control. When the engine is at idle speed,
the speed control unit applies droop to the governor system to insure stable operation.
7. Speed Droop Operation
Droop is typically used for the paralleling of engine driven generators.
Place the optional external selector switch in the DROOP position, DROOP is increased by
clockwise rotation of the DROOP adjustment control. When in droop operation, the engine speed
will decrease as engine load increases.
The percentage of droop is based on the actuator current change from engine no load to full load.
A wide range of droop is available with the internal control. Droop level requirements above 10%
are unusual.
If droop levels experienced are higher or lower than those required, contact the factory for
assistance.
After the droop level has been adjusted, the rated engine speed setting may need to be reset.
Check the engine speed and adjust the speed setting accordingly.
- 132 -
8. Accessory input
The Auxiliary Terminal N accepts input signals from load sharing units, auto synchronizers, and
other governor system accessories, accessories are directly connected to this terminal It is
recommended that this connection from accessories be shielded as it is a sensitive input terminal.
If the auto synchronizer is used alone, not in conjunction with a load sharing module, a 3M ohm
resistor should be connected between Terminals N and P This is required to match the voltage
levels between the speed control unit and the synchronizer.
When an accessory is connected to Terminal N, the speed will decrease and the speed
adjustment must be reset.
When operating in the upper end of the control unit frequency range, a jumper wire or frequency
trim control may be required between Terminals G and J. This increases the frequency range of
the speed control to over 7000 Hz.
9. Accessory Supply
The +10 volt regulated supply, Terminal P, can be utilized to provide power to governor system
accessories. Up to 20mA of current can be drawn from this supply. Ground reference is Terminal
G. A short circuit on this terminal can damage the speed control unit.
10. Wide Range Remote Variable Speed Operation
A single remote speed adjustment potentiometer can be used to adjust the engine speed
continuously over a specific speed range. Select the desired speed range and the corresponding
potentiometer value. (Refer to “Speed Range Potentiometer Value”) If the exact range cannot be
found, select the next higher range potentiometer. An additional fixed resistor may be placed
across the potentiometer to obtain the exact desired range. Connect the speed range
potentiometer as shown in the next diagram.
< Speed Range Potentiometer Value >
Speed Range
Potentiometer Value
900 Hz.
1K
2,400 Hz.
5K
3,000 Hz.
10K
3,500 Hz.
25K
3,700 Hz.
50K
G
J
K
L
* Select Proper Potentiometer Value
Caution :
To maintain engine stability at the
CW
EA6M4005
minimum speed setting, a small amount
of droop can be added using the
DROOP adjustment. At the maximum speed setting the governor performance will be near
isochronous, regardless of the droop adjustment setting.
Contact the factory for assistance if difficulty is experienced in obtaining the desired variable
speed governing performance.
- 133 -
h) System Trouble shooting
1. System Inoperative
If the engine governing system does not function, the fault may be determined by performing the
voltage tests described in Steps 1, 2, 3, and 4.Be careful of the meter polarities measuring.
Should normal values be indicated as a result of following the trouble shooting steps, the fault
may be with the actuator or the wiring to the actuator See the actuator publication for testing
details.
STEP TERMINALS NORMAL READING PROBABLE CAUSE OF ABNORMAL READING
1
F(+) & E(-) Battery supply voltage 1. DC battery power not connected. Check for blown
(12 or 24 VDC)
fuse
2. Low battery voltage.
3. Wiring error.
2
C&D
1.0 VAC RMS min., 1. Gap between speed sensor and gear teeth too great.
while cranking
Check gap.
2. Improper or defective wiring to the speed sensor.
Resistance between terminals C and D should be
30 to 1,200 ohms.
3. Defective speed sensor.
3
P(+) & G(-) 10 VDC,
1. Short on terminal P (This will cause a defective unit.)
Internal Supply
2. Defective Speed Control.
4
F(+) & A(-) 1.0 ~ 2.0 VDC
1. SPEED adjustment set too low
while cranking
2. Short/open in actuator wiring.
3. Defective speed control.
4. Defective actuator.
- 134 -
2. Unsatisfactory Performance
If the governing system functions poorly, perform the following tests.
SYMPTOM
TEST
PROBABLE FAULT
Engine overspeeds
1. Do not crank.
Apply DC power to
the
governor
system.
2. Manually hold the
engine
at
the
desired
running
speed. Measure
the DC voltage
between Terminals
A(-) & F(+) on the
speed control unit.
1. Actuator goes to full fuel. Then, disconnect speed
sensor at Terminals C & D.
If actuator still at full fuel speed control unit
defective. If actuator at minimum fuel position erroneous speed signal. Check speed sensor
data.
1. If the voltage reading is 1.0 to 2.0 VDC.
a) SPEED adjustment set above desired speed.
b) Defective speed control unit.
2. If the voltage reading is above 2.0 VDC, a)
Actuator or linkage binding.
3. If the voltage reading is below 1.0 VDC, a)
Defective speed control unit.
4. Gain set too low.
Actuator does not
energize fully.
1. Measure
the
voltage at the
battery
while
cranking.
2. M o m e n t a r i l y
connect Terminals
A and F The
actuator
should
move to the full
fuel position.
1. If the voltage is less than 7V for a 12V system,
or14V for a 24V system, replace the battery if it is
weak or undersized.
1. Actuator or battery wiring in error.
2. Actuator or linkage binding.
3. Defective actuator.
4. Fuse opens. Check for short in actuator or
actuator wiring harness.
Engine remains below
desired governed
speed.
1. Measure
the
actuator
output.
Terminals A & B,
while running under
governor control.
1. If voltage measurement is within approximately 2
volts of the battery supply voltage, then fuel
control restricted from reaching full fuel position.
Possibly due to interference from the mechanical
governor, carburetor spring or linkage alignment.
2. Speed setting too low.
3. Insufficient Magnetic speed Sensor Signal
A strong magnetic speed sensor signal will eliminate the possibility of missed or extra pulses. The
speed control unit will govern well with 0.5volts RMS speed sensor signal. A speed sensor signal
of 3volts RMS or greater at governed speed is recommended. Measurement of the signal is made
at Terminals C and D.
- 135 -
4. Electromagnetic Compatibility (EMC)
The governor system can be adversely affected by large interfering signals that are conducted
through the cabling or through direct radiation into the control circuits.
All speed control units contain filters and shielding designed to protect the units sensitive circuits
from moderate external interfering sources.
Although it is difficult to predict levels of interference, applications that include magnetos, solid
state ignition systems, radio transmitters, voltage regulators or battery chargers should be
considered suspect as possible interfering sort traces.
If it is suspected that external fields, either those that are radiated or conducted, are or will affect
the governor systems operation, it is recommended to use shielded cable for all external
connections.
Be sure that only one end of the shields, including the speed sensor shield, Is connected to a single
point on the case of the speed control unit. Mount the speed control unit to a grounded metal back
plate or place it in a sealed metal box.
Radiation is when the interfering signal is radiated directly through space to the governing system
To isolate the governor system electronics from this type of interference sort roe, a metal shield or
a solid metal container is usually effective.
Conduction is when the interfering signal is conducted through the interconnecting wiring to the
governor system electronics. Shielded cables and installing filters are common remedies.
As an aid to help reduce the levels of EMI of a conductive nature, a battery line filter and shielded
cables are conveniently supplied by KT130. To reduce the levels of EMI of a radiated nature, a
shielded container P/N CA114 can be sourced from GAC and its distributors.
In severe high energy interference locations such as when the governor system is directly in the
field of a powerful transmitting source, the shielding may require to be a special EMI class
shielding.
For
these
conditions,
contact
GAC
recommendations.
- 136 -
application
engineering
for
specific
5. Instability
Instability in a closed loop speed control system can be categorized into two general types.
1
PERIODIC appears to be sinusoidal and at a regular rate.
2
NON-PERIODIC is a random wandering or an occasional deviation from a steady state band
for no apparent reason
Switch C1 controls the “Lead Circuit” found. The normal position is “ON “ Move the switch to the
“OFF” position if there is fast instability in the system.
Switch C2 controls an additional circuit added is designed to eliminate fast erratic governor
behavior, caused by very soft or worn couplings in the drive train between the engine and
generator.
The normal position is “OFF”. Move to the “ON” position if fast erratic engine behavior due to a soft
coupling is experienced.
The PERIODIC type can be further classified as fast or slow instability. Fast instability is a 3Hz. or
faster irregularity of the speed and is usually a jitter Slow periodic instability is below 3Hz., can be
very slow, and is sometimes violent.
If fast instability occurs, this is typically the governor responding to engine firings.
Raising the engine speed increases the frequency of Instability and vice versa.
In this case, placing switch C1 in the “OFF” position will reduce the speed control unit’s sensitivity
to high frequency signals.
Readjust the GAIN and STABILITY for optimum control Should instability still be present, the
removal of E1 to E2 jumper may help stabilize the engine. Post locations are illustrated. Again,
readjust the GAIN and STABILITY for optimum control. Interference from powerful electrical
signals can also be the cause. Turn off the battery chargers or other electrical equipment to see if
the system disappears.
Slow instability can have many causes. Adjustment of the GAIN and STABILITY usually cures
most situations by matching the speed control unit dynamics. If this is unsuccessful, the dead time
compensation can be modified. Add a capacitor from posts E2 to E3 (negative on E2). Post
locations are illustrated. Start with 10mfds. and increase until instability is eliminated. The control
system can also
be optimized for best performance by following this procedure.
If slow instability is unaffected by this procedure, evaluate the fuel system and engine
performance. Check the fuel system linkage for binding, high friction, or poor linkage. Be sure to
check linkage during engine operation. Also look at the
engine fuel system. Irregularities with carburetion or fuel injection systems can change engine
power with a constant throttle setting Th is can result in speed deviations beyond the control of the
governor system. Adding a small amount of droop can help stabilize the system for
troubleshooting.
NON-PERIODIC instability should respond to the GAIN control. If increasing the gain reduces the
instability, then the problem is probably with the engine. Higher gain allows the governor to
respond faster and correct for disturbance. Look for engine misfirings, an erratic fuel system, or
load changes on the engine generator set voltage regulator If the throttle is slightly erratic, but
performance is fast, move switch C1 to the “OFF” position. This will tend to steady the system.
If unsuccessful in solving Instability, contact the factory for assistance.
- 137 -
7.3.3. Fuel feed pump
1) General descriptions and construction
The P-type injection pump is mounted with NP-FP or KD-PS type feed pump. These pumps
have the same basic construction and operation, and the general descriptions of the KD
type pump are given below:
The figures show its construction (right figure) and operation (below figure). The piston in
the fuel feed pump is driven by the push rod and tappet via the camshaft of injection pump
and performs reciprocating operation to control the suction and delivery of fuel. When the
cam reaches the Bottom Dead Center as shown in the figure, the fuel is drawn in through
the check valve on the inlet side.
The fuel pressurized as the cam rotates on flows through the check valve on the outlet side
as shown in (B). If the feeding pressure increases abnormally, the spring is compressed,
resulting in interrupting further delivery of fuel as shown in (C).
Priming pump
Check valve
Check valve
Outlet
side
Inlet
side
Tappet
Piston
Cam shaft
EQM4019I
- 138 -
(A)
Inlet side
(B)
Outlet side
(C)
Interruption
EQM4020I
This feed pump is mounted with a priming pump designed to permit manual feeding of fuel from the
fuel tank with the injection pump mounted in the engine. During the manual feeding operation, air
must be bled from the fuel lines.
When using the priming pump, fix it securely to prevent the possible entry of moisture or other foreign
substances in the inside of feed pump.
In addition, a strainer is fitted into joint bolt on
the inlet side of the fuel feed pump to filtrate
any foreign substances possibly mixed in fuel.
Strainer
EB1M4003
- 139 -
2) disassembly
•
Clamp the feed pump with a vise and disassemble the plugs (30, 32), strainer (31) and gaskets
(35, 36).
•
•
•
•
Take off the priming pump (25), plug (16), both gaskets (18), spring (15), and check valve (14).
Take off the plug (7), gasket (8), spring (6), and piston (5) on the piston side.
Pull out the snap ring (20) holding the tappet (10).
Disassemble the snap ring, then take off the tappet (10) and push rod (1).
3) Inspection
•
•
•
If the check valve is damaged or scored on its seat face, replace it with a new one.
Inspect the piston and tappet for damage.
Replace the push rod if excessively worn, and replace together with the pump housing if
required. The inspection for wear should be performed in the same procedure as for suction
pressure test described below.
4) Re-assembly
•
Re-assembly operation is performed in reverse order of disassembly. All the gaskets must be
replaced with new ones at re-assembly.
- 140 -
5) Testing
(1) Suction capacity test
Connect one end of a hose to the inlet
side of the feed pump and immerse the
Outlet hose
other end of it into the fuel tank as
Feed pump
illustrated.
Hold the feed pump in position about 1 m
above the level of fuel in the fuel tank.
Operate the tappet at the rate of 100 rpm
and check to see if fuel is drawn in and
Inlet hose
delivered for 40 seconds or so.
Fuel tank
EQM4022I
(2) Delivery test
Make a test with the feed pump mounted
on a pump tester as illustrated. Operate
the pump at the rate of 1,000 rpm and
check to see if the pump delivery is more
than 405 cc/15 seconds.
EAMC016I
(3) Sealing test
Plug up the delivery port on the feed
pump and apply compressed air of 2
Compressed
air 2kg / cm2
Mass cylinder
kg/cm2 into the inlet side.
Submerge the feed pump in a container
of diesel fuel and check for air leak.
Feed pump
EQM4023I
- 141 -
7.3.4. Fuel injection nozzle
The injection nozzle assembly consists of the nozzle body and needle valve assembly.
Pressurized fuel delivered from the fuel injection pump is sprayed into the combustion
chamber past the injection nozzle at proper spray pressure and spray angle, then burnt
completely to achieve effective engine performance.
The fuel injected should necessarily be ignited immediately and combusted in a short period
of time as too long a combustion period will prevent the high speed operation of the engine
and can cause serious engine knocking.
(1) At valve closed
(2) At valve opened
EQM4024I
1) Construction
1. Nozzle holder
2. Union nut
3. Shim
4. Coil spring
1
5. Guide bush
2
3
6. Intermediate washer
7. Nozzle nut
4
5
6
7
8. Nozzle
8
EFM2054I
2) Maintenance
Exercise extreme care when handling the injection nozzle assembly, particularly nozzle body
and needle valve as these parts are ultra precisely finished.
Wash clean the injection nozzle and remove it from the engine prior to disassembling.
- 142 -
(1) Disassembly
• Clamp the nozzle holder in a vise and remove the cap nut.
• Loosen the adjust screw lock nut and remove the adjust screw then detach the spring and
push-rod
• Clamp the nozzle holder body with the nozzle side up in a vise.
• With a wrench remove the nozzle nut using care not to drop the nozzle. Remove the nozzle
carefully not to drop the needle valve.
1
4
3
노즐 홀더
쉼
코일 스프링
2 가이드 부쉬
6
7
조정 와셔
1. Nozzle Holder
노 즐
2. Guide bush
5
3. Coil spring
유니언 너트
4. Shim
5. Union nut
8
시일 링
6. Intermediate washer
EB1M4004
7. Nozzle
8. Seal ring
EB1M4004
•
Visual inspection
After washing, check the injection nozzles against the following:
(1) Needle valves
Check the valve seats, guide shafts and injection shaft for damage.
(2) Nozzle body
Check the valve seats for carbon deposit and damage. Also check the injection orifices
for uneven wear.
Replace both of the parts by using assembly even if either of the needle valve or the nozzle
body is found to be defective.
•
Sliding test
A sliding test should be made on the entire injection nozzle often visual inspection.
Hold the nozzle body vertically and pull the needle valve upward about 1/3 of its entire
length and release it and see if it lowers onto its seat by its own weight.
If lowering of the needle valve is not smooth, check for presence of foreign matter and
repeat the test. If the trouble persists, replace the entire nozzle assembly with a new one.
- 143 -
(2) Adjustment
•
Remove the cap nut and assemble a
nozzle to a nozzle tester.
•
With the adjusting screw loosened,
operate the nozzle 2 ~ 3 times to bleed it.
•
Operate the nozzle tester lever at the
specified rate.
•
Adjust the injection pressure to the
standard pressure using the adjusting
screw.
•
EFM2056I
After adjusting the injection pressure,
tighten the cap nut to specified torque.
•
Re-check the injection pressure and see
if the spray pattern is normal. Spray
pattern should be uniform and free of
spattering.
Normal
Abnormal
Abnormal
EFM2057I
(3) Testing
With the nozzle assembled to a nozzle tester and specified pressure applied, check the nozzle for
fuel leakage.
Model
L136/T/TI/086TI
Opening pressure
214 + 8 kg/cm2
If the joints are free from leaks and the
needle valve is working normally, the
operation of the nozzle will be accompanied
by whistling sound.
Adjust the standard pressure by means of
the spring adjusting screw.
EAMC022I
- 144 -
(4) Re-assembly
•
•
•
After removing carbon deposit, submerge the nozzle in diesel oil and clean it.
Replace all the gaskets with new ones.
Assemble the parts and tighten them to specified torque.
Items
Torque (kg.m)
Nozzle holder cap nut
7
Nozzle cap nut
6~8
Injection pipe cap nut
2.9 ~ 3.2
Injection pump delivery valve holder
2.5 ~ 3.0
7.4. Turbocharger
The turbocharger is a system designed to make use of the engine exhaust gas energy to
charge high-density compressed air into the cylinders, thereby to increase the engine output.
As explained, the compressing of air to supply into the cylinders is called “Supercharging” and
the making use of the energy of exhaust gas discharged from the combustion chamber to
charge the compressed air into the cylinders is called “Turbocharging”.
7.4.1. Specification
1) Main data and specifications
Sepecification
L136T/TI
Turbocharger Model
At maximum
output
L086TIH
L086TIM
T04E55
HX35
Air pressure at compressor
About 1.2 kg/cm2
About 1.24 kg/cm2 About 1.44 kg/cm2
Air suction volume
About 19.0 m3/min About 15.4 m3/min About 18.6 m3/min
Speed of turbine revolution
About 100,000 rpm
Maximum allowable speed
Max. allowable temperature of
exhaust gas at turbine inlet
About 83,000 rpm
About 83,000 rpm
130,000 rpm
130,000 rpm
750°C
700°C
Lubricating system
External oil supply
Weight
10 kg
- 145 -
21 kg
7.4.2. Turbo charger assembly
1) L136T / TI : TO4E55
20
21
22
14
3
6
7
8
4
18
13
17
2
15
12
19
16
5
1
9
10
23, 24, 25
11
EB7O7017
1. Turbine Shaft
10. Bolt
19. Heat Plate
2. Thrust Bush
11. Clamp
20. Compressor Housing
3. Oil Shut Off
12. Bearing Housing
21. Clamp
4. Lock Nut
13. Retainer Ring
22. Bolt
5. Seal Ring
14. Seal Plate
23. Liquid Gasket
6. Seal Ring
15. Thrust Bearing
24. Loctite
7. Seal Ring
16. Journal Bearing
25. Liquid Anti-Burn Agent
8. Compressor Seal
17. Screw
9. Turbine Housing
18. Screw
- 146 -
2) L086TI (HX35)
EA7M4003
2. Center housing rotating assembly 31. Oil slinger
57. Bolt, turbine housing
4. Bearing Housing
32. O ring seal, bearing housing
58. Screw thrust bearing
5. Turbine housing
33. Oil baffle
59. Bolt compressor cover
6. Assembly turbine wheel
36. Thrust collar
61. Lock nut,
7. Compressor wheel
38. Heat shield
8. Compressor housing
40. Lock plate compressor
62. V-band lock nut
11. Journal bearing
41. O ring seal, compressor
64. Ring retainer bearing
12. Thrust bearing
43. Oil seal plate
66. Insert, retaining ring
13. Piston ring seal, turbine
44. Thrust bearing spacer
77. Flat retaining ring
16. Piston ring seal, compressor
51. Clamp plate, compressor cover 78. Washer, compressor
29. V-band clamp
54. Lock washer, compressor
- 147 -
compressor wheel
88. Clamp plate, turbine
7.4.3. Inspection
As the condition of turbocharger depends greatly on how well the engine is serviced, it is very
important to maintain the engine in accordance with the specified maintenance procedure and
pay particular attention to checking oil & air leaks, unusual sound on running.
1) Checking of the rotor for rotating condition
The inspection of the rotor assembly for rotating condition should be performed by the
degree of unusual sound on running. If a sound detecting bar is used, install its tip on the
turbocharger housing and increase the engine revolutions slowly. If a high-pitch sound is
heard every 2~3 seconds or continuously , it means that the rotor assembly is not normal.
In this case, as the metal bearing and rotor are likely to be in abnormal conditions, the
turbocharger should be replaced or repaired.
2) Checking of the rotor end play
The radial and axial clearances of the rotor should check after every 2,000 hours operation.
This precaution will enable measuring for any wear of axial clearance bearings to be
detected in good time before serious damage is caused to the rotor and bearings.
Disassemble the turbocharger from the engine, then check the rotor axial play and radial
play.
(1) When disassembling the turbocharger, be sure to plug the oil inlet and outlet ports
(2) If the measured axial and radial plays are beyond the limit of wear, replace or repair the
turbocharger.
•
Measuring rotor axial clearance
Radial clearance
•
Turbine
wheel
chamber
터보
하우징
Magnetic
vise
바이스
0.12 mm
Measuring radial clearance
Radial clearance
Move the
축 좌,우turbine
움직임
shaft in axial
direction
0.58 mm
게이지
Dial
gauge
마모한계
: 0.12mm
wear limit
: 0.12 mm
Dial gauge
게이지
Magnetic
바이스
EA7O5011
EA7O5011
vise
Oil
outlet
오일
출구
Move
the turbine
양
축을 잡고
상,하의 shaft in
direction
simultaneousty
간극을
측정함
Radial play
원주 방향
Limit of마모
wear
: 0.58
mm
한계
: 0.58mm
오일
입구
Oil inlet
- 148 -
EA7O5012
both
EA7O5012
3) Precautions for reassembling the turbocharger onto the engine
For re-assembly of the turbocharger or handling it after re-assembly operation, be sure to
observe the following precautions : Especially, pay attention to prevent foreign matters
from entering the inside of the turbocharger.
(1) Lubricating system
•
Before reassembling the turbocharger onto the engine, inject new oil in the oil inlet port
and lubricate the journal and thrust bearings by rotating them with hand.
•
Clean not only the pipes installed between the engine and oil inlet port but also the oil
outlet pipe and check them for damage or foreign matters.
•
Assemble each joint on oil pipes securely to prevent oil leaks.
(2) Intake system
•
•
Check the inside of the intake system for foreign matters.
Assemble each joint on the intake duct and air cleaner securely to prevent air leaks.
(3) Exhaust system
•
•
Check the inside of the exhaust system for foreign matters.
Be sure to use heat resisting steel bolts and nuts. Do not interchange them with ordinary
steel bolts and nuts when performing re-assembly operation. Apply anti-seizure coating
to the bolts and nuts.
•
Assemble each joint on the exhaust pipes securely to prevent gas leaks.
7.4.4. Maintenance
1) Component identification
•
Turbocharge identification
A
dateplate
compressor
is
fitted
housing
to
(8).
the
The
information on this dateplate must
be quoted for service and parts
support.
EA7M4004
- 149 -
•
Center
housing
rotating
assembly
(H2D)
EA7M4005
•
Watercooled bearing housing (5)
This can have additional water feed drain
plug fittings. Special attention should be
made to the position of these fittings as
this may be specific for each application.
EA7M4006
2) Disassembly
•
Before disassembling the turbocharger,
scribe the parts listed below to help in
alignment during assembly.
EA7M4007
•
Secure the turbine housing (5) in a vice.
Loosen and remove the 8 bolts (59) lock
washers (54) clamp plates (51).
Loosen and remove the compressor side
V-band lock nut (62).
EA7M4008
- 150 -
•
Gently remove the compressor cover (8),
and fitted, remove the O ring seal (41).
Caution : The compressor wheel blades
can be easily damaged when
the compressor housing is
removed.
EA7M4009
•
Loosen and remove the 6 bolts (57) and
clamp plates (88).
EA7M4010
Caution : The turbine blades can be
easily damaged when the
turbine housing is removed.
EA7M4011
•
Locate
the
Center
Housing
Rotating
Assembly (CHRA) onto a 19mm socket
clamped in the jaws of a vice or a suitable
fixture.
Caution : Always make sure the turbine
wheel
shaft
compressor
alignment
and
wheel
marks
the
have
before
disassembly of the CHRA.
- 151 -
EA7M4012
•
Remove the compressor wheel lock nut (61).
Note : Left hand thread.
EA7M4013
•
Remove the compressor wheel (7).
EA7M4014
•
Remove the remaining CHRA from the
socket and gently slide the shaft and wheel
(6) from the bearing housing (4).
EA7M4015
•
Discard the two piston ring seals (13).
Caution : Care should be taken not to
score the assembly turbine
wheel shaft.
EA7M4016
- 152 -
•
Remove the heat shield (38).
EA7M4017
•
Place the bearing housing on a flat surface
and using a flat screwdriver, remove the
insert retaining ring (66).
EA7M4018
•
Using two flat screwdrivers, gently remove
the oil seal plate (43).
EA7M4019
•
Remove the oil slinger (31).
EA7M4020
- 153 -
•
Remove and discard the piston ring seal
(16).
EA7M4021
•
Remove and discard the O ring seal (32).
EA7M4022
•
Remove the oil baffle (33).
EA7M4023
•
Remove and discard the 3 flat head screws
(58).
Remove the thrust bearing (12).
EA7M4024
- 154 -
•
If fitted remove the thrust bearing spacer
(44).
Remove the thrust collar (36). Also
remove flat retaining ring (77) if fitted.
EA7M4025
•
Using circlip pliers, remove and discard
the two circlips (64) and the journal
bearing (11) from the compressor end.
EA7M4026
•
Turn the bearing housing over and repair
the process.
EA7M4027
3) Cleaning
With the turbocharger completely dismantled for overhaul, soak all the components in a noncaustic metal cleaner to loosen deposits. Bead blast the turbine housing if chemicals do not
clean sufficiently.
On aluminium parts a bristle brush can be used. Never use a wire brush or metal scraper on
any turbocharger component. Ensure that all the palls are finally cleaned with an air jet,
especially drilled passages and machined apertures. Turbine Wheel: In the event of carbon
build-up, it may be necessary so carefully blast the Piston Ring
Groove area of the turbine wheel using low grade shot medium.
- 155 -
Caution : Shot blasting specific areas for long periods of time may effect component balance.
The surface adjacent to the turbine and compressor wheels on the stationary housings must
be clean, smooth and free from deposits.
4) Inspection
Caution : Do not attempt to straighten the turbine shaft.
(a) Place the shaft on a vee block, using
a dial gauge rotate the turbine wheel
and check for movement on the dial
gauge.
Replace
the
assembly
turbine wheel if it is bent. Max shaft
bend allowed 0.025 mm (0.001 ins).
Shaft Bend
(Max.)
mm
in.
0.025
0.001
EA7M4028
<Major Components>
•
Assembly Turbine Wheel (6)
(b) Inspect the piston ring groove
walls for wear.
Turbine wheel
piston ring groove
mm
in.
Single ring (Min.)
1.664
0.0665
Twin ring (Min.)
3.538
0.1393
EA7M4029
(c) Inspect the bearing journals for excessive scratches and wear. Minor light scratches may
be tolerated.
Assembly turbine
Wheel journals
(Min.)
mm
in.
3.538
0.1393
(d) Inspect for cracked, bent or damaged blades but DO NOT ATTEMPT TO STRAIGHTEN
BLADES.
- 156 -
•
Turbine Housing (5)
Inspect the profile for damage caused
by possible contact with the rotor. Check
all threads for damage. Inspect the outer
and internal walls for cracks or flaking
caused by overheating also check
mounting flanges for signs of distortion.
Replace with new if any of the above are
visible.
EA7M4030
•
Compressor Housing (8)
Inspect the profile for damage due to
possible contact with the rotor. Check
the V-band groove.
Replace with new if any of the above is
visible.
EA7M4031
•
Bearing Housing (4)
Inspect the bore for wear or score mark
on both the bearing and piston ring area.
Also check all tapped holes are clean
and free from dirt.
Replace with new if any damage is
found.
Bearing housing
bore (Max.)
mm
in.
19.063
0.7505
EA7M4032
•
Compressor Wheel (7)
Inspect carefully for cracked, bent or
damaged
blades
but
DO
NOT
ATTEMPT TO STRAIGHTEN BLADES.
Replace with new if any damage is
found.
EA7M4033
- 157 -
<Minor Components>
•
Oil slinger (31)
Inspect and replace if the piston ring
seal
groove
walls
are
scored
or
damaged. Also check for signs of
rubbing on the flat surfaces.
EA7M4034
•
Oil seal plate (43)
Inspect the seal bore, replace if scored
or damaged.
EA7M4035
•
Heat shield (38)
Check and replace if the heat shield id
distorted or if signs of rubbing or
cracking are visible.
EA7M4036
5) Assembly
•
Rotor balance
Before assembly, always make sure that
both compressor wheel and assembly
turbine wheel are individually balanced.
Then
check
balance
of
the
rotor
assembly to ensure it is within the
required limits.
Mark up each individual item to help
ensure
correct
alignment
during
assembly.
EA7M4037
- 158 -
Rotor balance
limits (Max.)
g.mm
oz. ins.
Turbine end
2.2
0.003
Compressor end
4.4
0.006
• Make sure that the circlips are always
fitted with the bevelled edge facing
the journal bearing.
Caution : Circlips
(64).
Premature
failure will result if the circlips
are fitted incorrectly.
EA7M4038
• Place the bearing housing (4) on a
bench with the turbine end facing
uppermost.
Fit the inner circlip (64) with the
bevelled edge facing upwards.
EA7M4039
• Lubricate the journal bearing (11) and
install into position.
Fit the outer circlip (64) with the
bevelled edge facing the bearing.
Turn the bearing housing over and
repeat the process.
EA7M4040
- 159 -
•
Install the heat shield (38).
EA7M4041
• Install the two new piston ring seals
(13) to the assembly turbine wheel (6).
EA7M4042
• Lubricate the shaft using clean engine
oil.
Caution : Align the piston ring seals
(13) so the gaps is positioned
180 ° from the oil drain hole.
Gently press down on the
turbine
wheel
-
a
slight
rotation of the wheel will
EA7M4043
assist in properly locating the
piston ring seals.
• Support the assembly turbine wheel
(6) and bearing housing in a suitable
fixture.
EA7M4044
- 160 -
• Install the thrust bearing spacer (44) if
fitted.
Install the thrust collar (36).
Caution : Align the balance mark on the
thrust collar with that on the
shaft.
EA7M4045
• Using clean engine oil, lubricate the
thrust bearing (12).
Install the thrust bearing.
Install the 3 flat hear screws (58).
Using
torque
wrench,
tighten
to
required torque.
Nm
in-lbs
4.5
40
Torque value
EA7M4046
• Fit the new piston ring seal (16) to the
oil slinger (31).
EA7M4047
• Fit flat retaining ring (77) in base of
bearing housing (4) if required.
Install oil baffle (33).
EA7M4048
- 161 -
• Apply a small amount of oil to the O
ring seal, install O ring seal (32).
EA7M4049
• Insert the oil slinger (31) into the oil
seal plate (43).
EA7M4050
• Install the oil seal plate (43) into the
bearing housing (4).
Caution : Align the balance marks on
the oil slinger (31) with that on
the shaft end.
EA7M4051
• Gently tap the oil seal plate (43) with a
soft hammer to seat in position.
EA7M4052
- 162 -
• Install the retaining ring (66).
Check
correct
location
using
a
screwdriver.
EA7M4053
• Align
the balance marks and install
the compressor wheel (7).
EA7M4054
• Install the compressor wheel lock nut
(61) and tighten to the torque value.
Note : Left hand thread.
Nm
in-lbs
17
150
Torque value
Caution : Ensure
that
the
balance
marks are aligned on the
compressor wheel and the shaft.
- 163 -
EA7M4055
• Locate
the CHRA into the turbine
housing (5).
Install the 3 clamp plates (88) and
tighten the 6 bolts (57) to the torque
value.
Torque value
Bolts (57)
Nm
in-lbs
20
180
EA7M4056
Caution : Make sure the scribe marks
are aligned.
• Secure the turbine housing and check
the trust clearance using a dial gauge.
Trust clearance
mm
in
Minimum
0.038
0.0015
Maximum
0.093
0.0037
EA7M4057
• Check
the radial clearance using a
dial gauge.
Radial clearance
(H2D)
mm
in
Minimum
0.364
0.014
Maximum
0.550
0.022
EA7M4058
• Loosely fit the V-band clamp.
Lubricate and install the O ring seal
(41) if fitted.
Install the compressor cover (8).
Caution : The compressor wheel blades
can be easily damaged when
the compressor housing is
installed.
EA7M4059
- 164 -
• Install the 2 clamp plates (51), eight
lock washers (54) and tighten the 8
bolts (59) to the torque value.
Install the V-band clamp (29) and
tighten the lock nut (62) to the torque
value.
Trust value
Nm
in-lbs
Lock nut (62)
8.5
75
Bolts (57)
8.5
75
EA7M4060
Caution : Make sure the scribe marks are aligned.
- 165 -
8. Troubleshooting
The following description summarizes the probable cause of and remedy for general failure by
item. Immediate countermeasures should be taken before a failure is inflamed if any symptom is
detected.
Hard to start the engine
Fuel system admits air
Bleed air (check feed pump)
Clogged fuel supply piping or clogged air
vent pipe in tank.
Detect the cause and remove clogs or
obstacles.
Clogged fuel filter
Replace filter element with a new one.
Fuel feed pump failure
Check for function. Service fuel pump or
replace with a new one if less discharge
volume is found.
Insufficient compression
Check according to “Insufficient output”
Improperly adjust valve stick or clearance in
intake/exhaust vlaves.
Adjust clearance of intake/exhaust valves.
Cheek valve guide, spring, and rocker arm
mechanism for damage.
Improper injection timing or valve timing.
Check for injection timing and valve timing.
Clogged exhaust pipe (too high back pressure)
Totally check exhaust system (for dented or
twisted pipes and clogged silencer, etc.)
Fuel injection valve failure or errors in
selection types.
Check for part type No.
Service or replace fuel injection valves.
Fuel injection pump failure
Check, service or adjust.
Does starting-aid in cold weather function
normally?
Check whether a proper voltage continuously occurs in low temperature starting-aid
circuit while switch is turned ON.
When glow plugs are used, key switch is
turned “HEAT” position of key switch.
If glow plug is reheated, engine starts.
If not, glow plugs fail or circuit is defective.
If fire once occurs, and goes out if starter
motor is switched ON, voltage is insufficient
or circuit is defective (such as erroneous
selection of starter switch)
- 166 -
Insufficient output
Driven machine normal?
Hydraulic pressure source
Excess intake air resistance
Change or reduce the propeller pitch
Clogged air cleaner
Clogged intake air pipe
Clean
Clean
Excess exhaust
resistance
Clogged
muffler
Clean or replace
Fuel system
failure
Air intrusion into
fuel system
Air bleeding
Clogged exhaust
pipe
Clogged cylinder
head exhaust outlet
Clean
Clogged
fuel filter
Clogged
fuel pipe
Clean
Clean or replace
Clogged air vent in fuel tank
Insufficient fuel volume from feed pump
Governor
Improper
adjustment
Lever link
malfunction
Fuel injection pressure
Clogged fuel
injection valve
nozzle
Fuel injection valve
seizure
Adjust
Clean or replace
Clean
Improper
fuel injection
timing
Adjust
Reduced
compression
pressure
Improper clearance
of intake/exhaust
valves
Adjust
Fuel pump
rack malfunction
Repair or
replace
Defective
intake/exhaust
valve seat
Reshape or replace
Faulty
delivery
valve
Worn
plunger
barrel
Repair or
replace
Replace
Intake/exhaust
valve stem
seizure
Replace
Fatigued or
broken valve
spring
Replace
Pressure
leak through
cylinder
Replace
Seizure, breakage
and wear of piston
ring
Replace
Overheat
Refer to “Overheating”
- 167 -
Flaws or
wear of
piston
Flaws
or wear
of liner
Replace
Replace
Overheating
Driven unit normal?
Cooling
system
Hydraulic pressure source
Insufficient
cooling water
Sagged
V-belt
Add water
Adjust
Pressure cap
clogging and
malfunction
Broken or
worn V-belt
Clogged heat
exchanger
Replace
Clean
Clogged heatexchanger
tubes
Thermostat
malfunction
Clean or replace
Set relief pressure of control valve
Replace
Incresed exhaust
pressure
Clean
Reduction in cooling water pump
performance
Clean
Replace
Heat exchanger
malfunction
Clean
Excess intake
air resistance
Clogged air
cleaner
Clogged
intake air pipe
Clean or replace
Excess exhaust
resistance
Clogged
muffler
Clean
Clogged
exhaust pipe
Clean
Cylinder head
Leakage through
head gasket
Clean
Improper fuel
injection timing
Repair
Injection OPEN/
CLOSE timing
Piston
Clean
Cracked cylinder
head
Replace
Fuel system
Clogged cylinder
head exhaust outlet
Replace
Defective fuel
injection valve
Clean or replace
Improper valve
clearance
Improper fuel
injection timing
Adjust
Adjust
Seizure likeliness
Replace
- 168 -
Black smoke is produced.
Driven machine normal?
Insufficient output
Fuel
Hydraulic pressure source
Set relief pressure of control valve
Refer to “Insufficient output.”
Improper fuel
Replace
Fuel pump
Too early injection timing
Adjust or replace
Governor
Improper adjustment
Adjust
Excess injection volume
Uneven injection volume
Adjust
Adjust or replace
Malfunction of lever and linkage
Repair or replace
White smoke is produced.
Fuel
Water intrusion in fuel
Intrusion of low-quality fuel or impurities
Replace
Replace
Lube oil
Improper SAE grade
Replace
Excess intake air risistance
Fuel pump
Clogged air cleaner
Clogged intake air pipe
Repair or replace
clean or replace
Too late injection timing
Adjust or replace
Oil pressure drop
Defective valve
stem sealing
Damaged or worn
valve stem
Replace
Breather oil rise
Seizure, breakage, or
wear of piston ring
Replace
Flaws or wear
of piston
Damaged or worn
valve guide
Replace
Flaws or wear
of liner
Leakage through cylinder
head gasket
Over-cooling
Thermostat malfunction
- 169 -
engine seizure and
[ Except
trouble of driven machine ]
Starter motor will not turn
or output less power.
Disconnection &
faulty connection
Battery
terminal
Grounding
termainal
Repair
Battery
Repair
Specific gravity
Coupler
connection
Repair
Voltage
Charging
Key switch
Disconnected
wiring
Repair
Damaged battery
Replace
Add electrolyte or
charge
Switch inner contactor
Damaged or rusted
starter motor terminal
Replace
Damaged switch
Replace
Replace or repair
Safety relay
Damaged or
rusted terminals
Faulty really functioning
Replace
Replace or repair
Startor motor
Damaged
or rusted
terminal
Magnet switch,
malfunction &
defective contactor
Defective
brush
Replace
Replace or repair
Burnt
coil
Replace
or repair
Short
circuited
Replace
starter motor
Clutch slip
Replace
Hydraulic pressure source
Hydraulic system will not
operate or to slow function
Lube oil quantity
Insufficient
Deterioration
Replace
Add Lube oil
Piping
Trouble in piping
Viscosity
Recommended Hydro-oil
(Aeration cavitation)
Correct
Gear pump
Worn spline in flange
Replace
Filter
Broken shaft
Replace
Clogging
Clean or replace
- 170 -
Worn gears and housing
Replace
Battery is dead or not
chargeable.
[During operation]
Poor charging
Defective
wiring and
connection
Discharged
Battery
terminal
Disconnected
wiring
Grounding
terminal
Coupler
connection
Key
switch
ON condition
Repair
Repair
Wiring
Battery
Battery
terminal
Key switch
ON
Replace
Damaged
or rusted
terminals
Turn ON
Switch
inner
contactor
Repair or replace
Electric
appliance
Short-circuit
Alternator
Replace
Short-circuited
or disconnected
lead wire
Replace
Sagged fan belt
Faulty IC regulator
Adjust
Replace alternator
Damaged diode
Replace
Defective brush
Repair or replace
Burnt coil
Replace alternator
Short-circuited
Replace alternator
- 171 -
Electric
appliance
Alternator
Damaged
diode
Replace
Shortcircuited coil
Replace
alternator
9. Special Tool List
No.
Tool Names
Tool No.
1
Front Oil Seal
Assembly Jig
EF.123-173(NOK)
Descriptions
Applications
EAMD086I
2
Front Oil Seal
Puller Jig
EF.123-052
EAMD025I
3
Rear Oil Seal
Assembly Jig
EF.123-184(NOK)
EA8M3003
4
Rear Oil Seal
Puller Jig
EF.123-048
EAMD042I
5
Valve Spring Press
EF.123-065
EA8
6
Crank Shaft Gear
Punch
EU.2-0647
7
Valve Stem
Seal Punch
EF.122-089
EA0M4007
EAMD096I
8
Adapter for
Cylinder Pressure Test
EU.2-0530
EB4O403L
No. 3 : CR (U.S.A CR Industries Co.)
NOK (Japan NOK Co.)
- 172 -
No.
Tool Names
Tool No.
9
Injection Pump
Alignment Jig
EF123-015
(Only L086TI)
Descriptions
Applications
EAMD107I
10
Piston Sleeve
EF.123-064
11
Cylinder Liner Puller
EF.123-086
12
Filler Gauge
60.99901-0027
EF.120-208
(For all engines)
EAOO4014
13
Filter Wrench
65.98801-0001
EA7O5008
14
Snap Ring Plier
T7610001E
EA3M2029
15
Piston Ring Plier
T7621010E
- 173 -
10. Tightening Torque
• Tightening torque for major parts
Screw
Strength
(diameter x pitch)
(grade)
Cylinder head bolt
M14 x 1.5
10.9T
6.0 kg.m + 180 + 150 (Angle)
Connecting rod bearing cap bolt
M14 x 1.5
12.9T
18.0 kg.m
Crankshaft main bearing cap bolt
M16 x 1.5
12.9T
30.0 kg.m
Balance weight fixing bolt
M12 x 1.5
10.9T
10.0 kg.m
Flywheel fixing bolt
M14 x 1.5
10.9T
21.5 kg.m
Crankshaft gear fixing bolt
M12 x 1.5
10.9T
13.0 kg.m
Major Parts
Tightening Torque
• Tightening torque for injection pump system
Parts
Tightening Torque
11.0 ~ 12.0 kg.m
Injection pump delivery valve holder
7.0 kg.m
Nozzle holder fixing cap nut to cylinder head
6.0 ~ 8.0 kg.m
Nozzle fixing cap nut of nozzle holder
Max. 2.9 ~ 3.2 kg.m
High pressure injection pipe fixing cap nut
- 174 -
Remarks
• Tightening torque table for standard bolt
Refer to the following table for bolts other than described above.
Degree of strength
Diameter
x
3.6
4.6
4.8
5.6
5.8
6.6
6.8
6.9
8.8
10.9
12.9
(4A)
(4D)
(4S)
(5D)
(5S)
(6D)
(6S)
(6G)
(8G)
(10K)
(12K)
54
64
90
108
pitch
(mm)
Limit value for elasticity (kg/mm2)
20
24
32
30
40
36
48
Tightening torque (kg•m)
M5
0.15
0.16
0.25
0.22
0.31
0.28
0.43
0.48
0.50
0.75
0.90
M6
0.28
0.30
0.45
0.40
0.55
0.47
0.77
0.85
0.90
1.25
0.5
M7
0.43
0.46
0.70
0.63
0.83
0.78
1.20
1.30
1.40
1.95
2.35
M8
0.70
0.75
1.10
1.00
1.40
1.25
1.90
2.10
2.20
3.10
3.80
M8x1
0.73
0.80
1.20
1.10
1.50
1.34
2.10
2.30
2.40
3.35
4.10
M10
1.35
1.40
2.20
1.90
2.70
2.35
3.70
4.20
4.40
6.20
7.40
M10x1
1.50
1.60
2.50
2.10
3.10
2.80
4.30
4.90
5.00
7.00
8.40
M12
2.40
2.50
3.70
3.30
4.70
4.20
6.30
7.20
7.50
10.50
12.50
M12x1.5
2.55
2.70
4.00
3.50
5.00
4.60
6.80
7.70
8.00
11.20
13.40
M14
3.70
3.90
6.00
5.20
7.50
7.00 10.00
11.50 12.00
17.00
20.00
M14x1.5
4.10
4.30
6.60
5.70
8.30
7.50 11.10
12.50 13.00
18.50
22.00
M16
5.60
6.00
9.00
8.00 11.50
10.50 17.90
18.50 18.00
26.00
31.00
M6x1.5
6.20
6.50
9.70
8.60 12.50
11.30 17.00
19.50 20.00
28.00
33.00
M18
7.80
8.30
12.50
11.00 16.00
14.50 21.00
24.20 25.00
36.00
43.00
M18x1.5
9.10
9.50
14.50
12.50 18.50
16.70 24.50
27.50 28.00
41.00
49.00
M20
11.50 12.00
18.00
16.00 22.00
19.00 31.50
35.00 36.00
51.00
60.00
M20x1.5
12.80 13.50
20.50
18.00 25.00
22.50 35.00
39.50 41.00
58.00
68.00
M22
15.50 16.00
24.50
21.00 30.00
26.00 42.00
46.00 49.00
67.00
75.00
M22x1.5
17.00 18.50
28.00
24.00 34.00
29.00 47.00
52.00 56.00
75.00
85.00
M24
20.50 21.50
33.00
27.00 40.00
34.00 55.00
58.00 63.00
82.00
92.00
M24x1.5
23.00 25.00
37.00
31.00 45.00
38.00 61.00
67.00 74.00
93.00 103.00
Others : 1. The above torque rating have been determined to 70% or so of the limit value for bolt
elasticity.
2. Tension is calculated by multiplying tensile strength by cross section of thread.
3. Special screws should be tightened to 85% or so of the standard value.
For example, a screw coated with MoS2 should be tightened to 60% or so of the
standard value.
- 175 -
11. Maintenance Specification Table for Major Parts
Group
Part
Inspection Item
Inside diameter of
cylinder liner for wear
Cylinder
block &
liner
Engine
body
Amount of liner
projection
The flatness of upper
surface of cylinder block
Hydraulic test for 1
minute (kg/cm2)
Cylinder
head &
valve
Valve seat
depression
Piston ring
parts
gap
Piston
ring
Piston ring
side
clearance
4
Correct with a
Referenced length :
surface grinder
200mm
Replace if leaky
0~0.3
-
seat
109.9 ~110.1
108.4
4
110.801~
110.959
0.041~0.221
Top ring
3.50
2nd ring
3.06~3.08
Oil ring
4.04~4.06
Permissible weight
difference of each piston
moving
0.05/200
Exhaust
Piston projection from
cylinder block upper
surface
Major
0.03~0.08
Replace valve
Clearance between
piston and liner
0.3
1.5
2nd ring
0.40~0.65
1.5
Oil ring
0.30~0.60
1.5
2nd ring
0.07~0.102
0.15
Oil ring
0.05~0.085
0.15
Top ring
pin
Clearance between
piston pin and its bush
Replace liner
Measure at 13mm
away from lower
surface of piston
Replace one worn
more
Replace ring
Replace ring or
Limit for use if for
piston
standard clearance
41.994~42
Replace piston pin
0.009~0.015
Replace one worn
more
- 176 -
Measure unworn
portion beneath the
rim of the upper side
Standard gauge
inside diameter :
108
Cross Install by
120˚C
Direction of ring gap
pin
Water temp. 70˚C
96 g vl Replace piston
0.40~0.65
Piston
Replace if leaky
Must exist
Top ring
Outer diameter of piston
Replace cyl. head
Replace piston if
groove width is beyond
specified value
0~0.12
±15 g
-
Need amount of
Projection difference
projection without between adjacent
fail
liners : 0.15 vl
-
Hydraulic test for 1
minute (kg/cm2)
Remark
111.222 Replace liner
(Limit0.2)
0~0.3
Outer dia. piston
Piston
111~ 111.022
Correction
Intake
Cylinder head height
Width of
piston ring
grooves
Limit
Stand value
for assembly for use
Group
Part
Inspection Item
Radial run-out of journal
and pin
Outside diameter of
journal
Outside diameter of pin
Crank
shaft
Ellipticity of journal
and pin
Concentricity of journal
and pin
Taper of journal and pin
Clearance between
crankshaft and bearing
Stand value
Limit
for assembly for use
0.01
83.966~
83.988
70.971~
70.990
0.025
0.01
0.03
0.01
0.03
0.052~0.122
0.25
End play of crankshaft
0.15~0.325
0.5
Run-out of crankshaft
0.1 vl
Crush height of journal
bearing
60 vl
Connecting rod Crush height of con-rod
bearing
Side clearance of bigend and small-end
Allowable weight
difference per con-rods
Torque valve of
con-rod bearing cap bolt
(kg•m)
Diameter of cam shaft
journal
Clearance between cam
shaft and cam bush
End play of camshaft
Correct
Measure In horizontal
with a grinder
and vertical directions
Use under sized
bearings
respectively(0.25,
0.5, 0.75, 1.0)
Replace bearing
Measure at crown
part not parting line
Replace
thrust bearing
0.50
0.25
Replace bearing
60 or
less
0.08~0.110
Measure after
installing the bearing
and releasing one bolt
After completing of
bearing loosen one
stud bolt & measure
0.12
0.30~0.50
0.50
Replace con-rod
18 g vl
Clean out foreign
Coat the bolt with objects on joining
engine oil
surface
18
57.86~ 57.88
0.12~0.17
0.24
0.28~0.43
0.6
Run-out of camshaft
Timing
gear
Remark
Measure at No.4
Adjust by a press bearing(No. 1 & 7
if bended
bearing supported)
Check dynamic
Measure
balance
at 400 rpm
Clean out foreign
Coat the bolt with objects on joining
engine oil
surface
Measure after
tightening metal cap
and releasing one
stud
Replace oil seal
if oil leaking
Replace con-rod
30
Oil seal for wear(crank
shaft rear)
End play of con-rod
0.170 ~ 0.248
Clearance between conrod bearing and crank
0.034 ~ 0.098
pin
Clearance between
small end bush &
0.050~0.081
piston pin
Cam
shaft
70
0.008
Balance of
crankshaft(g•cm)
Torque valve journal
bearing cap bolt
(kg•m)
Major
moving
parts
83
Correction
0.1
Clearance between idle
shaft bush and idle shaft 0.025~0.091
End play of idle gear
0.043~0.167
shaft
Back-lash between
gears(cam, idle, crank
0.16~0.28
and injection)
- 177 -
Replace cam bush
Replace thrust
washer
Correct or replace
the cam shaft
0.15
0.3
0.35
Correct or replace
gear
Replace gear
Group
Part
Inspection Item
Stand value
Limit
for assembly for use
Diameter of intake valve
stem
8.950~ 8.970
0.02
Diameter of
exhaust valve stem
8.935~ 8.955
0.02
Clearance
Intake
between valve
stem and
Exhaust
valve guide
0.030~0.065
0.15
0.045~0.080
0.15
Intake
Thickness
of valve head Exhaust
2.2
Clearance
Intake
between valve
guide and valve
Exhaust
spring seat
2.7
Correction
Remark
Replace valve &
When replacing
valve, replace
valve guide alike
valve guide
Replace valve &
Replace one worn
valve guide
more
Max. 1 Replace valve
1.0
1.0
Clearance between valve
-0.039~-0.010
guide and cyl. head
(Press fit)
installing hole
Spread oil over
valve guide and
press it into the hole
Concentricity between
valve stem and valve
head
Without spring seat
Valve
Intake
valve
spring
0.15
Free length
Approx.64
Tension force
(when pressed
to 41mm)kg
67.9~72.1
2.5°
Valve
Squareness
(along free
length direction)
system
Free length
Approx.60
Exhaust
Tension
I force(when
n pressed to
n 38mm)kg
e Squreness
r
(along free
length
valve
direction)
spring
Free length
Tension
O force(when
u pressed to
t 41mm)kg
e
r Squreness
(along free
length
direction)
Valve
clearance
(at cold)
26.9~30.3
66.5
Replace
valve spring
2.5°
Approx. 71
62.7~69.3
Replace
valve spring
2.5°
Intake
0.3
Exhaust
0.3
-
Adjust
Grind or replace if
severely pitted on
tip of rocker arm
and stem
Joining surface of valve
stem and rocker arm
bush
Clearance between
rocker arm shaft &
rocker arm bush
Diameter of rocker arm
shaft for wear
Run-out of push rod
Replace
valve spring
0.020~0.093
0.25
Replace bush
or shaft
23.939~
23.96
23.75
Replace
-
0.3
Replace
- 178 -
Group
Part
Inspection Item
Clearance between
tappet & cyl. block
Valve
Tappet
system
Diameter of tappet
Stand value
Limit
for assembly for use
0.035 ~ 0.077
0.1
19.944 ~ 19.965 19.89
Replace tappet
Replace tappet
-
Replace
if severely worn or
deformed
4.8 or less
3.5
Check oil leakage
and clearance
between each part
0.8~1.4
0.6
Use recommended
oil
-
105
-
120
Axial play
of oil pump gear
0.055 ~ 0.105
-
Clearance between
drive gear shaft &
oil pump cover hole
0.032 ~ 0.077
-
0.040 ~ 0.094
-
Oil
Clearance between
drive gear shaft and
cover hole
pump
Diameter of gear shaft
16.950 ~ 16.968
Replace gear shaft
17e7
Diameter of driving gear
bush
28.000 ~ 28.033
Replace bush
28e7
Oil
pressure
(normal speed)kg/cm2
Oil pressure
(idling)kg/cm2
Oil
Max. permissible
oil temperature˚C
tempera Permissible
ture
oil temperature
in short time˚C
ing
Remark
-
Tappet face in contact
with cam
Oil pressure
Lubricat
Correction
system
or cover
or cover
0.8
Backlash
Adjust back-lash
Between oil
pump drive
gear & idle gear
0.15 ~ 0.25
0.8
Oil pressure control
valve (kg/cm2)
4.0 + 0.8
0.8
By-pass valve for filter
element (kg/cm2)
1.8 ~ 2.3
0.8
Valve
By-pass valve for full oil
opening filter (kg/cm2)
pressure Relief valve for oil
pump (kg/cm2)
Spray nozzle control
valve (kg/cm2)
filter
Replace gear
Replace bush
Between crank
gear & idle
0.15 ~ 0.25
gear
Oil
Must not exceed this
valve
Replace valve
10 ± 1.5
Replace valve
1.5 ~ 2.0
Damage of oil filter
cartridge
Clean or replace
- 179 -
Group
Part
Inspection Item
Limit
Stand value
for assembly for use
Heat exchanger &
water pump for
corrosion, damage &
improper connecting
Heat
Exchang Test for leakage
(air pressure) (kg/cm2)
er
Pressure valve for
opening pressure
(kg/cm2)
Cooling
system Water
pump
Delivery volume l/min
- Engine speed 2,300rpm
- Water temp.85 ˚C
- Back pressure :
0.5 kg/cm2
Correction
Correct or replace
Submerge in water
and replace if air
bubbles found
3.0
0.9
Check the water
For any restrictions
passage
260 Lit/min
Clearance between
impeller & housing
0.35
Replace if impeller
& housing are intact
Perpendicularity of
pulley
0.3
Adjust by a bench
press
Fan belt depression
(with thumb)
10 ~ 15
15
Adjust
85
95
Must not exceed this
valve
103
-
Cooling Operating temperature
(permissible temp) ˚C
water
Permissible temperature
temp
in a short time. ˚C
Thermostat
opening temp. ˚C
Remark
71
Replace
85
Replace if defective
stroke min. 8mm
Thermostat (under atmospheric pressure)
Full opening temp. ˚C
Piping
&
others
Fuel pipe, injection pipe
& nozzle holder for
damage, cracks,
improper packing, etc.
Fuel filter cartridge for
Fuel
damage or dimple
system Injection pressure of injection
nozzle (kg/cm2)
Repair or replace
Replace cartridge
220
Operating pressure of overflow
valve (kg/cm2)
1.0 ~ 1.5
Projection height of nozzle from
the cyl. head surface(mm)
3.6 ~ 4.1
Adjust by shim
1st :160 , 2nd : 220
Replace valve
Replace cyl. head &
nozzle
Refer to supplement
“running-in”
Running-in the engine
Inspection
24 or
Compression pressure of
24 ~ 28
more
at
Cylinder cylinder (kg/cm2)
completion pressure Compression pressure ±10% or less
against average
difference of each
cylinder
- 180 -
Correct
at 200rpm or more
Correct
more(20 ˚C)
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