Operating Manual - Chang Shin International

Operating Manual
For CS-100 Drilling Rig
Serial No. : 2013-003
Chang Shin International Co., Ltd.
Office - Tel : 82-2-425-3877
Fax : 82-2-425-3879
Factory : 402-3, WHASAN-RI, ONSAN-EUP, ULSAN, KOREA
Tel : 82-52-239-3878
Fax : 82-52-237-0358
Email : csi@okcsi.com,
www.okcsi.com, www.dth-hammer.com
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Contents
1. TECHNICAL SPECIFICATION
1-1. GENERAL
1-2. OVERALL DIMENSIONS
1-3. RATED DRILLING CAPACITY
1-4. CRAWLER BASE
1-5. RIG FRAME
1-6. MAST
1-7. ROTARY HEAD
1-8. ENGINE
1-9. HYDRAULIC SYSTEM
1-10. CLAMP & BREAK OUT
1-11. WINCH
1-12. OUTRIGGER
1-13. CONTROL PANEL
1-14. CONNECTION MANIFOLD BLOCK
1-15. ELECTRICAL SYSTEM
1-16. MUD PUMP
1-17. IDENTIFICATION
2. PRE-OPERATIONAL CHECKS
2-1. ENGINE
2-2. HYDRAULIC OIL
2-3. CONTROL VALVE
3. OPERATION AND MANAGEMENT
3-1. ENGINE
3-2. PRESSURE OIL & COOLANT
4. Control Panel Description
4-1. Engine & Work control Panel
4-2. Move control Panel
5. Reference Drawings
6. Engine Manual
Chang Shin
int'l co.,ltd.
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1. TECHNICAL SPECIFICATION
1-1. GENERAL
CS-100 Drilling rig is very powerful drilling rig with simple design providing excellent
performance at minimum maintenance for percussion drilling with down the hole hammer,
rotary drilling with mud, reverse drilling crown core drilling and reverse circulation drilling
with optional drive head.
This rig adapts powerful engine & hydraulic pump, carries out various drilling task
efficiently.
With strong and extensible mast, it grants very stable & strong power in pull back & pull
up operation.
1-2. OVERALL DIMENSIONS
Length
Width
4.9
1.8 M
Height
Mast Down
Mast Up
2.3 M
5.5 M
Weight
3.8 Ton
Chang Shin
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1-3. RATED DRILLING CAPACITY
In favorable condition
Max 100 meters for 6" Hammer with
- For DTH Hammering
:
- For Rotary Drilling
(Tricone bit, coring)
:
Max 100 meters
:
:
:
:
:
1.9 M
1.8 M
0.45 M
0.25 M
Max 3km / h)
88.9mm Drill rod
1-4. CRAWLER BASE
Overall
Overall
Overall
Rubber
Moving
Lenght
Width
Height
Track Width
Speed
1-5. RIG FRAME
Rig frame is mounted on the crawler base frame and has four(4) hydraulic outriggers
(two on front, two on rear) to avoid any deforming of the crawler. This rig frame makes
possible powerful and steady drilling.
1-6. MAST
▶ FEATURES
- Mast has strong square box feature made of high quality mechanic structure steel
plate, assures safe & easy handling for 3meter drill pipes & drill strings.
- Mast is self standing & lying by hydraulic cylinders controlled on control panel.
- There are several wire or chain sheaves at top & bottom of the mast for the
operation of pull-back & pull down.
▶ SPECIFICATIONS
Total Load Capacity
Length
Feeding Method
:
:
:
5ton
4.6 M
Hydraulic cylinder with chain
Chang Shin
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1-7. ROTARY HEAD
- Head box is made of electrically welded high grade steel.
- Output shaft : API 2-3/8" REG Pin
- Output shaft of shock absorber : API (NC23 Pin).
- Rotation provided through oil bath gear and bearing with air proof.
- Feed operation is provided by hydraulic cylinder with chain.
- For the down the hole hammer is standard, Can be changed for the other works.
▶ SPECIFICATIONS
Pull-up Capacity
:
Max
3,260 kgf
Pull-down Capacity
:
Max 01,970 kgf
Rotation Torque
:
100 kgf*m (Max 200kgf*m)
Rotarion Speed
:
0~60 rpm
Output Shaft Connection
:
API NC23 Pin
Swivel Connection
:
1 1/2"
Feed Speed
:
0 ~ 36.6 m / min
1-8. ENGINE
- Doosan Commercial Engine / PU066
1-9. HYDRAULIC SYSTEM
- This rig is totally operated by hydraulics.
- Hydraulic system is open loop system with 3 hydraulic pumps.
- Hydraulic power is generated by deck mounted diesel engine for following operation.
▶ OPERATION
- Pull up - Pull down
- Rotation of the Rotary Head
- Hydraulic clamp
- All hydraulic cylinder
- Main winch
- Other operations
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▶ MAIN COMPONENTS
- Hydraulic Pump
:
SAP5030-40*40*20RSS
- Hydraulic Cooler
:
Air fan driven by engine
- Hydraulic Tank Capacity
:
140ℓ
- Heavy Duty Filter
:
10µ grade
- Motors
- Valves
- Distributor
- Gauges
- Rigid and flexible pipes & hoses
- Other necessary accessories in other to assure the afficient working condition.
1-10. CLAMP & BREAK OUT
- Hydraulic clamp works for Holding and unscrewing the drill pipes and drill
casing or drill collars, stabilizer and drill strings with hydraulic cylinder.
- Clamp is attached to the mast frame by welding.
Opening
:
 225 mm
1-11. WINCH
▶ MAIN WINCH
The winch works with jib boom & sheaves mounted at top of the mast.
Working Capacity
:
1 Ton
1-12. OUTRIGGER
▶ FUNCTION
- Stabilize the rig itself
- Keep the horizental & leveling during operation
- Sustain the power in pull-back operation
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▶ FEATURES
- Each outrigger moves independently.
- Pilot check valve attached for failure.
- Square structure outside.
- Non slip floor shoe.
1-13. CONTROL PANEL
Control panel contains all engine gauges, hydraulic system controllers.
It makes the driller control all operation easily at the platform located on Side of mast.
▶ FEATURES
- Engine Throttle
- Engine start and stop
- cooling water temperature.
- Hydraulic pressure
- All control lever including for machine operating.
- Main indicator
1-14. CONNECTION MANIFOLD BLOCK
Connection manifold block locates at side of mast in order to connect the fluid(air or mud)
to top head drive for each operation.
▶ PORT SIZE
Air Port
: 1 1/2" connector
Mud Port
: 1 1/2" connector
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1-15. ELECTRICAL SYSTEM
- 24V
1-16. MUD PUMP
Main purpose
:
Rotary Drilling / Water Pumping
Controlled by control panel &
Control & Operation
:
Capacity
:
Hydraulically driven
107ℓ / min
Pressure
:
Max. 20 bar
1-17. IDENTIFICATION
1-17-1. Engine
Model
PU066
Serial Number
EARPA318968
Rating
116(85) ps(kW)
Engine Speed
2,800 rpm
Displacement
Production Date
5.785 liters
6-102 × 118 (Cyl. - Bore × Stroke, mm)
2013 (year)
1-17-2. Hydraulic Pumps & Motor
Model Name
Serial No.
OIL PRESSURE PUMP
ASEDA
120821PB
MUD PUMP
P-200
A 6745
Picture
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Hydraulic Motor
PARKER : TE165
Model Name
Serial No.
10913AB 2495
16913AB 0309
Picture
Model Name
Serial No.
WINCH
JMF-16-01-VBC-RJ-31
2011-06-0012
Picture
1-17-3. Cylinders
Part Name
Dimension
Cylinder (ID-OD)
Stroke
QTY
1
Outrigger Up/Down
70-80
1340
4
2
Master Tilting
70-80
420
1
3
Top Feed
80-90
1730
1
4
Break
60-70
85
1
5
Jaw
90-100
165
2
6
Rotary Head Sliding
50-60
230
1
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2. PRE-OPERATIONAL CHECKS
2-1. ENGINE
a) Allow the engine to warm up after starting.
b) Avoid racing the engine.
c) Limit load to 70% maximum.
d) Avoid changing Extreme load.
e) Checking Engine Oil Level
Remove the oil level gauge, wipe clean with a cloth, reinsert remove again. If the
oil level is between the upper and lower notched lines, the oil level is good.
If the oil level is low, add oil through the oil filler.
At the same time, check the oil for contamination and viscosity, and replace as
necessary. Check for oil leaks, too.
NOTE :
1.With the engine placed on a flat sur-face, inspect the oil level before
starting the engine or about 30 minutes after it has stopped.
2.Allow 5 to 6 minutes between addition of engine oil and checked
immediately after addition of added because the oil level may be checked
before all added oil falls down.
f) Checking fuel Level
Check to ensure that the fuel tank is filled.
Check for fuel leaks, too.
To start an engine after a long period of shutdown or after fuel has run out,
the fuel system should be bled beforehand.
For bleeding procedure.
g) Checking Coolant Level
Check the coolant level in the radiator or coolant tank.
h) Water Leaks
Check for water leaks from the radiator, radiator hose and other parts of the
cooling system. Check also for traces of water leaks under the engine.
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2-2. HYDRAULIC OIL
a) Hydraulic oil must be filled a half of gauge when it's checking.
b) By operating, proper temperature is 30℃~80℃, and critical temperature is
80℃~100℃.
c) In the joint part, hydraulic oil is run out or, if hydraulic tank inner oil is more
lower than suction hole it's to happen demage in hydraulic pump and if
suction or return pipe joint part is released, the air is indrafted in circuit,
that's cause to noise and insecurity of operating.
d) Hydraulic oil of check point
① Fitted quantity oil
② Check the leak part
③ Fitted quantity oil pressure
④ Check the substance of mixing material.
⑤ Check the strange smell.
⑥ Check the blazing fire.
2-3. CONTROL VALVE
a) Control valve lever is set neutrality.
b) Control valve is check of oil run out.
c) Control valve pressure is set of fitting.
※ Around of machine is checked of dangerous element.
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3. OPERATION AND MANAGEMENT
3-1. ENGINE
a) Insert the key when the starting position.
b) Turn on the start position by key to operate the starter and then engine is
operated.
d) After operating of engine, for more fast warming up, please turn the little high
position than low speed rotation.
※CAUTION : Engine must be operated at least 5 minute-so please a little wait.
d) Check the gauge of switch board.
e) Check the machine of surrounding to dangerous of element.
f) And after to operate the pressure oil control valve, and to begin the job.
g) Air Cleaner
The air cleaner should be periodically check the status and cleaned.
If the air cleaner do not clean, Causes loss of efficiency the engine And
damage to parts in the engine.
3-2. PRESSURE OIL & COOLANT
a) Pressure oil check point
① Fitted quantity the inner in tank.
② Oil temperature-high or low than standard.
③ Water moisture or dust or defacement etc.
④ Oil run out to fitted.
⑤ Use the oil quality with outside temperature.
▶ Replace engine oil
After the first 60 hours and every 250 hours there after (Every 125 hours for
the engine without bypass filter) On a new engine, be sure to replace the oil
after the first 60 hours of operation.
⑴ After shutdown of the engine, remove the drain plug of the oil pan to
remove the oil while it is still hot At the same time, the oil in the oil filter
should also be removed.
⑵ Install the drain plug and pour in fresh engine oil[API CC OR API CD]from
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the oil filler port up to the FULL mark on the level gauge.
⑶ After running the engine at idle for several minutes, check the oil level.
b) Fuel
Characteristics of diesel fuel for a high speed diesel engine such as cetane
number, specific gravity, and viscosity will affect engine starting, output,
consumption, injection system function, knocking noise, and exhausting smoke.
Diesel fuel containing much sulfur will deteriorate engine oil sooner, and it
requires earlier replacement of engine oil with new one Accordingly, it is
recommended to use fuel oil with cetane number of 45 or more of well-known
maker's products for a high speed diesel engine.
Select lower viscosity fuel under low temperature.
▶ Handling fuel
The injection pump and injection nozzle are precision built and lubricated by
the fuel itself. Therefore, use of fuel contaminated with water or dust may lead
to a serious trouble. Always use clean fuel and pay attention to the following
when handling the fuel.
⑴ After the end of the day's work, fill the fuel tank with fuel to its capacity.
This is to expel air from the tank as otherwise the moisture in the air
might condense into water drops which contaminate the fuel.
Also, this gives enough time for dust and water to be separated and set
before operation on next day.
⑵ Store the fuel in a storage tank for at least 24 hours to allow rust and
water to precipitate before use. Use only the supernatant.
⑶ When filling the fuel tank from a drum, take care not to allow deposit on
the bottom to be carried over into the tank.
⑷ Open the drain plug at the bottom of the storage and fuel tanks
occasionally to drain off deposits and water
⑸ For prevent the moisture, if the job is finished, please full filled the oil in oil tank.
c) COOLANT
Use soft water with a low impurity content as the coolant.
Use of water containing salt, or spa could accelerate deposit of scale in the
water jacket and corrosion of the external surface of the cylinder liner.
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Use anti-corrosion in hot weather to prevent corrosion and use anti-freeze in
cold weather to prevent freezing of the coolant.
NOTE :
If the coolant in the cooling system contains anti-freeze or anti-corrosive, add
a solution of the same concentration as the solution initially put into the
system.
▶ Cautions on use and handling of anti-freeze
⑴ Use a permanent type anti-freeze.
⑵ When anti-freeze is to be applied or when the coolant with anti-freeze is
to be replaced by coolant without anti-freeze to comply with the rise in
the atmospheric temperature, wash and clean the cooling system.
⑶ The anti-freeze/water mixing ratio depends on the lowest temperature
expected. Fill anti-freeze as per the instruction Manual.
THE KINDS OF OIL
HYDRAULIC OIL
ENGUINE OIL
GEAR OIL
MULTIPURPOSE TYPE GREASE
SPECIFICATION
ISO VG 68
SAE 30
API GL-3
NLGI NO.2
d) BATTERY
Pay attention to the following when handing the battery
⑴ The battery fluid is a dilute sulfuric acid solution. be careful not to allow the
fluid to come in contact with eyes. skin, clothing and metal surface. if the
fluid has come in contact with them, wash it out immediately with water
⑵ The battery is emitting inflammable hydrogen gas. Avoid using fire near the battery.
⑶ When the battery is inspected or charged or when the electrical system is
serviced, the stater switch should be to OFF and the negative terminal of
the battery disconnected beforehand for safety's sake.
⑷ When the battery is removed, make sure that the negative terminal is
disconnected first. When the battery is installed, the negative terminal
should connected last.
⑸ The battery installed in an emergency engine must be handled in a different way.
Refer to the instruction manual supplied with the battery
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▶ Check for fluid level
Every 125hours (or every two weeks every week in summer)
⑴ The fluid level should be between the "UPPER" AND "LOWER" level lines, if
the level line is below the "LOWER" level line, add fluid or distilled water
up to the "upper" level line.
⑵ As for a battery which has no level lines, the
level should be 10 to 15
above the battery surface of the case.
▶ Inspection of battery terminals Every 250hours
Check the terminals for looseness. If contamination or corrosion is evident, clean.
⑴ If there is white powder on corroded terminals, wash away with warm water.
Badly
corroded
terminals
should
be
polished
with
a
wire
brush
sandpaper.
⑵ After cleaning, apply a very thin coat of grease to the terminals.
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int'l co.,ltd.
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4. Control Panel Description
4-1. Engine & Work control Panel
A. Flow control (Hydraulic open / blocked)
B. Engine Start Key
C. Engine Stop Button
D. Engine Speed Dashboard
E. Water Temperature Dashboard
F~H. Oil Pressure Dashboard
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I. Engine RPM Control
1. Drill Down/Up (Main Feed)
2. Feed Fast (Feed Speed Plus)
3. Rotation (Plus)
4. Rotation (Main)
5. Feed (Plus)
6. Pull Down Pressure (Feed pressure)
7. Feed Down Speed
8. Rotation Pressure
9. Rotation Speed
10. Jaw
11. Jaw
12. Break Out
13. Rotary Head Sliding
14. Water Pump
15. Winch
[1] Drill Down/Up(Main Feed) & [6] Feed(Plus) : Rotary head up&down operating.
Movement speed and pressure control are possible through Pull Down
Pressure(6) and Feed Down Speed(7) control valve.
→ Main ▶ Lever Up : Rotary head move up /
Lever Down : Rotary head move down
※ Lever is fixed for continuity working. Before operating engine, Check the
valve lever to "Neutral" position to prevent unintended movement.
→ Feed plus ▶ Same direction with Main / Make up & down speed more fast.
[4] Rotation(Main) & [3] Rotation(Plus) : Rotary head rotation control. Rotation
power and speed control are possible through Rotation pressure(8) and
Rotation Speed(9) control valve.
※ Lever is fixed for continuity working. Before operating engine, Check the
valve lever to "Neutral" position to prevent unintended movement.
[10]&[11] Jaw : Clamp jaw is controlled clamp & un-clamp.
→ Lever Up : clamp / Lever Down : un-clamp
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[12] Breaking : To break out the drill rod, use the breaking cylinder with rod spanner.
[13] Rotary Head Sliding : Rotary head is moved to left or right.
[14] Water pump(or Mud pump) : When the rotary drilling(Tricone or drag bit),
use the pump.
※ Lever is fixed for continuity working. Before operating engine, Check the
valve lever to "Neutral" position to prevent unintended movement.
[15] Winch : Winch operating
4-2. Move control Panel
1. Travel Left
2. Travel Right
3. Leveling Jack 1 Up/Down
4. Leveling Jack 2 Up/Down
5. Leveling Jack 3 Up/Down
6. Leveling Jack 4 Up/Down
7. Master Tilting(Rising)
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[1]~[2] Travel R/L : This lever is used to move the drilling rig.
→ Lever Up : Forward / Lever Down : Backward
[3]~[6] Leveling Jack Up/Down : Adjust leveling of the rig.
→ Lever Up : Leveling pad up / Lever Down : Leveling pad down
[7] Mast Tilting(Rising) : Mast tilting(stand up & lay down)
→ Lever Up : Rising / Lever Down : Laying
Cautions :
- During Traveling, Don't put your foot under the track.
- During Leveling the Rig, Don't Put your foot under leveling pad.
- During Mast tilting(rising), Carefully check around the mast to prevent any
accident. And slowly move the mast.
- After Mast tilting, fix the pivot pin to clamp the mast.
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5. Reference Drawings
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int'l co.,ltd.
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CS-100-RH-000
DWG NO.
품번
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
14
B
12
10
1
7
9
D
10
DATE
DESCRIPTION
REV.
0
A
C
7
'13.08.29
도면정리를 위한 신규 등록.
DWG
J.M.SEO
CH'D
CH'D
CR.R.KIM T.Y.JANG
품명
APP'D
C.K.LEE
수량
1
1
1
16
2
2
2
1
1
2
1
2
1
2
1
Rotary Head _ Case
Rotary Head _ Front Cover
SLA-C-100
Hex Socket Bolt M10 x 20L
Thrust Bearing ID120, OD170, 39T
Rollar Bearing ID80, OD140, 33T
Rollar Bearing ID40, OD80, 23T
Lower Cover
Upper Cover
Oil-Seal-TC-ID80, OD100, 12T
Oil Pump HTOP-3F
Driving gear 4.5M 17T 20PA
Main Gear 4.5M 51T 20PA
Parker Motor - TE0165AP100
Rotary Head Main Shaft 89mm(API 2 3_8 Pin)
A
B
C
D
3
6
E
E
5
F
13
F
15
G
G
2
H
H
4
11
8
I
I
CHANG-SHIN INT'L CO.,LTD
ULSAN KOREA
APP'D
CH'D
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'13.08.29
DRAW
'13.08.29
DATE
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TITLE
'13.08.29
SIGN.
MATERIAL
MODEL
STANDARD
CS-100 Drilling Rig
Proj'
Weight
9
Rotary Head Assy(1/2)
3각법
142.5 KG
DWG
NO.
CS-100-RD-000
10
J
2
1
3
4
5
6
7
9
8
DESCRIPTION
DWG NO.
REV.
0
10
DATE
'13.08.29
도면정리를 위한 신규 등록.
DWG
J.M.SEO
CH'D
CH'D
CR.R.KIM T.Y.JANG
APP'D
C.K.LEE
CS-100-RH-000
A
A
B
B
C
C
D
D
E
E
F
F
G
G
H
H
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CHANG-SHIN INT'L CO.,LTD
ULSAN KOREA
APP'D
CH'D
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CH'D
'13.08.29
DRAW
'13.08.29
DATE
1
2
3
4
5
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8
TITLE
'13.08.29
SIGN.
MATERIAL
MODEL
STANDARD
CS-100 Drilling Rig
Proj'
Weight
9
Rotary Head Assy(2/2)
3각법
142.5 KG
DWG
NO.
CS-100-RD-000
10
J
2
1
3
4
5
6
7
9
8
도면정리를 위한 신규 등록.
DWG NO.
품번
CS-100-RH-030
9
A
4
B
1
C
8
DWG
'13.08.29
J.M.SEO
DESCRIPTION
REV.
0
10
DATE
CH'D
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품명
C.K.LEE
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1
Swivel _ Housing
1
2
Swivel _ Tube
1
3
Ball Bearing 6210
2
4
Swivel _ Cap
1
5
Swivel _ Lower Cover
1
6
Oil-Seal-TC-507011
1
7
SKY ID50, OD60, 6T
2
8
Grease nipple-1_8inch
1
9
Hex Socket Bolt M12 x 45L
16
D
A
B
C
D
7
E
E
3
F
F
2
G
G
6
5
H
H
I
I
CHANG-SHIN INT'L CO.,LTD
ULSAN KOREA
APP'D
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TITLE
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SIGN.
MATERIAL
MODEL
STANDARD
CS-100 Drilling Rig
Proj'
Weight
9
Swivel Assy
3각법
12.3 KG
DWG
NO.
CS-100-RH-030
10
J
2
1
3
4
5
6
7
9
8
DWG
'13.08.29
J.M.SEO
DESCRIPTION
DWG NO.
REV.
0
10
DATE
도면정리를 위한 신규 등록.
CH'D
CH'D
CR.R.KIM T.Y.JANG
APP'D
C.K.LEE
CS-100-RH-020
A
A
5
B
B
6
4
C
C
7
D
D
8
3
E
E
1
F
F
품번
G
2
H
I
품명
수량
1
Case_shock absorbor
1
2
Shaft_shock absorbor
1
3
우레탄_shock absorbor
1
4
Guide_shock absorbor
1
5
Flange_shock absorbor
1
6
Hex Socket Bolt M12 x 45L
12
7
Buffer Plate_shock absorbor
1
8
Grease nipple-1_8inch
1
9
Snap Ring D60(구멍용)
1
G
H
I
CHANG-SHIN INT'L CO.,LTD
ULSAN KOREA
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SIGN.
MATERIAL
MODEL
STANDARD
CS-100 Drilling Rig
Proj'
Weight
9
Shock Absorbor Assy
3각법
25.2 KG
DWG
NO.
CS-100-RH-020
10
J
2
1
3
6
5
4
7
9
8
10
DESCRIPTION
DWG NO.
REV.
First Issued
0
DATE
DWG
'13.08.29
J.M.SEO
CH'D
CH'D
CR.R.KIM T.Y.JANG
APP'D
C.K.LEE
CS-100-FS-000
A
A
B
B
1
2
5
6
4
3
C
C
D
D
E
E
Grease Nipple "A" type PT 1/8" 2EA
축용 멈춤링 : D50용 6EA
F
품번
G
H
품명
수량
1
Chain Roller
4
2
Feed sheave frame
1
3
Feed Sheave Pin1 D50
2
4
Feed Sheave Pin2 D50
1
5
DU Bush OD55 ID50 40L
4
6
Feed Cylinder Yoke
1
I
F
G
H
I
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Feed Sheave Assy
MATERIAL
MODEL
STANDARD
SIGN.
Proj' 3각법
Weight
41.6 kg
9
CS-100 Drilling Rig
DWG
NO.
CS-100-FS-000
10
J
2
1
3
4
6
5
7
9
8
DWG
'13.10.02
J.M.SEO
DESCRIPTION
DWG NO.
REV.
0
10
DATE
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CH'D
CH'D
APP'D
CR.R.KIM T.Y.JANG
C.K.LEE
CS-100-WI-000
A
A
B
4
품번
6
C
1
D
품명
수량
1
Winch Frame
1
2
JMF-16-VBC Travel Motor
1
3
UCFC 208
1
4
Winch Drum
1
5
Cover
1
6
Distance Bolt
3
2
B
C
D
5
E
E
F
F
G
G
H
H
3
I
I
CHANG-SHIN INT'L CO.,LTD
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7
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SIGN.
MATERIAL
MODEL
STANDARD
CS-100 Drilling Rig
Proj'
Weight
9
Winch Assy
3각법
40.2 KG
DWG
NO.
CS-100-WI-000
10
J
학
C
·
H
·
A
·
N
·
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·
S
·
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N
6. Engine Manual
Chang Shin
int'l co.,ltd.
PAGE 20
학
TO THE CUSTOMERS
This maintenance manual is designed to serve as a reference for DOOSAN Heavy Industries &
Machinery LTD. (here after DOOSAN) customers and distributors who wish to gain basic product
knowledge on DOOSAN DB58 and PU066 engine.
To maintain the engine in optimum condition and retain maximum performance for a long time,
CORRECT OPERATION and PROPER MAINTENANCE are essential.
In this manual, the following symbols are used to indicate the type of service operations to be
performed.
Removal
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
During engine maintenance, please observe following instructions to prevent environmental damage;
• Take old oil to an old oil disposal point only.
• Ensure without fail that oil and diesel fuel will not get into the sea or rivers and canals or the ground.
• Treat undiluted anti-corrosion agents, antifreeze agents, filter element and cartridges as
special waste.
The
• regulations of the relevant local authorities are to be observed for the disposal of spent
coolants and special waste.
If you have any question or recommendation in connection with this manual, please do not hesitate
to contact our head office, dealers or authorized service shops.
For the last, the content of this maintenance instruction may be changed without notice for some
quality improvement. Thank you.
DOOSAN Infracore Co., Ltd.
Oct. 2000
CONTENTS
1. General Informations ..................................................................................................... 1
1.1. General Repair Instructions
1.4. Engine Assembly (DB58)
1.2. Engine Specification
1.5. Engine Assembly (PU066)
1.3. Performance Curve (PU066)
2. Major Maintenance .......................................................................................................... 6
2.1. Preventive Maintenance
2.3. Engine Inspection
2.2. Diagnosis and Remedy
3. Disassembly and Reassembly of Major Components ................................... 31
3.1. Major part fixing nuts and bolts
3.3. Inspection
3.2. Major components disassembly
3.4. Engine reassembly
4. Maintenance of Major Components ...................................................................... 96
4.1. Lubricating System
4.3. Fuel System
4.2. Cooling System
5. Engine Electrical .......................................................................................................... 117
5.1. Starting motor
5.2. Alternator
6. Special Tool List ........................................................................................................... 119
• Appendix
• WORLDWIDE NETWORK
1. General Information
1.1. General repair 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 for preventing the components from damage or pollution.
3. Engine oil and anti-freeze solution must be handled with reasonable care as they cause paint
damage.
4. The use of proper tools and special tools where specified is important to efficient and reliable
service operation.
5. Use genuine DOOSAN parts necessarily.
6. Used cotter pins, gaskets, O-rings, oil seals, lock washer and self-lock nuts should be
discarded and new ones should be prepared for installation as normal function of the parts
can not be maintained if these parts are reused.
7. To facilitate proper and smooth reassemble operation, keep disassembled parts neatly in
groups. Keeping fixing bolts and nut separately is very important as they vary in hardness and
design depending on position of installation.
8. Clean the parts before inspection or reassembly. Also clean oil ports, etc. using compressed
air to make certain they are free from restrictions.
9. Lubricate rotating and sliding faces of parts with oil or grease before installation.
10. When necessary, use sealer on gaskets to prevent leakage.
11. Carefully observe all torque specifications for bolts and nuts.
12. When service operation is completed, make a final check to be sure service has been done
properly.
-1-
1.2. Engine specification
DB58
( Generator )
Engine Model
Items
PU066
( Power unit )
Engine type
Water- cooled, 4 cycle in -line
Naturally aspirated
Combustion chamber type
Direct injection type
Cylinder liner type
Dry liner
Timing gear system
Gear driven type
No. of piston ring
Compression ring 2, oil ring 1
No. of cylinder-bore x stroke
(mm)
Total piston displacement
6 - 102 x 118
(cc)
5,785
(mm)
1,155 x 705 x 854
(kg)
450
Compression ratio
17.5 : 1
Engine dimension (length x width x height)
Engine weight
Rotating direction (from flywheel)
Counter clockwise
Fuel injection order
1-5-3-6-2-4
Fuel injection timing (B.T.D.C static)
20 °
Injection pump type
Zexel in - line A type
Governor type
Mechanical governor RSV type
Injection nozzle type
Multi-hole type (5 hole)
Fuel injection pressure
(kg/cm )
220
Compression pressure
(kg/cm2)
28 (at 200 rpm)
Power ( ISO 3046 )
2
60 Hz
( 1,800 rpm )
50 Hz
( 1,500 rpm )
DIN6270B
( ISO 3046 )
Prime
87 PS
( 64 kW )
73 PS
( 54 kW )
Power
116 PS/ 2,800 rpm
Stand by
95 PS
( 70 kW )
80 PS
( 59 kW )
Torque
36kg .m / 1,600 rpm
Intake and exhaust valve clearance (at cold) (mm)
Intake valve
Exhaust valve
0.4
Open at
28 ° (B.T.D.C)
Close at
62 ° (A.B.D.C)
Open at
70 ° (B.B.D.C)
Close at
28 ° (A.T.D.C)
Lubrication method
Pressurized circulation
Oil pump type
Gear type
Oil filter type
Lubricating oil capacity (max./min.)
Full - flow, Cartridge type
(lit)
13 / 10
Oil cooler type
Water cooled
Water pump
Belt driven impeller type
Cooling Method
Cooling water capacity (engine only)
Pressurized circulation
(lit)
12
Wax pallet type
( 82 ~ 95 °C )
Thermostat type
Alternator voltage - capacity
Wax pallet type
( 71 ~ 90 °C )
(V - A)
24 - 45
Starting Motor voltage - output
(V - kW)
24 - 4.5
Battery - capacity
(V - AH )
24 - 120
-2-
1.3. Performance Curve ( PU066 )
kg . m N . m
360
36
kW PS
32
100
300
28
120
90
100
80
70
80
60
60
50
g/PS . h g/kW . h
40
40
180
250
220
140
1000
1600
2200
2800
REVOLUTION (rpm)
EDM1012I
DESCRIPTION
POWER OUTPUT
TORQUE
DIN6270B ( ISO- 3046 )
( Rated )
85 kW ( 116PS ) / 2,800 rpm
353 N .m ( 36 kg .m ) / 1,600 rpm
( Max.)
245 g / kW .h (180 g / PS . h)
FUEL CONSUMPTION ( Rated )
-3-
1.4. Engine assembly ( DB58 )
3
4
5
6
29
7
11 12
10
9
2
1
8
14
18
16 15 17
26
13
27
28
19 20
21 22 23
24 25
EDM1001I
1. Oil filter
11. Water outlet
21. Drain valve
2. Lifting hook
12. Oil filler cap
22. Oil pan
3. Injection nozzle
13. Cooling fan
23. Starter
4. Oil cooler
14. Alternator
24. Flywheel
5. Intake stake
15. Oil level gauge
25. Flywheel housing
6. Intake manifold
16. Cylinder head cover
26. Exhaust manifold
7. Fuel filter
17. Guide tube
27. Breather hose
8. Injection pump
18. Push rod chamber cover
28. Fuel pipe
9. Cooling water pump
19. Crank shaft pulley
29. Fuel Injection pipe
10. Thermostat
20. Mounting bracket
-4-
1.5. Engine assembly ( PU066 )
3
4
29
6
5
7
11 12
10
9
2
1
87
14
26
18
16 15 17
27
13
28
19 20
21
22 23
24 25
EDM1013I
1. Oil filter
11. Water outlet
21. Drain plug
2. Lifting hook
12. Oil filler cap
22. Oil pan
3. Injection nozzle
13. Cooling fan
23. Starter
4. Oil cooler
14. Alternator
24. Flywheel
5. Intake stake
15. Oil level gauge
25. Flywheel housing
6. Intake manifold
16. Cylinder head cover
26. Exhaust manifold
7. Fuel filter
17. Guide tube
27. Breather hose
8. Injection pump
18. Push rod chamber cover
28. Fuel pipe
9. Cooling water pump
19. Crank shaft pulley
29. Fuel Injection pipe
10. Thermostat
20. Mounting bracket
-5-
2. Major Maintenance
2.1. Preventive maintenance
The preventive maintenance means that the operator performs the servicing of engine to obtain
long life and best performance from DOOSAN diesel engine.
2.1.1. Cooling water
• Regarding the engine cooling water, the hard water must be used (Do not use the soft water).
• The engine cooling water can be used diluting it with antifreezing solution 40 % and the
additive for rust prevention (DCA4) 3 ~ 5 %.
• The density of above solution and additive must be inspected every 500 hours to maintain it
properly.
NOTE
The proper density control of antifreezing solution and rust preventing additive will be
able to prevent the rusting effectively and maintain the stable quality of engine.
For the improper control might give the fatal damage to the cooling water pump and
cylinder liners, detail care is needed.
• Since DB58 and PU066 cylinder liner is dry type, particularly the cooling water control should
be applied thoroughly.
• The density of antifreezing solution and additive for rust prevention is able to be confirmed
by the cooling water test kit. ( Fleetguard CC2602M )
• How to use the cooling water test kit
(1) When the cooling water temp. of engine is in the range of 10 ~ 55 °C, loosen the plug for
cooling water discharge and fill the plastic cup about a half.
NOTE
In taking the cooling water sample, if the water in auxiliary tank were taken, it is hard to
measure the accurate density. Take the cooling water sample necessarily loosening the
cooling water discharge plug.
(2) At the state of a test paper soaked in the sampled water, after taking the paper out
through water agitation, shake off the water.
(3) Wait for about 45 sec. till the color change of test paper.
NOTE
However, it should not elapse longer than 75 sec, and if it did, the hue would change.
(4) Make the numerical value by comparing the test paper which hue has changed with the
color list of label on storage bottle.
(5) By comparing the hue changed into yellowish green or so with the green color indication
of test paper storage bottle, confirm the density.
( Then, the density indication must be in the hue range of 33 % to 50 % ).
-6-
(6) The brown at the middle of test paper and the lower pink color indication represent the
additive state for rust prevention, and the proper range is that the meeting numerical
value of brown ( vertical) and pink color ( horizontal) locates in the range of 0.3 to 0.8 at
the color list of label on the test paper storage bottle.
(7) In case of less than 0.3, replenish the additive for rust prevention (DCA4), and in case of
more than 0.8, pour out the cooling water about 50 % and then readjust the density after
refilling with clean fresh water.
• Amount of Anti- freeze in winter
Ambient
Cooling water (%)
Anti-freeze (%)
Over -10
85
15
-10
80
20
-15
73
27
-20
67
33
-25
60
40
-30
56
44
-40
50
50
Temperature (˚C)
2.1.2. Fan belt
• Use a fan belt of specified dimensions,
and replace if damaged, frayed, or
Depress here
deteriorated.
Fan pulley
(Water pump pulley)
• Check the fan belt for belt tension.
10 mm
If belt tension is lower than the
specified limit, adjust the tension by
Alternator pulley
relocating the alternator. ( specified
deflection: 10 ~ 15 mm when pressed
Crank pulley
down with thumb )
EDO6001I
-7-
2.1.3. Engine oil
• Check oil level with the oil level gauge and replenish if necessary.
• Check the oil level with the engine cooled. If the engine is warm, allow time for 5 ~ 10 minutes
for oil drain into the crankcase before checking oil level.
The oil level must be between Max and Min. lines on the gauge.
• Engine oil should be changed at the specified intervals. (200 hr)
Oil in the oil filter should be changed simultaneously.
- First oil change : 50 hr operating
• The oil viscosity grade should be selected SAE NO.15W40 and the oil grade be selected API
CH-4 or above.
Designation
ACEA-E2 or ACEA-E3
(LUBIA 6000 or CH-4)
or above CD
SAE No.
Content
15W40
bellow 0.5% sulfur
15W40
-
* If long oil change intervals are to be used, ACEA-E3 oil must be used.
2.1.4. Oil filter
• Check
for oil pressure and oil leaks,
and repair or replace the oil filter if
necessary.
• Change the oil filter cartridge
simultaneously at every replacement
Oil filter
(Cartridge)
of engine oil.
Head, oil filter
Drain plug
EDO3001I
-8-
2.1.5. Fuel filter
• The
fuel filter should be replaced at
DB58
every 400 hours.
Element,
Fuel filter
Housing,
Fuel filter
EDM3002I
PU066
Head, filter
Cartridge,
Fuel filter
EDM3003I
2.1.6. Air cleaner.
• In case that elements are deformed,
damaged or if the air cleaner has a
crack, replace it.
• By the definite interval, the elements
must be cleaned and replaced.
EFM1002I
2.1.7. Radiator
• The radiator is air cooling type and has
a large cooling fan capacity.
Radiator Cap
- Cleaning of radiator fins: Every 600
Radiator
hours.
EA5O3002
-9-
2.1.8. Valve clearance and adjustment
Caution
The cylinder head bolts were previously
tightened
with
the
Therefore it is not
torque
wrench.
necessary to
retighten the cylinder head bolts before
adjusting the valve clearance.
EA0O4014
• Bring
the piston in either the No.1
cylinder or the No.6 cylinder to TDC
(top dead center) on the compression
stroke by turning the crankshaft until
the TDC notched line on the crankshaft
pulley is aligned with the timing pointer.
Check to see if there is play in the No.1
intake and exhausts valve rocker
EJM1035S
arms.
If No.1 cylinder intake and exhaust
valve rocker arms are shifted, the No.6
piston is at TDC on the compression
stroke.
If the No.1 cylinder intake and exhaust
valve rocker arms are fixed, the No.1
piston is at TDC on the compression
stroke.
• Adjust valve clearances when No.1 or
No.6 piston is TDC on the
Front side
compression stroke
Intake and exhaust valve
Clearance (at cold)
Rear side
0.40 mm
When No.1 piston at TDC
in compression stroke
• Loosen each valve clearance adjusting
EJM1036S
screw as shown in the figure.
- 10 -
• Insert
the feeler gauge ( 0.4 mm )
between rocker arm and valve stem
end.
• Turn
the valve clearance adjusting
screw until slight drag can be felt on
the feeler gauge.
• Tighten the lock nut securely.
• Rotate the crankshaft 360 °.
Realign the crankshaft pulley TDC
Front side
Rear side
notched line with the timing pointer.
• Adjust
the
valve
clearances
for
remaining valves as shown in the
Exhaust
figure.
Intake
Rocker arm screw
lock nut torque
2.6 ± 0.5 kg.m
When No.6 piston at TDC
in compression stroke
EJM1037S
2.1.9. Injection Timing
Caution
Take care to avoid entry of dust or
foreign particles into the pump interior
when the timing adjustment is made.
< Check procedure >
• Align the crankshaft pulley TDC mark
with the pointer.
Remove the inspection hole cover at
the front of the injection pump on the
timing gear case cover.
EJM1035S
- 11 -
Check the alignment between the
pointer 4
on the injection pump gear
nut lock plate and the projection area
mark 3
on the injection pump gear
case.
If it is in misalignment, recheck with
turning the crankshaft pulley one more
turn to repeat the foregoing procedure
to mark sure that it is in alignment.
EJM1038S
Check the alignment of the notched
lines 1 and 2 . (These notched lines
were aligned at
3
the factory to set the injection pump
body and the mounting flange.)
Next, inspect the crank angle position
of the injection timing.
4
• Turn the crankshaft pulley
EJM1039I
counterclockwise about 30° crank
angle.
• Disconnect the injection pipe from the
No.1 plunger.
This will allow you to visually check the
full injection starting flow at No.1
plunger.
EDM1009I
• Remove the delivery valve holder 1
,
the valve seat 2 , valve spring 3 , and
the delivery valve 4
from the No.1
plunger.
• Assemble
the delivery holder 1
and
tighten it to the specified torque.
Do not reassemble the delivery valve,
the delivery valve spring and the valve
seat.
EJM1041S
These parts will be reassembled later.
- 12 -
• Hold the fuel control lever at the fully
open position.
EJM1042S
• Slowly
turn
the
crankshaft
pully
clockwise, at the same time, continue
to feed the fuel with pumping the
priming pump.
When the fuel stop to flow out from the
No.1 delivery valve holder, stop the
pump instantaneously.
This
crank
angle
position
is
the
injection starting of the engine.
• Observe
and make sure that mark
TDC
(injection starting angle line a °) on the
Crankshaft pulley
crankshaft pulley is aligning with the
pointer.
Blow out the remaining fuel from the
a°
delivery valve holder.
Make sure that there is no fuel being
delivered from the priming pump.
EJM1044I
Fuel injection timing (BTDC)
20 °
• Remove the delivery valve holder from
the No.1 plunger.
•
Holder
Reassemble the delivery valve internal
parts to the delivery valve holder.
Seat
• Reassemble the delivery valve holder
assembly to the No.1 plunger and
Spring
tighten it to the specified toque.
Delivery valve
holder torque
EJM1041S
4.25 ± 0.25 kg.m
- 13 -
Delivery Valve
• Assemble the No.1 cylinder injection
pipe and tighten it to the specified
torque.
Injection pipe
nut torque
3.1 ± 0.2 kg.m
Caution
Do not overtighten the injection pump
body.
The injection pump body is made of
aluminum.
Overtighten will distort the injection
pump body shape and adversely affect
control rack operation.
< Adjusting procedure >
• Align
the pointer and the specified
timing mark on the crank pulley.
• Perform the steps of “Check
Procedure” of Injection Timing. (2.1.9)
• Loosen
the 4 injection pump fixing
nuts.
• Timing adjustment
To advance the timing
Pivot the injection pump at the pump
drive shaft toward out.
4 fixed nuts
To retard the timing
Pivot the injection pump at the pump
drive shaft toward in. (toward the
EJM1045S
cylinder block)
Caution
The 1 mm misalignment between the
two setting mark lines corresponds to
about 2 ° in crank angle.
• Do
a fine injection pump position
adjustment,
while
continue
the
pumping operation to feed the fuel,
and stop to pivot the injection pump
when the fuel stop to flow out from the
No. 1 delivery valve holder.
- 14 -
• Tighten the four injection pump fixing
nuts.
• Once remove the No. 1 delivery valve
holder, and reassemble the delivery
valve, spring and the valve holder with
the specified torque.
• Install
the No.1 injection pipe and
tighten it to the specified torque.
2.1.10. Cylinder compression pressure
• Stop the engine after warming up, and
take out preheating plug and injection
pipe.
• Install
the special tool (compression
gauge adapter) at the preheating plug
hole, and connect the compression
pressure gauge there.
EJM1046S
Standard value
Limit value
Difference between
each cylinder
28 kg / cm2 over
24 kg / cm2
Within ± 10 %
- Condition : Water temperature 75 °C.
- Engine rotation 200 rpm (10 rotation )
EJM1047S
- 15 -
2.1.11. Injection nozzle
Normal
Abnormal
Abnormal
EFM1006I
• Install a nozzle on the nozzle tester.
• If the inspected injection pressure is less than the specified value, adjust using the adjusting
shims.
Engine Model
DB 58
PU066
Injection nozzle pressure
220 kg / cm 2
220 kg / cm 2
• Check the atomizing state and replace it if abnormal.
2.1.12. Fuel injection pump
• Check the housing crack, damage etc. and replace it if abnormal.
• Check if the idle operation and speed regulating lever’s sealing is removed.
• The adjustment and testing of fuel injection pump should necessarily be done at the test
bench.
2.1.13. Feed pump strainer
• Release joint bolt A.
• Remove the strainer with a screwdriver
and wash the strainer with clean diesel
fuel.
A
EJM1029S
EJM1029S
Strainer
EJM1030S
- 16 -
2.1.14. Separator (Add if necessary )
• Check water level of the separator.
• Release the plug at the bottom
to
eliminate water when water level
( floating ) reaches the warning point.
Elimination plug
torque
Warning
surface
1.2 ± 0.3 kg.m
Floating
Elimination plug
EJM1031S
2.1.15. Air bleeding
• Loosen the priming pump cap
1
on the
Injection pump.
• Loosen
the
hollow
2
screw
for
air
bleed 2 .
• Operate
the priming pump until there
are no more bubbles visible in the fuel
1
being discharged from the fuel filter fuel
return eye bolt.
• Retighten the hollow screw.
• Operate the priming pump
times and check for fuel
EJM1032S
several
leakage
around the injection pump and the fuel
filter.
2.1.16. Battery
• Inspect for any leakage of electrolytic solution owing to battery crack, and replace the battery
in case of poor condition.
• Inspect for amount of electrolytic solution, and replenish if insufficient.
• Measure the gravity of electrolytic solution, if less than specified value
(1.12 ~ 1.28),
replenish.
Viewing
the gravity
meler
Liquid level
indicating line
1,100
1,200
1,300
Liquid level upper limit
Liquid level lower limit
Isolator
UPPER LEVEL
LOWER LEVEL
EFM1007I
- 17 -
2.1.17. Starting motor
• In case of engine maintenance, clean pinion and ring gear thoroughly putting in the fuel, and
coat them with grease.
Also, in case of washing engine room and so forth, inspect the wiring state being careful for
water not to get in.
- 18 -
2.2. Diagnosis and remedy
1. Engine Starting Impossible
Starting motor operation poor
Starting motor revolution
Inspection of battery electorlytic
Iiquid amount & gravity
Normal
Too low
Engine
Fuel
Inspect air cleaner
Inspect amount of fuel
Normal
Ajustment・
Recharging
Polluted
Replace or
clean element
Inspection of loose electric
wiring & short
Normal
Check compression
pressure
Retigten・
Replace
Repair・
Replace
Inspection of starting switch
Inspect of
other parts
Repair・
Replace
Check valve
clearance
Inspection of starting relay
Normal
Replace
Normal
Adjust
Inspection of magentic switch
Normal
Check cylinder
head gasket
Repair
Replace
Replace
Inspect fuel
injection
No injection
Normal
Continuous
operation after
air removal
Inspect
injection
timing
Normal
Adjust
Inspect injection
nozzle (injection
pressure, injection
state, etc.)
Normal
Normal
Starting motor
disassembly
None
Replenish
Too low
Normal
Normal
Normal
Engine disassembly
(valve assembly, piston
cylinder liner, etc.)
Repair・
Replace
Injection pump
disassembly
Inspect supply pump operation
Inspect supply pump valve・strainer
Normal
Injection pump
disassembly
Clean・
replace
Air mixture in fuel
Normal
Retighten connection
parts・Replace gasket
Inspect fuel filter
Air removal
Element polluted・
Overflow valve poor
Continuous air mixing
Replace
- 19 -
Supply pump
disassembly
2. Engine Overheated
Operating state
1. Overload
2. Radiator core clogged
3. Continuous over-run
Fuel unit
Cooling unit
Check coolant
Inspect fuel quality
Normal
Check fan belt
tension wear
or damage etc.
Normal
Check fresh
water tank cap
Too low
Repair
Replace
Replenish
Replace
Check thermostat
Poor
Clean and replace
with specified fuel
Inspect cooling
water leakage
Exteranl
Retighten
Replace
Normal
Replace
Normal
Inspect
Radiator
Damage
Normal
Check cooling
water pump
Clean cooling
water passage
Normal
Fuel excessive supply
Repair
Replace
Repair
Replace
Engine
disassembly
- 20 -
Internal
Engine
disassembly
Check injection nozzle
Normal
Abnormal
Adjust
repair
injection
pump
Repair
Replace
3. Output Insufficient
Installation improper
Engine
Fuel unit
Others
Check for air mixing
in fuel
Inspect air cleaner
Normal
Check for coupling
alignemnt
Adjust or replace
coupling
Clean Relpace
Inspect fuel supply pump
Normal
Clean Replace
Inspect fuel filter over flow valve
Inspect engine control
rod, link, cable, etc.
Normal
Inspect air leakage
of air piping line
Adjust
Normal
Normal
Replace
Inspect injection pipe
Normal
Repair Replace
Inspect injection nozzle,
injection pressure,
atomizing state
Normal
Adjust Replace
Check valve clearance
Normal
Adjust
Inspect cylinder head
gasket for damage
Normal
Replace
Engine disassembly
(valve assembly)
Check injection timing
Normal
Adjustment
Disassemble engine or
injection pump
- 21 -
Retighten
Replace
4. Oil pressure lowered
Check if oil pressure
gauge indicates wrongly
Check oil amount
Normal
Too low
Check cooling
temperature
Use recommended oil
(replenish)
Too high
Normal
Inspect oil quality
Refer to engine overhea
Normal
Check oil relief
valve
Normal
Retighten
Replace
Water & fuel mixed
in oil
Disassemble engine
or injection pump
Disassemble
engine
- 22 -
Improper
Replace with
recommended oil
5. Fuel Consumption Excessive
Causes according to Use Conditions
Inspect fuel leakage
1. Overload
2. Govemor's Arbitrary Adjustment
3. Full Speed Operation for Long time
4. Sudden Speed Change from Low to
High Speed
Normal
Inspect injection nozzle
(injection pressure
atomizing state, etc.)
Oil leakage
Adjust Replace
Retighten Replace
Normal
Check injection timing
Adjust
Normal
Inspect compressed
pressure
Check valve
clearance
Normal
Disassemble
injection pump
Adjust
Normal
Inspect head gasket
Replace
Normal
Disassemble engine
(valve assembly, piston,
cylinder liner, etc.)
- 23 -
Repair Replace
Cylinder liner,
Piston ring, Piston
6. Oil Consumption Excessive
Cause according to use conditions
1. Excessive oil infusing
2. Continuous operation in low or
extremely cold state
Inspect oil leakage
Inspect air cleaner
Normal
Oil leakage
Check oil quality
External
Retighten
Replace
Replace with
specified oil
Engine disassembly
(piston, cylinder liner)
Clean Replace
Internal
Check compressed
pressure
Normal
Disassemble
cylinder head
(valve stem seal)
7. Engine Knocking
Inspect combustion of fuel & oil
(carbon residue of exhaust gas)
Confirm
Unconfirmed
Disassemble
engine
Inspect compressed
pressure
Too low
Normal
Check valve clearance and
cylinderhead gasket for damage
Inspect injection
pump
Normal
Check fuel quality
Adjust
Replace
Adjust
Normal
Disassemble
engine
Use specified fuel
- 24 -
8. Battery Discharge
Battery
Check electrolytic
liquid amount
Wiring, Switch
Generator
Inspect cut wire
shorts and loose
connections
Check fan belt
tension & damage
Repair Replace
Normal
Electrolytic
liquid's
standard
Replenish
Battery room
damage
Replace
Battery self
discharge
Battery over
charging
Charging
Inspect Generator
Voltage regulator
Normal
Abnormal
Check charged stated
Adjust
Replace
Discharging
Disassemble
Generator Voltage
regulator
- 25 -
Condition
1) Starting difficult
(1) Compression pressure
2) Idle operation abnormal
Causes
Remedies
•
•
•
•
Valve’s poor shut, stem distortion
Repair or replace
Valve spring damage
Replace valve spring
Cylinder head gasket’s leak
Replace gasket
Wear of piston, piston ring or liner
Adjust
•
•
Injection timing incorrect
Adjust
Air mixing at injection pump
Remove air
•
•
•
•
•
•
•
Valve clearance incorrect
Adjust
Valve tightness poor
Repair
Cylinder head gasket’s leak
Replace gasket
Wear, stick, damage of piston ring
Replace piston ring
Injection timing incorrect
Adjust
Fuel injection amount insufficient
Adjust injection pump
Nozzle injection pressure
Adjust or replace
3) Engine output insufficient
(1) Continuous output
insufficient
improper or stuck
•
•
•
Supply pump’s function lowered
Repair or replace
Fuel pipe system clogged
Repair
Air suction amount insufficient
Clean or replace air
cleaner
(2) Output insufficient
•
when in acceleration
Compression pressure
Disassemble engine
insufficient
•
•
•
Injection timing incorrect
Adjust
Fuel injection amount insufficient
Adjust injection pump
Injection pump timer’s function
Repair or replace
insufficient
•
Nozzle injection pressure, injection
Repair, replace
angle improper
•
•
Supply pump’s function lowered
Repair or replace
Air intake amount insufficient
Clean or replace air
cleaner
4) Overheating
•
•
•
•
•
•
•
Engine oil insufficient or poor
Replenish or replace
Cooling water insufficient
Replenish or replace
Fan belt loosened, worn, damaged
Adjust or replace
Cooling water pump’s function lowered
Repair or replace
Water temp. regulator’s operation poor
Replace
Valve clearance incorrect
Adjust
Exhaust system’s resistance increased
Clean or replace
- 26 -
Condition
5) Engine noisy
Cause
Remedies
For noises arise compositely such as
rotating parts, lapping parts, etc., there is
necessity to search the cause of noises
accurately.
(1) Crankshaft
•
•
•
As the wear of bearing or crankshaft
Replace bearing &
progress, the oil clearances increase.
grind crankshaft
Lopsided wear of crankshaft
Grind or replace
Oil supply insufficient due to oil
Clean oil passage
passage clogging
•
Stuck bearing
Replace bearing &
Grind
(2) Con rod and
Con rod bearing
•
•
•
•
Lopsided wear of con rod bearing
Replace bearing
Lopsided wear of crank pin
Grind crankshaft
Connecting rod distortion
Repair or replace
Stuck bearing
Replace &
grind crankshaft
•
Oil supply insufficiency as clogging
Clean oil passage
at oil passage progresses
(3) Piston, piston pin &
piston ring
(4) Others
•
Piston clearance increase as the wear
Replace piston &
of piston and piston ring progresses
piston ring
•
•
•
•
Wear of piston or piston pin
Replace
Piston stuck
Replace piston
Piston insertion poor
Replace piston
Piston ring damaged
Replace piston
•
Wear of crankshaft, thrust bearing
Replace thrust
bearing
•
•
Camshaft end play increased
Replace thrust plate
Idle gear end play increased
Replace thrust
washer
•
•
Timing gear backlash excessive
Repair or replace
Valve clearance excessive
Adjust valve
clearance
6) Fuel Consumption
Exttive
•
Abnormal wear of tappet, cam
Replace tappet, cam
•
•
Injection timing incorrect
Adjust
Fuel injection amount excessive
Adjust injection
pump
- 27 -
Condition
7) Oil Consumption
Excessive
(1) Oil level elevated
Cause
•
Clearance between cylinder iiner &
Remedies
Replace
piston
•
Wear of piston ring, ring groove
Replace piston,
piston ring
•
•
Piston ring’s damage, stick, wear
Replace piston ring
Piston ring opening’s disposition
Correct position
improper
•
Piston skirt part damaged or
Replace piston
abnormal wear
(2) Oil level lowered
(3) Oil leak
•
•
Oil ring’s oil return hole clogged
Replace piston ring
Oil ring’s contact poor
Replace piston ring
•
•
•
Looseness of valve stem & guide
Replace in set
Wear of valve stem seal
Replace seal
Cylinder head gasket’s leak
Replace gasket
•
Looseness of connection parts
Replace gasket,
repair
•
•
Various parts’ packing poor
Replace packing
Oil seal poor
Replace oil seal
- 28 -
2.3. Engine inspection
2.3.1. Stopping engine
Cut off the main circuit breaker of the generator control panel. After checking the engine for
any unusual condition at the idling speed, then press the stop button to stop the engine.
2.3.2. General engine inspection cycle
In order to insure maximum, trouble-free engine performance at all times, regular inspection,
adjustment and maintenance are vital.
• Daily inspections in below figure should be checked every day.
• The following maintenance details should be executed thoroughly at regular internals.
: Check & adjust
Inspection
Daily
Every Every
50hrs 200hrs
: Replace
Every Every Every
Remark
400hrs 600hrs 1200hrs
Check for leakage(hoses, clamp)
Check the water level
Cooling
System
Change the coolant water
Every
2,000hrs
Adjust the V-belt tension
Clean the radiator
Check for leakage
Check the oil level gauge
Lubrication
System
Change the lubricating oil
1st
Replace the oil filter cartridge
Intake &
Exhaust
System
1st
Check the leakage for intake
manifold
Clean and change
the air cleaner element
clean
Check the leakage fuel line
Clean the fuel strainer
of fuel feed pump
Remove sediment from fuel tank
Fuel
System
Drain the water in separator
Replace the fuel filter element
Check fuel Injection timing
When
necessary
Check the injection nozzles
When
necessary
Check the state of exhaust gas
Check the battery charging
Engine
Adjust
When
necessary
Check the compression pressure
Adjust Intake/Exhaust
valve clearance
1st
- 29 -
When
necessary
2.3.3. Use of original parts for repair and replacement
For engine is being mechanically harmonized with many parts, only when the original parts that
the manufacture recommends to use is used, the engine trouble would be preventively
maintained and capable to keep up the maximum performances.
For the analogous parts not the original parts are poor in qualities and gives ill performance,
it may rather bring early engine failure.
- 30 -
3. Disassembly and Reassembly of Major Components
3.1. Major Part Fixing Nuts and Bolts
3.1.1. Cylinder head cover
( Unit : kg . m )
3.0 ± 0.5
Cylinder Head Bolt Torque
5.3 ± 1
- Type A) Hexagon bolt : 11.5 ± 0.5
- Type B) Dodecagonal bolt
1st : 4 kg.m
2nd : 90 °
3rd : 90 °-10 ° (Angle method)
2.7 ± 0.25
(19.5 ± 1.8)
Preheating plug
5.3 ± 1
EJM1001S
- 31 -
3.1.2. Cylinder block
( Unit : kg . m )
5.3 ± 1
2.6 ± 0.5
2.6 ± 0.5
2.6 ± 0.5
2.1 ± 0.5
24.1 ± 1
EJM1002S
- 32 -
3.1.3. Oil pan and level gauge
( Unit : kg . m )
2.9 ± 0.3
2.6 ± 0.5
8.0 ± 1
EJM1003S
- 33 -
3.1.4. Camshaft and rocker arm
( Unit : kg . m )
2.2 ± 0.5
2.2 ± 0.5
2.2 ± 0.5
2.6 ± 0.5
16 ± 1.5
Lubricate engine oil
5.5 ± 1
EJM1004S
- 34 -
3.1.5. Crankshaft, piston and flywheel
( Unit : kg . m )
A Type : 12 ± 0.25
B Type : 9.25 ± 0.25
Mark : on bolt head
B Type
12
A Type
11
60 ± 5
22.3 ± 2.2
EJM1005S
- 35 -
3.1.6. Thermostat and housing
( Unit : kg . m )
2.6 ± 0.5
5.3 ± 1
5.3 ± 1
EJM1006S
- 36 -
3.1.7. Intake and exhaust manifold
( Unit : kg . m )
_ 0.5
2.6 +
_ 0.5
2.9 +
_ 0.3
2.6 +
EJM1009S
- 37 -
3.1.8. Timing gear case and flywheel housing
( Unit : kg . m )
+ 0.5
2.2 _
+ 1.0
16.0 _
+ 0.5
2.2 _
+ 1.0
16.0 _
EJM1010S
- 38 -
3.1.9. Oil cooler, oil filter and oil pump
( Unit : kg . m )
_ 1.0
5.3 +
_ 1.0
5.3 +
_ 1.0
5.3 +
_ 0.5
2.6 +
_ 0.5
2.6 +
EJM1011S
- 39 -
3.1.10. Fuel system
( Unit : kg . m )
1.9 ± 0.2
1.3 ± 0.2
1.7 ± 0.1
3.1 ± 0.2
4.2 ± 0.8
4.2 ± 0.8
EJM1012S
- 40 -
Engine repair parts
EJM1053S
1. Cylinder head gasket
17. Gear case to cylinder block gasket
2. Cylinder head cover gasket
18. Cover to timing gear case gasket
3. Intake manifold gasket
19. Relief valve O-ring
4. Exhaust manifold gasket
20. Cylinder block side plug gasket
5. Thermostat housing gasket
21. Water drain valve gasket
6. Thermostat gasket
22. Oil pump hole cover gasket
7. Tappet chamber cover gasket
23. Water pump gasket
8. Tappet cover fixing bolt gasket
24. Oil pipe gasket
9. Crank shaft rear oil seal
25. Oil pipe gasket
10. Timing gear case oil seal
26. Fuel pipe joint bolt gasket
11. Valve guide oil seal
27. Leak off pipe joint bolt gasket
12. Oil pan gasket
28. Injection nozzle gasket
13. Drain plug gasket
29. Injection pump gasket
14. Oil filter cover gasket
30. Injection pump oil pipe gasket
15. Oil filter fixing bolt gasket
31. Cylinder head cover nut gasket
16. Oil cooler gasket
- 41 -
3.2. Major components disassembly
3.2.1. Main structure parts (1)
Repair kit
EJM2010S
1.Rubber hose (Coolant by-pass)
9. Oil pump driving pinion
2. Rocker arm shaft assembly
10. Nut
3. Push rod
11. Crankshaft pulley and dust cover
4. Cylinder head bolt
12. Taper bushing
5. Cylinder head assembly
13. Timing gear cover
6. Cylinder head gasket
14. Oil thrower
7. Coolant pump assembly
15. Fly wheel
8. Tappet chamber cover
- 42 -
Importance
2) Rocker arm shaft
Loosen the rocker arm shaft fixing
bolts a little in numerical sequence as
specified.
EJM2013S
5) Cylinder head
Loosen the cylinder head bolts a little
in the numerical order shown in the
figure.
Front
EJM2014S
11) Crankshaft pulley
Use an appropriate wrench (54 mm)
Crankshaft pulley
to remove the crankshaft pulley nut.
Wrench
EJM2015S
12) Taper bushing
Use the taper bushing remover to
remove the crankshaft end taper
Remove tool
Taper bush
bushing.
Crankshaft
Pulley
Bolt (M14 X 1.50)
EDM1010I
15) Flywheel
Loosen the flywheel bolts a little in the
numerical order as specified.
3
1
2
4
5
6
EJM2017S
- 43 -
3.2.2. Main structure parts (2)
Repair kit
EJM2018S
1. Oil cooler
9. Timing gear case
2. Oil pan
10. Idler gear shaft
3. Oil pump and coupling
11. Crank shaft bearing cap
4. Flywheel housing
12. Crank shaft bearing (lower part)
5. Piston and connecting rod
13. Thrust bearing
6. Idler gear
14. Crank shaft
7. Cam shaft
15. Crank shaft bearing (upper part)
8. Tappet
16. Oil spray nozzle (PU066 only)
- 44 -
Importance
6) Idler gear
Measure the following points before
disassembly.
< Idler gear end play >
Standard
Limit
0.058 ~ 0.115 mm
0.2 mm
Feeler gauge
EJM2019S
< Timing gear back lash >
Standard
Limit
0.10 ~ 0.17 mm
0.3 mm
Includes the crankshaft gear, the
camshaft gear and the idler gear
Dial indicator
EJM2020S
7) Camshaft
Measure the following points before
Camshaft gear
disassembly.
< Cam Gear End Play >
Thrust plate
Standard
Limit
0.050 ~ 0.114 mm
0.2 mm
Camshaft
Feeler gear
EJM2021S
11) Crankshaft bearing cap
Measure the crankshaft endplay at
the
thrust
bearing
(center
Feeler gear
main
bearing) before disassembly.
< Crankshaft End Play >
Standard
Limit
0.15 ~ 0.33 mm
0.4 mm
Crankshaft
- 45 -
EJM2022S
3.2.3. Rocker arm disassembly
EJM2023S
1. Bracket
3. Spring
2. Rocker arm
4. Rocker arm shaft
- 46 -
3.2.4. Cylinder head disassembly
EJM2024S
1. Exhaust manifold and gasket
7. Spring seat ( upper )
2. Intake manifold and gasket
8. Valve spring
3. Coolant outlet pipe
9. Spring seat ( lower )
4. Thmostat
10. Valve
5. Thermostat housing and gasket
11. Valve stem oil seal
6. Valve cotter
Importance
6) Valve cotter
Use the valve spring compressor to
remove the valve cotter.
Valve spring compressor
- 47 -
EJM2027S
3.2.5. Piston and connecting rod disassembly
4
1
2
3
2
3
5
EJM2028I
1. Piston rings
4. Piston
2. Snap ring
5. Connecting rod bearing
3. Piston pin and connecting rod
- 48 -
Importance
Caution
Carbon deposit
Remove any carbon deposits from the
upper part of the cylinder bore.
This will prevent damage to the piston
and the piston rings when they are
removed from the cylinder bore.
EDM1011I
1) Piston rings
Use a piston ring remover to remove
the piston rings.
Do not attempt to use other tools.
Piston ring
remover
Stretching piston ring will result in
reduced piston ring tension.
EJM2030I
2) Snap ring
Use a pair of snap ring pliers to
remove the snap ring.
EJM2031S
3) Piston pin
Tap the piston pin out with a hammer
Piston pin
and brass bar.
EJM2032S
- 49 -
3.3. Inspection
3.3.1. Cylinder block
• Clean the cylinder block thoroughly and make a visual inspection for cracks or damage.
• Replace if cracked or severely damaged, and correct if slightly damaged.
• Check oil and water flow lines for restriction or corrosion.
• Make a hydraulic test to check for any cracks or air leaks.
( Hydraulic test ) : Stop up each outlet port of water/oil passages in the cylinder block, apply
air pressure of about 5 kg / cm2 against the inlet ports, then immerse the
cylinder block in water for about 3 minute to check any leaks. ( Water
temperature : 70 °C )
3.3.2. Cylinder head
1) Inspection
• Carefully remove carbon from the lower lace of the cylinder head using nonmetallic material
to prevent scratching of the valve seat faces.
• Check the entire cylinder head for very fine cracks or damage invisible to ordinary sight
using a hydraulic tester or a magnetic flaw detector.
2) Distortion at the lower face
• Measure
the amount of distortion
(t)
using a straight edge and a feeler
gauge at six positions ( A ~ F) as
B
shown in the right figure.
• If
A
the measured value exceeds the
C
D
standard value, retrace the head with
grinding paper of fine grain size to
E
F
correct such defect.
• If
the measured value exceeds the
EA3M2031
maximum allowable limit, replace the
cylinder head.
< Lower face warpage and height >
Warpage
Standard
Limit
0.2 mm or less
0.3 mm
Thickness : t 89.95 ~ 90.05 mm 89.65 mm
EJM2034S
- 50 -
3) flatness
Measure flatness of the intake/exhaust
manifolds
fitting
surfaces
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 method for the cylinder
head is same as that for cylinder block.
EJM2036S
3.3.3. Valve stem and valve guide clearance
1) Measuring method - I
• After install dial gauge needle on the
inserted valve stem, set up calibrator
to “0”. ( as shown in figure )
• Move valve head from side to side.
Record total dial indicator reading.
This valve is the clearance between
the valve stem and valve guide.
• Valve and guide set must be replaced
if
measured
value
exceed
the
EJM2037S
specified limit
< Valve stem clearance (T.I.R) >
Standard
Limit
0.039 ~ 0.071 mm
0.20 mm
Exhaust side 0.064 ~ 0.096 mm
0.25 mm
Intake side
- 51 -
2) Measuring method - II
• Measure
valve
stem
outside
diameter.
• Measure valve guide inside
diameter by using of caliper calibrator
of telescoping gauge.
• The
difference between the valve
stem outside diameter and the valve
guide inside diameter is the valve
stem clearance.
EJM2038S
3) Valve guide replacement
• Removal of valve guide
Pull out the valve guide, by using
hammer and valve guide remover,
Remover
from bottom of cylinder head.
EJM2039S
• Install of valve guide
The height from the bottom of the
Installer
cylinder head to the edge of valve
guide top should be 14.1 mm.
EJM2040S
- 52 -
4) Valve depression
• Install
the valve 1
to the cylinder
head 2 .
• Measure
2
valve depression by using
the depth gauge or calibrator from the
bottom of cylinder head.
• Seat
insert
replaced
if
and
the
valve
must
measured
be
1
value
exceed the specified limit.
• If
the valve is replaced, the valve
EJM2041I
guide must be also replaced.
Intake and exhaust
valve depression
Standard
Limit
1.0 mm
2.5 mm
5) Valve contact width
• Inspect the valve contact faces for the
roughness and unevenness.
Make valve contact surfaces smooth.
• Measure the width of valve contact.
Standard
Valve contact width, Intake
2.4 mm
Valve contact width, Exhaust
1.6 mm
EJM2042I
6) Valve seat replacement
• Arc weld entire inside
circumference 1
of the valve seat 2 .
Driver
( see figure )
• Cool
valve seat for a few minutes.
Cylinder
head
This will make removal of the valve
seat easier.
• Pull out the valve seat by using the
inner extractor.
• Carefully
other
remove the carbon and
foreign
material
from
EJM2043S
the
cylinder head insert bore.
- 53 -
7) Valve seat installation
• Carefully place Jig 1
.
Presser
3
Caution
1
The smooth face of jig must contact the
valve seat.
Valve
2 seat
• Assemble
valve insert by slowly
pressing it against the jig with the
Cylinder
head
bench press.
EJM2044I
( The amount of needed pressure is
more than 2,500 kg. )
Caution
Do not press the valve seat excessively
with the bench press.
It may damage the valve seat.
8) Valve seat correction
• Remove the carbon deposits from the
150
valve seat surface.
• Remove
A
30
the rough areas by using
valve cutter. ( 30°, 90° or 150° )
Do not cut the valve seat too much.
Angle Location
Standard
Intake valve seat
90 °
Exhaust valve seat
90 °
Valve seat
Valve guide
EJM2045I
Caution
Use an adjustable valve cutter pilot.
Do not allow the cutter pilot to wobble
inside the valve guide.
EJM2046S
- 54 -
• Spread compound on the surface of
valve seat.
• Insert valve into valve guide.
• Lap the valve and valve seat with the
lapping tool.
• Check
that valve contact width is
correct.
45°
B
EJM2047I
• Check that the entire surface of valve
seat is in contact with the valve.
EJM2048S
3.3.4. Valve spring
1) Valve spring free length
• Measure
the valve spring with the
vernier caliper.
• Replace
the spring if the measured
value is less than the specified limit.
EJM2049I
Model
DB58
PU066
Standard
Limit
-
53.65 mm
52 mm
Valve spring
Outer
53.65 mm
52 mm
free length
inner
52.4 mm
51 mm
Exhaust and intake
- 55 -
2) Valve spring inclination
• Measure the valve spring inclination
by the using of square.
• Replace
the
valve
Inclination
spring
if
the
measured value exceed the specified
limit.
Free
spring
Valve spring
Inclination
Standard
Limit
2.5 mm
3.5 mm
EJM2050I
3) Valve spring tension
• Measure the valve tension by using
spring tester.
• Replace
the
valve
spring
if
the
measured value exceed the specified
limit.
Spring tester
EJM2051S
Model
DB58
PU066
Standard
Limit
-
22.5 kg
20.0 kg
At 41.5 mm
Outer
22.5 kg
20.0 kg
set length
inner
10.9 kg
9.9 kg
Valve spring tension
3.3.5. Tappet
• Check the valve tappets for excessive
wear, damage or abnormalities.
Pitting
Clack
normal contact
Abnromal contact
- 56 -
EA0M4070
• Measure
the outside diameter of
tappet with the micrometer.
Standard
Limit
Tappet outside
ø27.96 ~ ø27.98 mm ø27.92 mm
diameter
EJM2052S
• Measure
the
clearance
between
Dial indicator
tappets and cylinder motion parts by
the using dial indicator.
Standard
Limit
Tappet and tappet
0.020 ~ 0.054 mm
bore clearance
0.1 mm
EJM2053S
3.3.6. Push rod
• Measure the run out of push rod with
the feeler gauge.
• Roll the push rod along a smooth flat
surface as shown in the figure.
Limit
Push rod of run-out
0.2 mm
feeler gauge
EA0M4073
3.3.7. Rocker arm correction
• Check the valve stem contact part of
rocker arm.
• Grind contact surface with an oil stone
if it is irregularly contacted.
• Replace
the
rocker
arm
if
it
is
extremely damaged.
EJM2055S
- 57 -
1) Rocker arm and shaft
• Check
the disassembled parts for
wear, damage and abnormalities.
EJM2056S
2) Rocker arm shaft outside diameter
• Measure
the outside diameter of
rocker arm with the micrometer.
• Replace
shaft if measured value
exceed the specified limit.
Standard
Limit
Diameter of rocker
ø18.98 ~ ø19.00 mm ø18.85 mm
arm shaft
EJM2057S
3) Rocker arm and shaft clearance
• Measure the inside diameter of rocker
arm bushing with the vernier caliper.
• Measure
the out side diameter of
rocker arm shaft.
Replace the rocker arm or rocker arm
shaft if measured value exceed the
specified limit.
Standard
Limit
EJM2058S
Diameter of rocker
ø19.02 ~ ø19.05 mm ø19.07 mm
arm bushing
Rocker arm bushing
and rocker
arm shaft clearance
Standard
Limit
0.02 ~ 0.07 mm
0.2 mm
• Check the rocker arm oil port whether
alien substance is in it or not.
Clean the rocker arm oil port with
compressed air if necessary.
EJM2059I
- 58 -
3.3.8. Idler gear and shaft
• Replace
the idler gear shaft if the
measured value exceeds the specified
limit.
Standard
Limit
Diameter of idler
ø44.945 ~ ø44.975 mm ø44.9 mm
gear shaft
• Measure
the inside diameter of idler
EJM2060S
gear with the dial indicator,
Clearance of idle
gear and shaft
Standard
Limit
0.045 ~ 0.105 mm
0.2 mm
EJM2061I
- 59 -
3.3.9. Camshaft
• Use
the jig to install or overhaul
camshaft bearing in cylinder block.
• Measure
the clearance between the
cam journal and the camshaft bearing.
Clearance of cam
journal and
cam bearing
Standard
Limit
0.03 ~ 0.09 mm
0.15 mm
Jig
EJM2062S
Cam bearing
EJM2061I
• Align the camshaft bearing oil port with
the mating oil port ( machined on the
cylinder block ).
Align oil pots
EJM2061I
• Measure
the
cam
lobe
with
the
micrometer.
Replace the camshaft if the measured
values exceed the specified limit.
Standard
Limit
Cam lobe height(C-D),In
7.44 mm
6.94 mm
Cam lobe height(C-D),Ex
7.71 mm
7.21 mm
Cam journal diameter
ø56.0 mm ø55.6 mm
I II
A
C
B
D
I II
B
A
EJM2065I
- 60 -
• Set up the camshaft on a measuring
stand.
• Measure the run out of camshaft with
the dial indicator.
Record the measured value (T.I.R)
Replace the camshaft if the measured
value exceeds the specified limit.
Limit
Camshaft run-out
EJM2066I
0.12 mm
3.3.10. Cylinder liner
1) Cylinder liner bore measurement
• Measure
the
position 1
bore
in
crankshaft 3
at
line
and
measuring
with
the
across
the
3
crankshaft 2 .
1
EJM2067I
• Measured position : 20 mm from the
top of liner. (max. wear portion)
• Replace
the cylinder liner if the
2
measured value exceeds specified
limit.
Standard
Diameter of cylinder
Limit
ø102.017 ~ ø102.046 mm ø102.20 mm
liner bore
EJM2068I
Caution
The casting liner is specially honed
without the chrome plating inside, so
that chrome plated ring ( top ring and oil
ring ) must be used.
- 61 -
2) Cylinder liner inspection
• Set up the straight square along the
Liner
Linerprojection
projection
top edge of cylinder liner.
• Measure
Square
Square
liner projection with the
feeler gauge.
Standard
Cylinder liner Cast liner 0.02 ~ 0.07 mm
Projection
Steel liner 0.015 ~ 0.115 mm
Feeler gauge
EJM2069S
The difference in the liner projection
height between any two adjacent
cylinders must NOT exceed 0.3 mm.
3) Cylinder liner replacement
• Set the cylinder liner remover to the
cylinder liner.
• Check
that cylinder liner remover
shaft ankle is firmly gripping the
cylinder liner bottom edge.
• Slowly turn the remover shaft handle
counter-clockwise to pull the cylinder
liner free.
EDM3004S
Caution
Take care not to damage the cylinder
body upper face when remove the
cylinder liner.
3.3.11. Cylinder block
1) Grade selection of cylinder liner
• Select
a grade from the outside
diameter of the cylinder liner and
inside diameter of block combination.
• Determine
liner
after
a grade of the cylinder
measuring
the
20mm
inside
diameter of the cylinder block.
• Loose fitting cylinder liners (the liner
is too small for the cylinder bore) will
adversely
affect
engine
cooling
EA3M2043
efficiency and may lead to serious
engine damage. Cylinder liners which
are too large for the cylinder bore will
be difficult to install.
- 62 -
2) Cylinder block bore measurement
• Measure
at
measuring
point 1
across the positions W- W, X-X, Y-Y
and Z-Z.
Measuring point 1
• Calculate
average
measurements
1
diameter : 115 mm
value
to
of
four
determine
the
correct cylinder liner grade.
EJM2072I
Grade marking
Cylinder block bore diameter
1
ø 105.090 ~ ø 106.000 mm
2
ø 106.000 ~ ø 106.010 mm
EJM2073S
3) Cylinder liner outside diameter
• Measure the liner outside diameter at
1 ,
2
and
3
measuring point
across X-X, Y-Y.
Measuring Points :
1
20.0 mm
2
105.0 mm
3
185.0 mm
• Calculate
the average value of 6
measurements
to
determine
EJM2074S
the
correct cylinder liner grade.
• Combination of the cylinder bore and
the cylinder liner outside diameter.
Steel liner Cast iron liner
( tightness ) ( clearance )
Cylinder liner
0.001
fitting clearance ~ 0.019 mm
0.005
~ 0.026 mm
- 63 -
< Cylinder bore and liner outside diameter >
(A) Steel cylinder liner
Grade
Cylinder bore
Cylinder liner outside diameter
1
ø105.001 ~ ø105.010 mm
ø105.011 ~ ø105.020 mm
2
ø105.011 ~ ø105.020 mm
ø105.021 ~ ø105.030 mm
3
ø105.021 ~ ø105.030 mm
ø105.031 ~ ø105.040 mm
(B) Cast iron cylinder liner
Cylinder liner diameter
Grade marking
2 position
1 , 3 position
øD
ø102.020 ~ ø102.031 mm
ø102.017 ~ ø102.035 mm
1
(Inner diameter)
ø102.031 ~ ø102.042 mm
ø102.028 ~ ø102.046 mm
2
øE
ø105.973 ~ ø105.984 mm
ø105.970 ~ ø105.988 mm
A
(Outer diameter)
ø105.984 ~ ø105.995 mm
ø105.981 ~ ø105.999 mm
B
Part no of
cylinder liner grade
Cylinder liner diameter
marking
Outer
Inner
65.01201 - 0068
1
A
1A
65.01201 - 0069
1
A
1B
65.01201 - 0070
2
B
2A
65.01201 - 0071
2
B
2B
Marking
EJM2172I
4) Cylinder liner assembly
• Carefully
wipe away any foreign
material from the cylinder liner inside
and outside surfaces and the cylinder
Cylinder liner
bore.
Cylinder block
• Cleanly wash cylinder liner and bore
surfaces with new kerosene or diesel
oil.
• Use a clean rag to remove all traces
of kerosene or diesel oil from cylinder
EJM2075S
liner and bore surfaces.
• Insert
the cylinder liner into cylinder
block from the top of the cylinder
block.
- 64 -
• Set the cylinder liner installer to the
top of the cylinder liner.
Installer
• Position the cylinder body so
Bench press
shaft center
that the installer center is directly
beneath the bench press shaft center.
• Check
that the cylinder liner is set
perpendicular to the cylinder.
• Use the bench press to apply an initial
EJM2076S
seating force of 500kg to the cylinder
liner.
• Use the bench press to apply a final
seating force of 2,500kg to fully seat
the cylinder liner.
• After
installing the cylinder liner,
measure the cylinder liner projection.
5) Piston grade selection
• ”Piston
grade” refers to the piston
diameter and the cylinder liner bore
combination.
• Selection of the proper piston grade
will ensure efficient engine operation,
free from cylinder liner and piston
2
1
problems.
• Measure the cylinder liner bore after
installing the cylinder liner.
•
EJM2077I
Determine the appropriate piston
grade after measuring cylinder liner
bore.
6) Cylinder liner bore measurement
• Loacte the two measuring points.
Cylinder liner measuring point 1
: 20 mm
Cylinder liner measuring point 2
: 105 mm
• Measure
cylinder
measuring points
1
liner
and
bore
2
at
in four
different directions ( X-X, Y-Y, W-W
and Z-Z ).
•
EJM2073S
Calculate the average value of the 8
measurements.
Standard
Cylinder liner bore
ø102.020 ~ ø102.042 mm
- 65 -
Caution
It is most important to use correct
piston-liner
combination.
Incorrect
combination will result in piston seizure.
Always measure the cylinder bore and
select the appropriate piston grade.
3.3.12. Piston
1) Piston outside diameter
• Piston
outside
diameter
vary
depending on the piston type to be
used.
• Measure the piston outside diameter
2
(see figure).
Steel
Strut
< Piston grade >
Grade
Limit
A
ø101.953 ~ ø101.967 mm
B
ø101.963 ~ ø101.977 mm
EJM2078I
< Cylinder liner bore and piston >
Clearance
0.053 ~ 0.077 mm
Caution
The cylinder liner-piston kit clearances
are preset.
However, the cylinder liner installation
EJM2079S
procedure may result in slight decreases
in the cylinder liner bore clearances.
Always measure the cylinder liner bore
clearance after installation to be sure
that it is correct.
- 66 -
2) Piston
ring
and
piston
groove
clearance
• Measure
the piston ring and the
piston ring groove clearance with a
feeler gauge.
• Measure it at several points around
the piston.
• Replace
the
measured
piston
value
ring
If
exceeds
the
the
specified limit.
EJM2080S
< Piston ring and piston groove clearance >
Standard
Limit
Top ring
0.070 ~ 0.120 mm
0.20 mm
2nd ring
0.050 ~ 0.085 mm
0.15 mm
Oil ring
0.030 ~ 0.070 mm
0.15 mm
3) Piston ring gap
• Insert the piston ring horizontally (in
the position it will assume if it were
installed
to
the
piston)
into
the
cylinder liner.
• Push the piston ring with an inverted
piston into the cylinder liner until it
reaches measuring point 1
or 2 .
The cylinder liner diameter is the
smallest at these two points.
EJM2082S
Do not allow the piston ring to slant to
one side or the other. It must be
perfectly horizontal.
Cylinder liner measuring point 1
: 10 mm
Cylinder liner measuring point 2
:130 mm
• Measure piston ring gap with a feeler
gauge.
The piston ring must be replaced if
the measured value exceeds the
specified limit.
Standard
Limit
Top ring gap
0.25 ~ 0.45 mm
1.50 mm
2nd ring gap
0.40 ~ 0.60 mm
1.50 mm
Oil ring gap
0.20 ~ 0.40 mm
1.50 mm
- 67 -
4) Piston pin
• Measure piston pin outside diameter
with micrometer at several points.
• Replace the piston pin if the
measured
value
exceeds
the
specified limit.
Standard
Limit
Piston pin
ø 35.000
ø 34.95 mm
outside diameter ~ ø 35.005 mm
EJM2083S
5) Piston pin hole
• Measure
diameter of the piston pin
hole with inside dial gauge.
Standard
Piston pin and
piston clearance
ø 35.010
~ 35.018 mm
EJM2084S
6) Piston pin and piston pin hole clearance
• Determine the clearance between the
piston pin and the piston pin hole by
calculating the difference between the
piston pin hole diameter and the
piston pin outside diameter.
Standard
Piston pin and
piston pin hole clearance
0.005
~ 0.018 mm
EJM2085S
• If
an inside dial indicator is not
available, use the following procedure
to check the piston pin fit.
(1) Heat piston to approximately 60°C
with the piston heater.
(2) Push strongly against the piston
pin with your thumb. The piston
pin fitting should feel tight.
EJM2086S
- 68 -
3.3.13. Maintenance of cylinder block, cylinder liner and piston
To maintain the engine in optimum condition and retain maximum performance for a long
time, the cylinder block, cylinder liner and piston which have the same grade marking number
( the same size tolerance ) should be assembled. The marking number ( the part’s grade ) and
marking position is as follows.
• Cylinder block
a) Marking number ; 1 or 2
( Size grade for of cylinder bore
Marking
diameter )
b) Marking position ; Top of the
cylinder block side surface
EJM2174I
• Cylinder liner
a) Marking number ; 1A, 1B, 2A or 2B
1A
Can used the piston A grade
Can used the cylinder block 1 grade
b) Marking position ; Cylinder liner
lower surface
Marking
EJM2173I
• Piston
a) Marking number ; A or B
( Size grade for piston outer diameter )
b) Marking position ; Center of the piston upper surface
Assembly process of cylinder block, cylinder liner and piston
(1) Check the marking number (1 or 2) of cylinder block. (Top of side surface)
(2) Then assemble the liner whose first digit of the marking (1A, 1B, 2A, 2B) is just the same
with it on the cylinder block.
(3) Assemble the piston whose marking is just same with the second digit (A or B) of the
assembled cylinder liner’s marking.
- 69 -
3.3.14. Connecting rod
1) Connecting rod alignment
• Measure the parallelism between the
connecting rod big end hole and small
end hole with a connecting rod
aligner.
• Replace
the connecting rod if the
measured
value
exceeds
the
specified limit.
Balance
Standard
Limit
0.05 mm or less
0.20 mm
EJM2087S
2) Piston pin and bush clearance
• Measure an inside of connecting rod
bushing and outside of piston pin with
the caliper gauge and micrometer.
• Replace
a connecting rod bush or
piston pin if the measured value
exceeds the specified.
Piston pin and
bushing clearance
Standard
Limit
0.012
~ 0.030 mm
0.05 mm
EJM2088S
3) Connecting Rod Bush Replacement
• Connecting Rod Bush Removal
(1) Clamp the connecting rod in a vise.
(2) Pull out connecting rod bush by
using a brass bar with a bench
press or a hammer.
• Connecting rod bush assembly
(1) Use special jig to assemble the
connecting rod bush.
Caution
Align the connecting rod bush oil hole
EJM2089S
with the connecting rod oil hole.
- 70 -
(2) Use a piston pin hole grinder 1
fitted with a reamer 2
or an
adjustable pilot reamer to ream
the piston pin hole.
Standard
ø 35.017
~ ø 35.030 mm
Connecting rod
bush inside diameter
EJM2090S
4) Connecting rod bearing Inspection
• Fit the connecting bearing lower half
into the connecting rod bearing cap.
• Check the tension of the connecting
rod bearing lower half.
If the tension is insufficient, the
bearing must be replaced.
• Tighten
the connecting rod and the
bearing cap to the specified torque.
EJM2091S
A type
Connecting rod
bolt torque
A type :
11
B type :
TY
11
• Measure
B type
12.0
9.75
± 0.25 kg.m
± 0.25 kg.m
Marked on bolt head
or
TY
12
the inside diameter of the
connecting rod bearing with an inside
dial gauge.
Standard
Connecting rod
bearing diameter
ø 63.974
~ ø 64.005 mm
EDM2044I
- 71 -
3.3.15. Crankshaft
1) Crankshaft and bearing inspection
• Check the crankshaft journal surfaces and pin surfaces for excessive wear and damage.
• Check oil seal fitting surfaces of the crankshaft front and rear ends for excessive wear and
damage.
• Replace or repair the crankshaft if any excessive wear or damage is discovered.
• Check the crankshaft oil ports for obstructions.
• Clean oil port with high pressure air if necessary.
2) Crankshaft journal and pin diameter
• Measure
the
crankshaft
journal
outside diameter with the micrometer
across 1 - 1
• Measure
and 2 - 2 .
crankshaft journal outside
diameter at two points 3
and 4
by
using the micrometer.
• Repeat step 1 and 2 to measure the
crankshaft outside diameter.
EJM2093S
The crankshaft must be reground if
the measured value of the crank pin
outside diameter and/or crankshaft
journal
diameter
exceeds
the
specified limit.
Standard
ø 79.905
~ ø 79.925 mm
Crankshaft journal
outside diameter
Standard
ø 63.924
~ ø 63.944 mm
Crankshaft pin
outside diameter
• Measure
outside
the
crankshaft
journal
diameter (and/or crankshaft
pin outside diameter) and bearing
inside diameter to determine the
bearing clearance.
- 72 -
3) Crankshaft journal and bearing clearance
• If the bearing clearance exceeds the
specified limit, the crankshaft must be
reground and/or the bearing must be
replaced.
Main bearing
clearance
Rod bearing
clearance
Standard
Limit
0.025
~ 0.090 mm
0.11 mm
Standard
Limit
0.03
~ 0.073 mm
0.10 mm
4) Crankshaft bearing diameter
• Install
the main bearing cap with
bearings to the cylinder block with the
specified torque and facing the arrow
mark on the bearing cap toward front.
Place them in order of punched
cylinder numbers.
• Measure the main bearing diameter
with an inside dial gauge.
Main bearing cap torque
24.1 ± 1 kg.m
Main bearing diameter
ø 80 mm
EJM2094S
5) Crankshaft run-out
• Mount the crankshaft on a set of Vblocks.
• Set the dial gauge to the center
of the crankshaft journal.
• Gently
rotate the crankshaft in the
normal direction of engine rotation.
Read the dial indicator (TIR) as you
turn the crankshaft.
The crankshaft must be replaced if
EJM2095S
the measured value exceeds the
specified limit.
Crankshaft run-out
Standard
Limit
0.05 mm
0.40 mm
If the repaired crankshaft generated a
crack, replace it.
- 73 -
6) Main bearing and con-rod bearing tension
• Check
to see if the bearing has
enough tension, and set bearing into
its regular position with the finger
pressure.
EJM2091S
7) Crankshaft regrinding
• Pay
close attention to the following
steps in order to ensure the regroundcrankshaft reliability.
Undersize bearing
Availability
0.25 mm
0.50 mm
< Crankshaft regrinding procedure >
(1) Grind the crankshaft journal part and
Less them 3.8
pin part.
(2) Fillet the crankshaft journal and
crank pin radius to a minimum of
R 3.5 ± 0.2.
There must be no stepping around
the fillet area.
(3) Finish the crankshaft journal, crank
R Part
pin and oil hole corners to a smooth
EJM2096S
surface having a chamfer radius of
1 mm.
Crankshaft journal
and crank pin roughness
0.4 μor less
(4) Measure the clearance between
crankshaft journal and crank pin.
(5) Measure the crankshaft run-out.
- 74 -
8) Crankshaft grinding limit
Classification
Limit
Crank journal outside
Diameter
ø 79.419 mm
Crank pin outside
Diameter
ø 63.424 mm
Undersize bearings ( 0.25 and 0.5 mm )
are
available
excessive
to
compensate
clearance
between
for
the
crankshaft journal bearing and the
crankshaft. Regrinding of the crankshaft
to fit the undersize bearings is required.
Main bearing
clearance
Connecting rod
bearing
Standard
Limit
0.039
~ 0.098 mm
0.11 mm
Standard
Limit
0.03
~ 0.073 mm
0.10 mm
9) Crankshaft gear replacement
• Visually inspect the crankshaft gear.
Remover
• Replace
the
crankshaft
gear
as
following steps if excessive wear or
damage is discovered.
(1) Disassemble the crankshaft gear by
using the crankshaft remover.
EJM2097S
(2) Replace new part.
(3) Use the crankshaft gear installer to
install the crankshaft gear.
Installer
EJM2098S
- 75 -
3.3.16. Flywheel and flywheel housing
1) Ring gear inspection
• Inspect the ring gear.
• If the ring gear teeth are broken or
excessively worn the ring gear must
be replaced.
2) Ring gear replacement
• Strike around the edges of the ring
gear with a hammer and chisel to
remove it.
EJM2099S
3) Ring gear installation
• Heat the ring gear evenly with a gas
burner to invite thermal expansion.
Pay attention that temperature of ring
gear is not exceeded 200 °C.
• Use a hammer to install the ring gear
when it is sufficiently heated.
EJM2100S
4) Oil seal replacement ( rear )
• Use a pry bar to remove the flywheel
housing oil seal.
• Assemble
housing
Installer
the oil seal to flywheel
by
using
the
oil
seal
assemble jig.
EJM2101S
5) Oil seal replacement ( front )
• Use
an adapter and a hammer to
remove the crankshaft front end oil
Installer
seal.
• Assemble
housing
the oil seal to flywheel
by
using
the
oil
seal
assemble jig.
EJM2102S
- 76 -
3.4. Engine Reassembly
3.4.1. Piston and connecting rod assembly
1
4
3
2B
3
2A
5
6
EJM2103I
1. Piston
4. Piston ring
2. Piston Pin and connecting rod
5. Connecting rod bearing
3. Snap ring
6. Connecting rod bolt
- 77 -
1) Piston
• Use a piston heater to heat piston to
approximately 60 °C.
Heater of piston
EJM2104S
2A) Connecting rod
• Install the piston and connecting rod
with setting the marks as illustrated.
•
Piston
Assemble the piston pin into the
Front mark
piston and connecting rod bushing.
Put cylinder number
marked side in this
piston
EJM2105S
3) Snap ring
• Assemble
the snap rings by using
snap ring flyer.
• Check
that
the
piston
moves
smoothly on the piston pin.
EJM2031S
4) Piston ring
• Assemble
the piston ring by using
piston ring assembly jig.
•
Top Ring
Systematically assemble piston rings
2st Ring
as follows:
(1) Oil ring
(2) 2nd compression ring
Oil Ring
(3) 1st compression ring
EJM2106I
- 78 -
Rightly assemble the 1st and 2nd
compression rings that the marked
side must be facing “up”.
Oil ring may be assembled any way
because it is not indicated.
• Lubricate
the surface of piston ring
with engine oil.
• Check
it whether piston rings are
smoothly rotating in the piston ring
grooves.
5) Connecting rod bearing
• Assemble the connecting rod bearing
to the big end and the cap.
• Lubricate the bearing with engine oil.
• Assemble
the connecting rod and
connecting rod bearing, and tighten
cap bolt as the specified torque.
- 79 -
3.4.2. Cylinder head assembly parts
Repair kit
EJM2107S
1. Valve stem oil seal
7. Thermostat housing and gasket
2. Intake and exhaust valve
8. Thermostat
3. Spring seat (lower)
9. Cooling water outlet
4. Intake and exhaust valve spring
10. Intake manifold and gasket
5. Spring seat (upper)
11. Exhaust manifold and gasket
6. Valve cotter
1) Valve stem oil seal
• Lubricate the oil seals and valve stem
Installer
sealing area with engine oil.
• Assemble the valve stem oil seal by
using oil seal installer.
EJM2109S
- 80 -
2) Intake arid exhaust valves
• Place
the cylinder head on a flat
wooden surface.
Valve stem
• Lubricate valve stem with the engine
oil.
• Assemble the valves to the intake or
exhaust valve guides.
Assemble the valves to their original
lapped valve seats.
EJM2110S
4) Intake and exhaust valve springs
• Assemble the valve spring with their
painted end facing top.
Painted part
EJM2111I
5) Spring seat
6) Valve cotter
• Use a spring compressor to push the
valve spring into position.
• Install the spring seat split collar.
Compressed spring
EJM2112S
• Set
the spring seat split collar by
tapping lightly around the head of the
collar with a rubber hammer.
EJM2113S
- 81 -
10) Intake manifold and gasket
• Assembly the intake manifold gasket.
Rear of unchamfered corner
The intake manifold gasket must be
installed with its unchamfered corner
facing “up” and to the front of the
engine.
Rear
EJM2114S
• Assemble the intake manifold.
• Tighten the intake manifold bolts
to
the specified torque a little at a time in
the numerical order. ( see figure )
Intake manifold bolt
torque
2.6 ± 0.5 kg.m
EJM2115S
11) Exhaust manifold and gasket
• Install the exhaust manifold gasket.
• The “TOP” mark must be facing up.
TOP
EJM2116I
• Install the exhaust manifold
• Tighten the exhaust manifold bolts to
the specified torque a little at a time in
the numerical order. ( see figure )
Exhaust manifold bolt
torque
2.9 ± 0.5 kg.m
EJM2117S
- 82 -
3.4.3. Rocker arm and shaft assembly
EJM2119S
1. Rocker arm shaft
3. Rocker arm
2. Spring
4. Bracket
Import Operation
1) Rocker arm shaft
• The rocker arm shaft must be installed with the oil holes facing up.
- 83 -
3.4.4. Main components
Repair kit
EJM2120S
1. Oil spray nozzle ( PU066 only )
9. Idler gear shaft
2. Crankshaft bearing ( lower )
10. Idler gear
3. Crank shaft
11. Piston and connection rod
4. Thrust washer
12. Oil pump and coupling
5. Crank shaft bearing ( upper ) and cap
13. Flywheel housing
6. Timing gear case
14. Oil pan
7. Tappet
15. Oil cooler
8. Camshaft
* The tappet must be installed before the camshaft installation.
- 84 -
2) Crankshaft bearing (lower)
• There is no oil hole and oil groove on
the lower bearing. But opposite upper
Oil hole and groove
(upper part)
bearing has oil hole and oil groove.
Rightly set up
No oil hole and groove
(Lower part)
EJM2122S
3) Crankshaft
• Assemble the crankshaft gear in front
side.
Caution
Make
sure
crankshaft
the
part
number
of
because its counterweight
size may be different depending upon
engines.
Front
EJM2123S
4) Thrust washer
• Assemble thrust washer with the oil
groove side facing the crankshaft
sliding face.
Oil groove
EJM2124S
5) Crankshaft bearing cap
• Lubricate the bearing cap bolts with
engine oil.
• Assemble
Arrow
the bearing caps to the
crankshaft.
The arrow mark must be pointing to
the front of the engine.
Front
EJM2125S
- 85 -
• Tighten the bearing cap bolts
specified torque a
to the
little at a time in
the numerical order. ( see figure )
Crankshaft bearing
cap bolt torque
• Check
that
the
24.0 ± 1 kg.m
crankshaft
turns
Spread engine oil
smoothly by manually rotating it.
EJM2126S
6) Timing gear case
• Tighten timing gear case bolt to the
specified torque.
Timing gear case
bolt torque
• Apply
2.6 ± 0.5 kg.m
silicon to the indicated area.
(see figure)
EJM2127S
8) Camshaft
• Tighten thrust plate bolt through the
camshaft gear hole.
Thrust plate
bolt torque
2.6 ± 0.5 kg.m
Camshaft gear
bolt torque
16 ± 1.5 kg.m
Camshaft gear
EJM2128S
9) Idler gear shaft
• Assemble an idler gear shaft by using
Oil hole
the thrust collar fixing bolt as a guide.
• The
oil hole must be facing the
camshaft.
• Lubricate
the idle gear shaft with
engine oil.
EJM2129S
- 86 -
10) Idler gear
• Assemble the idle gear.
Injection pump gear
Set the timing marks “A”, “B”, and “C”
Idle gear
as shown in the figure.
Mark "B"
• Tighten the idle gear bolts seating the
thrust collar to the specified torque.
The thrust collar must be installed
with the chamfered side facing the
front of the engine.
Idle gear bolt torque
Camshaft
gear
Mark "C"
Mark "A"
Camshaft gear
5.5 ± 1 kg.m
EJM2130S
11) Piston and connecting rod
• Set the piston ring gaps as shown in
2nd Ring compression ring
the figure.
• Lubricate the piston, the piston ring
and the connecting rod bearings with
engine oil.
Oil ring
• Position the piston front mark towards
Top ring
60°
60°
EJM2131S
the front of the engine.
• Use
the piston ring compressor to
Piston ring compressor
compress the piston rings.
• Push
Hammer grip
the piston in until it makes
contact with the crank pin by using a
Front
mark
hammer grip.
At
the
same
time,
rotate
the
crankshaft until the crank pin reaches
EJM2132S
its highest point.
• Set the bearing cap cylinder number
marks
and
the
connecting
rod
cylinder number marks.
• Lubricate the connecting rod cap bolt
Cylinder
number
threads and setting face with MoS2
grease.
• Tighten the connecting rod cap bolts
EJM2133S
to the specified torque.
Refer to the following table.
Torque
Bolt head
12 ± 0.25 kg.m 9.75 ± 0.25 kg.m
11
12
EJM2134S
- 87 -
12) Oil pump assembled
• Lubricate
the oil pump with the
specified engine oil.
Coupling
• Install the oil pump with the coupling.
• Tighten the oil pump bolts to the
specified torque.
Oil pump bolt torque
5.3 ± 1.0 kg.m
EJM2135S
13) Flywheel housing
• Apply silicon to the shaded area. (see
figure)
• Install the flywheel housing.
Tighten the flywheel housing bolts to
the specified torque.
Outer bolt
16.1 ± 1 kg.m
Inner bolt
2.6 ± 0.5 kg.m
Silicon
(for face of cylinder
body only)
EJM2136S
14) Oil pan
• Apply
liquid
gasket
to
the
area
indicated by the arrows in the figure.
• Install the gasket and oil pan.
• Tighten the oil pan bolts to
the
specified torque.
Oil pan bolt torque
2.6 ± 0.5 kg.m
EJM2137S
15) Oil cooler
• Assemble the oil cooler with gasket
after applying sealant to the oil cooler
gasket.
• Tighten
the oil cooler bolts to the
specified torque. in the numerical
order (see figure).
Oil cooler torque
2.6 ± 0.5 kg.m
EJM2138S
- 88 -
3.4.5. Major component assembly
Repair kit
EJM2139S
1. Flywheel
9. Oil pump driving pinion
2. Crankshaft pulley nut
10. Push rod
3. Tappet chamber cover
11. Taper bushing
4. Water pump
12. Crankshaft pulley and dust cover
5. Cylinder head gasket
13. Timing gear cover
6. Cylinder head bolt
14. Oil thrower
7. Cylinder head
15. Rubber hose
8. Rocker arm shaft assembly
- 89 -
1) Flywheel
• Lubricate
the
flywheel
bolt
with
engine oil.
• Install the flywheel.
Tighten the flywheel bolts to the
specified torque in the numerical
order. (see figure)
Flywheel bolt torque
20 ± 1.5 kg.m
Lubricate with engine oil
EJM2142S
Injection pump
•
Align the injection pump gear “C”
Injection pump gear
timing mark with the idler gear “C”
Mark "B"
Idle gear
timing mark.
Camshaft
gear
Mark "C"
Mark "A"
Camshaft gear
EJM2130S
• Tighten the injection pump bolts to the
specified torque.
Injection pump bolt torque
2.6 ± 0.5 kg.m
EJM1029S
2) Crankshaft pulley nut
• Tighten the crankshaft pulley nut to
Crankshaft pulley
the specified torque by using a
wrench.
Crankshaft pulley nut torque
60 ± 5 kg.m
Wrench
EJM2144S
- 90 -
3) Tappet chamber cover
• Apply silicon to the tappet chamber
cover gasket.
• Assemble the tappet chamber cover
and tighten the bolts to the specified
torque.
Tappet Chamber
Cover Bolt Torque
2.6 ± 0.5 kg.m
EJM2145S
4) Water pump
• Apply
silicon to the pump gasket
before installing the water pump.
Apply silicon
EJM2146S
5) Cylinder head gasket
• The
gasket “TOP” mark should be
faced up and “FRONT” mark is
Front, Mark TOP
towards the front of the engine.
Water Pump
Front
EJM2147S
6) Cylinder head bolts
7) Cylinder head
• Carefully place the cylinder head on
the cylinder block.
• Tighten the cylinder head bolts to the
specified steps and torque in the
numerical
order
as
figure
and
Front
following table.
EJM2148S
- 91 -
Bolt type
Torque
hexagonal bolt
1st step : 7.0 kg.m
2nd step : 11.5 + 0.5 kg.m
1st step : 4.0 kg.m
dodecagonal bolt 2nd step : 90 °
3rd step : 90 ° (-10 °)
< 12-gonal bolt limited value >
Standard (mm)
Limit (mm)
115
116.2
102
103.2
• Apply engine oil to the cylinder head
bolts threads and setting faces.
8) Rocker arm shaft assembly
• Tighten
the rocker arm bolts to the
specified torque a little at a time in the
numerical order. (see figure)
Rocker arm shaft
bracker bolt torque
• Lubricate
3.1 ± 0.5 kg.m
the rocker arm and the
rocker arm shaft with engine oil.
EJM2149S
• Adjust valve clearance.
- 92 -
3.4.6. External parts
3
4
7
29
4
30
11 12
10
9
23
5
8
14
18
1 15 17
26
13
27
6
19 20
21 22 2
24 25
EDM1014I
1. Cylinder head cover
11. Water outlet
22. Oil pan
2. Starter
12. Oil filler cap
23. Lifting hook
3. Injection nozzle
13. Cooling fan
24. Fly wheel
4. Injection pipe
14. Alternator
25. Flywheel housing
5. Oil filter
15. Oil level gauge
26. Exhaust manifold
6. Fuel pipe
17. Guide tube
27. Breather hose
7. Intake pipe
18. Push rod chamber cover
28. Oil cooler
8. Injection pump
19. Crank shaft pulley
29. Intake manifold
9. Cooling water pump
20. Mounting bracket
30. Fuel filter
10. Thermostat
21. Drain valve
- 93 -
1) Cylinder head cover
• Tighten the cylinder head cover bolts
4
to the specified torque a little at a time
2
in the sequence. (see figure)
1
Cylinder head cover
bolt torque
3.0 ± 0.5 kg.m
3
Fan belt
• Adjust the fan belt tension.
EJM2154S
2) Starter
• Tighten
specified
the
starter
torque
bolts
after
to
the
install
the
starter to the flywheel housing.
Starter fixing
bolt torque
8.4 kg.m
EJM2155S
3) Injection nozzle
• Install
the injection nozzle with the
injection nozzle gaskets.
o-ring
Injection nozzle
bolt torque
1.9 ± 0.2 kg.m
• Be careful not to damage the nozzle
tips.
Seal ring
EJM2163S
4) Fuel injection pipe
• Install the fuel injection pipes 1
and
tighten the bolts to the specified
torque.
Injection pipe torque
3.0 ± 0.2 kg.m
EJM2164S
- 94 -
• Carefully position and set the clips
2 .
It is very important that each clip be
positioned correctly.
An improperly positioned clip will
result in objectionable fuel pulsing
noise and injection pipe breakage.
• Install the fuel leak off pipes
3 .
5) Oil filter
• Install
the oil filter assembly with
tightening the bolts securely.
Oil filter assembly
mounting bolt torque
4.3 ~6.3 kg.m
EJM2175I
6) Fuel pipe
• Install
the fuel pipe and tighten the
fuel pipe joint bolts to the specified
torque.
Take care not to interchange the
check valves and joint bolts.
Fuel pipe joint
bolt torque
1.7 ± 0.1 kg.m
EJM2166S
7) Intake pipe
• Install the intake pipe and tighten the
intake
pipe
flange
bolts
to
the
specified torque.
Intake pipe flange
bolt torque
2.6 ± 0.5 kg.m
EJM2167S
- 95 -
4. Maintenance of Major Components
4.1. Lubrication system
4.1.1. General information
OPENNING PRESSURE
4.0 - 4.8 kg/cm2
RELIEF VALVE
CYLINDER BLOCK MAIN GALLERY
INJECTION PUMP
BY-PASS VALVE
2.0 kg/cm2
OIL COOLER
CAM SHAFT BEARING
IDLE GEAR SHAFT
CRANK JOURNAL
ROCKER ARM SHAFT
BY-PASS VALVE
1.0 kg/cm2
OIL FILTER
VALVE ROCKER ARM
CRANK PIN
PISTON
RELIEF VALVE
7.0 kg/cm2
OIL PUMP
IDLE GEAR FACE
TAPPET
VALVE
OIL STRAINER
OIL PAN
EA4M3001
- 96 -
4.1.2. Oil pump
1) Disassembly
4
5
3
6
1
EA4M3002
< Disassembly Steps >
1. Strainer
4. Drive shaft and gear
2. Suction Pipe
5. Pinion Gear
3. Cover and dowel
6. Pinion gear shaft
- 97 -
2) Inspection
• Visually
inspect the disassembled
parts for the excessive wear and
damage.
• Correct
or replace the parts if the
wear or damage is discovered during
inspection.
EJM3003S
(1) Oil Pump Drive Gear
• Use a feeler gauge to measure the
clearance between the oil pump
cover
(oil
pump
case)
inside
surface and the drive gear.
• If
the
clearance
exceeds
the
specified limit, the drive gear and/or
the
oil
pump
cover
must
be
replaced.
EJM3004S
Limit
0il pump cover and
drive gear clearance
0.12 mm
(2) Oil pump pinion gear
• Use a feeler gauge to measure the
clearance between the oil pump
case cover inside surface and the
pinion gear.
• If
the
clearance
exceeds
the
specified limit, the pinion gear
and/or the oil pump cover must be
replaced.
EJM3005S
Limit
0il pump cover and
pinion gear clearance
0.12 mm
3) Oil pump reassembly
• To assemble, follow the disassembly
procedures in reverse order.
- 98 -
4.1.3. Oil cooler
1) Disassembly
2
1
6
5
4
3
EJM3008S
< Disassembly Steps >
1. Oil cooler element
4. O - ring
2. Gasket
5. By - pass valve spring
3. By -pass plug
6. By - pass valve
2) Inspection
• Correct or replace the part if the wear or damage is discovered during inspection.
- 99 -
(1) Oil cooler element
• Install the oil cooler element to the
oil cooler, then tighten the oil cooler
element fixing bolts to the specified
torque.
Oil cooler element
fixing bolts torque
2.6 ± 0.5 kg.m
EJM3010S
3) Oil cooler reassembly
• To assemble, follow the disassembly
procedures in reverse order.
4.2. Cooling system
4.2.1. General information
Water pipe
Thermostat
Reserve tank
R
a
d
i
a
t
o
r
Cylinder head
Cylinder block
Water pump
EJM4001I
- 100 -
4.2.2. Water pump
1) Disassembly
5
3
6
2
4
8
7
1
EJM4003S
< Disassembly Steps >
1. Pulley
5. Unit bearing
2. Cover
6. Mechanical seal
3. Gasket
7. Hub
4. Impeller
8. Snap ring
Import Operation
(4) Impeller
• Remove the impeller by using the
Remover
jig.
EJM4005S
- 101 -
(5) Unit bearing
• Remove the unit bearing by using a
bench
press
and
a
suitable
remover.
EJM4008I
(6) Mechanical seal
• Remove
the mechanical seal by
using a suitable remover.
EJM4009S
(7) Hub
• Remove the hub by using a bench
press and a suitable rod.
Bench press
Hub
EJM4006S
(8) Snap ring
• Remove the snap ring by using a
pair of the snap ring plier.
EJM4007S
- 102 -
2) Inspection
(1) Unit bearing
• Correct
or replace the part if the
wear, defect or other damage is
discovered during inspection.
3) Water pump reassembly
EJM4011I
Import Operation
(1) Unit bearing
• Lubricate
the
bearing
with
Spreading of multipurposable grease
multipurpose grease.
• Use a bench press to assemble the
unit bearing at the pump.
Outside from sealed surface
EJM4011S
(2) Snap Ring
• Use
a pair of snap ring plier to
install the snap ring.
EJM4007S
(3) Hub
• Use
a bench press and a bar to
install the hub.
EJM4015S
- 103 -
(4) Mechanical seal
• Apply sealant to the seal unit outer
periphery before installation.
Spreading of
sealant
EJM4016S
• Use
a bench press and a bar to
install the seal unit into the pump
body.
EJM4017S
(5) Impeller
• Use
a bench press to install the
impeller to the shaft.
Bench press
• Use a feeler gauge to measure the
clearance between the impeller and
the pump body.
Clearance between
impeller and pump body
0.3 ~ 0.8 kg.m
Feeler gauge
EJM4018S
(6) Pulley
• Install
the pulley and tighten the
pulley bolts to the specified torque.
Pulley fixing
bolts torque
Fan flange
2.6 ± 0.5 kg.m
Pulley
Cooling fan
EDM4001I
- 104 -
4.2.3. Thermostat
• Correct
or replace thermostat if the
Thermometer
wear, defect or other damage is
Ruler
discovered during inspection.
Model
DB58
PU066
Valve
Temperature
Lift
Temperature
Lift
Close
82 °C
opening
71 °C
opening
Standard
95 °C
10 mm
90 °C
10 mm
Maximum
110°C
less 16 mm
90 °C
less 10 mm
Wood piece
EFM2055I
4.3. Fuel system
4.3.1. General information
Injection Nozzle
Fuel filter
Feed pump
Fuel tank
Water sedimentor
Injection pump
EJM5001S
• The fuel system consists of the fuel tank, water sedimentor, the fuel filter,
the injection pump
and the injection nozzle.
• The fuel from the fuel tank passes through the water sedimentor, and the fuel filter, where
particles and other foreign material are removed from the fuel.
• Fuel, fed by the injection pump plunger, is delivered to the injection nozzle in the measured
volume at the optimum timing for efficient engine operation.
- 105 -
4.3.2. Fuel filter
1) Disassembly ( DB58 )
4
3
5
2
6
7
7
1
Element kit
EJM5003S
< Disassembly Steps >
1. Drain plug
5. Fuel filter element
2. Center bolt
6. Spring seat
3. Fuel filter body
7. Spring
4. Body cover gasket
2) Inspection
• Make
the necessary adjustments, repairs and part replacements if excessive wear or
damage is discovered during inspection.
3) Fuel filter reassembly
•To reassemble the fuel filter, follow the disassembly procedure in the reverse order.
- 106 -
4.3.3. Injection Nozzle
1) Disassembly
6
11
1
10
3
9
2
4
8
7
5
EJM5008S
< Disassembly Steps >
1. Nozzle holder body
7. Push rod spring
2. Seal ring
8. Spring seat
3. Injection pipe connector
9. Nozzle adjusting screw
4. Injection nozzle
10. Cap nut gasket
5. Retaining nut
11. Nozzle holder cap nut
6. Nozzle holder push rod
Import Operation
4) Injection Nozzle
Remove the nozzle assembly from the nozzle body. Keep the parts separately to maintain
the proper needle valve to body combination.
2) Inspection
Make the necessary adjustments, repairs and parts replacements if excessive wear or
damage is discovered during inspection.
- 107 -
(1) Push rod spring
• Check the push rod spring for wear,
weakness and corrosion.
EJM5005S
(2) Nozzle holder push rod
• Check the nozzle holder push rod
curvature.
• Check the nozzle holder push rod
and needle valve contact surface
for
excessive
wear
and
poor
contact.
EJM5006S
(3) Injection nozzle
• Check the injection nozzle needle
valve, the valve seat, and the
injection nozzle hole for carbon
deposits.
If carbon deposits are present, the
injection nozzle and
the needle
valve must be replaced.
• Hold the nozzle body vertically.
Pull the needle valve about oneEJM5007S
third of the way out of the nozzle
body.
Release the needle valve.
Check that the needle valve falls
back into the nozzle body as far as
the valve seat.
If the needle does not fall back into
the nozzle body as far as the valve
seat, the injection nozzle and the
needle valve must be replaced.
- 108 -
3) Reassembly
(1) Injection pipe connector
Injection pipe
connector torque
5.5 ± 0.5 kg.m
EJM5009S
(2) Injection nozzle
• There must be no oil on the contact
surface of the injection nozzle and
the injection nozzle holder.
Clean these contact surface with
diesel fuel before installation.
• The
nozzle dowel pin must be
aligned with the dowel hole in the
nozzle holder body.
EJM5010S
(3) Retaining nut
• Clamp the injection nozzle in a vise.
• Tighten the retaining nut to the
specified torque by using a wrench.
Nozzle retaining
nut torque
7 ± 1 kg.m
EJM5011S
(4) Nozzle holder cap nut
• Clamp the injection nozzle in a vise.
• Tighten the nozzle holder cap nut to
the specified torque by using a
wrench.
Nozzle holder cap
nut torque
4.5 ± 0.5 kg.m
EJM5013S
- 109 -
(5) Nozzle adjusting screw
( injection starting pressure check )
• Attach the injection nozzle holder to
the injection nozzle tester.
EA0M3003
• Loosen the adjustment screw
1 .
1
• Check the injection nozzle starting
pressure and the spray condition by
operating the injection tester.
EJM5024S
< spray condition check >
Operate the injection nozzle tester
hand lever 4 to 6 times while
looking
for
abnormal
injection
Correct
nozzle spray conditions.
Incorrect
Incorrect
( See figure )
(1) Correct (Good)
(2) Incorrect (Bad - orifice)
(3) Incorrect (Bad - dripping)
• Adjust the injection nozzle starting
pressure.
Turn the adjusting screw clockwise
while operating the injection nozzle
tester handle.
DB58
PU066
Adjusting pressure ( setting )
225 ~ 230 kg/cm2
225 ~ 230 kg/cm2
Injection nozzle starting pressure
220 kg/cm2
220 kg/cm2
Caution
Keep away your skin from the tester
because pressure of nozzle tester is
very high when inject.
- 110 -
4.3.4. Injection pump calibration
1) DB58 engine
(1) Injection pump assembly : 65.11101 - 7266A ( 101605 - 9950 ZEXEL )
- Injection pump
: NP- PES6A95C410RS2000 ( 101061 - 8410 )
- Governor
: NP-EP/ RSV200-1200AQ36A311 (105419 - 3720 )
- Plunger and barrel
: 131153 - 3220
- Delivery valve
: 131110 - 6220
- Feed pump
: KP-FP/ KS-A (105220 - 4561 )
- Prestroke
: 3.6 ± 0.05 mm
(2) Nozzle holder assembly
: 65.10101 - 7295 ( 105160 - 465A DPICO )
(3) Nozzle
: 65.10102 - 6044 ( 105025 -138A DPICO )
(4) Injection pipe
: 65.10301 - 6144
(5) Injection order
:1-5-3-6-2-4
(6) Injection timing
: BTDC 20˚ ± 1˚
(A) Test condition
for injection pump
(B) Engine standard parts
Nozzle & Holder Ass’y
105760-6140
-
ø 2.0 x ø 6.0 - 650 mm
ISO4113
Temperature :40 ± 5˚C
65.10102-6044
Nozzle (5 x ø 0.27)
65.10101-7295
220 kg/cm2
65.10301-6144
ø 1.6 x ø 6.0 x 580 mm
Injection pipe( IDxODxL )
Test oil
Nozzle & holder Ass’y
Injection pipe ( IDxODxL )
Opening pressure : 175 kg/cm2
Rack diagram and setting valve at each point
Standby power
3
Pump Injection Q`ty on RIG(mm / 1,000st)
Press.
Speed
(A) Test condition
(mmHg)
Remarks
(rpm)
for inj. Pump
900
57.3
52.1 ± 2
-
Check
Point
Rack
position
(mm)
A
8.8
B
9.2
875
59.5
(59.9)
-
C
7.3
350
11.5
7.3
-
D
5.6
950
-
8.3
-
E
14.0
100
100
-
-
Boost pressure : zero boost
Governor weight
Weight = 740 g
Lever ratio(min/max)
1 : 1.2
Governor spring
k = 6.08 kg/mm
Plunger
ø 9.5 left hand 20 lead
Idle spring
k = 2.2 kg/mm
Delivery valve retraction volume
35 mm3/st, t=0.1
Start spring
k = 0.014 kg/mm
Delivery valve opening pressure
24.5 kg/cm2
Feed pump
105210-4561
Delivery valve spring
k = 1.63 kg/mm
- 111 -
(7) Rack diagram
Rock Position (mm)
14
E
B A
9.2
8.8
7.3
C
D
5.6
100 350
875 900
950
Injection pump speed (rpm)
EJM5022I
- 112 -
2) PU066 engine
(1) Injection pump assembly : 65.11101 - 7321 ( 101605 - 9630 ZEXEL )
- Injection pump
: NP- PES6A95C410RS2000 ( 101062 - 8120 )
- Governor
: NP-EP/ RSV200-1450AQ43A311 (105419 - 1340 )
- Plunger and barrel
: 131153 - 3220
- Delivery valve
: 131110 - 6220
- Feed pump
: KP-FP/ KS-A (105220 - 4561 )
- Prestroke
: 3.6 ± 0.05 mm
(2) Nozzle holder assembly : 65.10101 - 7295 ( 105160 - 465A DPICO )
(3) Nozzle
: 65.10102 - 6044 ( 105025 -138A DPICO )
(4) Injection pipe
: 65.10301 - 6144
(5) Injection order
:1-5-3-6-2-4
(6) Injection timing
: BTDC 20˚ ± 1˚
(A) Test condition
for injection pump
(B) Engine standard parts
Nozzle & Holder Ass’y
105760-6140
Opening pressure : 175 kg/cm2
-
ø 2.0 x ø 6.0 - 650 mm
Injection pipe( IDxODxL )
Test oil
Nozzle & holder Ass’y
Injection pipe ( IDxODxL )
ISO4113
Temperature :40 ± 5˚C
65.10102-6044
Nozzle (5 x ø 0.27)
65.10101-7295
220 kg/cm2
65.10301-6144
ø 1.6 x ø 6.0 x 580 mm
Rack diagram and setting valve at each point
3
Pump Injection Q`ty on RIG(mm / 1,000st)
Press.
Speed
(A) Test condition
(mmHg)
Remarks
(rpm)
for inj. Pump
Check
Point
Rack
position
(mm)
A
8.67
1400
54 ± 4
-
-
B
6.5
400
6.9 ± 14
-
-
C
8.84
900
55.3 ± 2
-
-
D
9
500
41.6
-
-
E
-
100
104
-
-
F
5.5
1540
10
Boost pressure : zero boost
Governor weight
Governor spring
Weight = 740 g
k = 12 kg/mm
Lever ratio(min/max)
Plunger
Idle spring
k = 1.9 kg/mm
Start spring
k = 0.0051 kg/mm Delivery valve opening pressure
Adapter spring
k = 11 kg/mm
Feed pump
105210-4561
Delivery valve retraction volume
- 113 -
1 : 1.2, 1 : 1.2
ø 9.5 left hand 20 lead
43 mm3/st, t=0.09 mm
25.9 kg/cm2
(7) Rack diagram
E
14
12
Rock Position (mm)
10
D
C
A
8
B
6
F
4
2
0
0
100
400 500
900
1400
1540
Injection pump speed (rpm)
EDM5001I
- 114 -
3) Injection pump
EJM5018S
1. Pump housing
56. Shim
117a. Connection bolt
2. Cover assembly
61. Plunger spring
118a. Gasket
3. Bolt, cover
62. Seat, spring(upper)
121. Plug screw
4. O-ring
63. Seat, spring(lower)
122. Gasket
5. Gasket
67. Control rack
130. Connect
16. Screw, plug
68. Stop bolt
130a. Adapter
18. Bolt, stud
76. Pinion
131a. Bolt
20. Spring washer
77. Sleeve
132a. Gasket
21. Nut
78. Bolt
133a. Gasket
23. O-ring
90. Camshaft
145. Plug screw
30. Plunger
91.91a. Taper roller bearing
146. Gasket
36. Delivery valve
92.92a Camshaft ring
152. Connection bolt
37. Delivery valve spring
93.93a. Shim
154. Packing
40. Delivery valve holder
95. Center bearing
191. Bracket
45. Lock plate assembly
101a. Bearing cover
192. O-ring
49. O-ring
104a. Bolt
194. Washer
55. Tappet
112a. Woodruf key
195. Spring washer
115a. Adapter
196. Nut
- 115 -
4) Governor
EJM5018S
1. Governor housing
80. Cover
182. Lever shaft
4. Plate
82. Bolt
183. Collar
6. Adapter
83. Bolt
190. Control lever
7. Bolt
100.Fly wheel
192. Nut
9. Spring
101. Woodruf key
195. Return spring
10. Bolt
102. Spring washer
198. Spring washer
13. Nut
103. Nut
201. O-ring
19. Adapter
117. Sleeve
202. Bush
20. Bolt
118. Shim
203. Shim
21. Gasket
130. Governor spring
205. Shaft lever
35. Governor cover
132. Starting spring
207. Support lever
38. Tension lever bolt
136. Nut
211. Snap ring
39. Nut
137. Gasket
220. Damper spring
44. Stop bolt
138. Cap
236. Gasket
46. Cap
140. Idle spring
239. Gasket
47. Plug
141. Nut
240. Lead seal
48. Adjusting bolt
150. Speed setting lever
241. Wire, lead seal
49. Nut
170. Guide lever
255. Bracket
50. Stop bolt
173. Split pin
331. Angleich spring
51. Bolt
174. Floating lever link
332. Connection nut
52. Bolt
181. Tension lever
- 116 -
5. Engine electrical
5.1. Starting motor
5.1.1. Main data and specification
Part name
Specification
Rated voltage
24 V
Rated output
4.5 kW
Rating
30 sec
Direction of rotation
Clockwise (viewed from the pinion side)
Operation speed
More than 3,500 rpm (No load)
More than 1,080 rpm (Load)
5.1.2. Construction
5
1
3
6
7 21
23
4
24
8
9
17 16 14 15
2
22
26
18 19 20
25 13 12 11 10
EDM5002I
1. Yoke assembly
10. Coil spring
19. Snap retainer
2. Bush holder assembly
11. Steel ball
20. Coil spring
3. End frame
12. Clutch assembly
21. Housing
4. Through bolt
13. Clutch shaft
22. Terminal cap
5. Armature assembly
14. Coil spring
23. Screw
6. snap retainer
15. Pinion starter
24. Cover
7. Idle gear
16.Pinion stop nut
25. Through bolt
8. Clutch roller
17. Snap ring
26. Magnet switch assembly
9. Retainer
18. Snap ring
- 117 -
5.2. Alternator
5.2.1. Main data and specification
Part name
Specification
Type
3 Phase AC alternator (Built in regulator)
Rated voltage
24 V
Rated output
45 A
Max. allowable speed
5000 rpm
Polarity
Negative (-)
Direction of rotation
Clockwise (viewed from the pulley side)
Weight
6 kg
5.1.2. Construction
5
4
1
2
6
Wiring Diagram
3
7
TO BATTERY +
24
16
17
REGULATOR
P
13
8
RL = 150~250 OHM
15
19
12
20
10
11
21
22
23
9
18
14
12
1. Hex nut
EA8O3007
9. Pin
17. Screw
2. Pulley
10. Stud bolt
18. Regurator
3. Fan
11. Insulator
19. Brush set ass’y
4. Collar
12. Bolt
20. Brush holder
5. Bearing ass’y
13. Frame
21. Spring
6. Rotor ass’y
14. Bushing
22. Brush
7. Stator ass’y
15. Neddle bearing
23. Brush
8. Cover
16. Rectipier
24. Baffle
- 118 -
6. Special Tool List
No.
Description
Part No.
1
Compression gauge adapter
EU.2-0529
2
Valve spring compressor
EF.122-249
3
Crankshaft gear punch
EF.122-265
4
Crankshaft pilot bearing remover
EF.122-253
5
Pilot bearing punch
EF.122-251
6
Crankshaft rear oil seal installer
EF.122-262
7
Crankshaft front oil seal installer
EF.122-255
8
Valve stem oil seal installer
EF.122-289
- 119 -
Illustration
No.
9
Description
Part No.
Piston sleeve
E1.03901-0124
10
Cylinder liner remover
EF.122-281
11
Cylinder liner installer
EF.122-261
12
Pulley bush puncher
EU.1-0022
13
Pulley bush puller
EU.2-0328
14
Feeler gauge
60.99901-0027
15
Snap ring plier
T7610001E
16
Piston ring plier
T7621010E
- 120 -
Illustration
Appendix
• Torque Specifications ( Standards Bolts )
The torque values given in the following table should be applied where a particular torque is not
specified.
( Unit : kg.m )
Bolt
identification
4
Bolt
diameter x pitch
4T
Low carbon steel
9
7T
High carbon steel
9T
Alloy steel
M6 x 1.0
0.6 ± 0.2
0.75 ± 0.2
-
M8 x 1.25
1.3 ± 0.5
1.75 ± 0.5
2.0 ± 0.7
M10 x 1.25
2.8 ± 0.7
3.75 ± 0.9
5.0 ± 1.3
M10 x 1.5
2.7 ± 0.7
3.7 ± 0.9
4.9 ± 1.2
6.25 ± 1.2
7.75 ± 1.5
9.65 ± 1.9
M12 x 1.5
5.8 ± 1.2
7.2 ± 1.4
9.1 ± 1.8
M14 x 1.5
8.75 ± 1.9
11.85 ± 2.3
14.50 ± 2.9
M14 x 2.0
9.1 ± 1.8
11.2 ± 2.2
13.6 ± 2.2
M16 x 1.5
13.3 ± 2.7
17.30 ± 3.5
20.40 ± 4.1
M16 x 2.0
12.7 ± 2.5
16.5 ± 3.3
19.5 ± 3.9
M18 x 1.5
19.2 ± 3.8
24.9 ± 5.0
29.30 ± 5.9
M20 x 1.5
26.3 ± 5.3
34.40 ± 6.9
40.40 ± 8.1
M22 x 1.5
33.0 ± 8.3
46.25 ± 9.2
54.10 ± 10.8
M24 x 2.0
45.8 ± 9.2
58.20 ± 14.0
70.60 ± 14.1
M12 x 1.25
The
7
mark indicates that the bolts are used for female-threaded parts that are made of soft
materials such as casting, etc.
- 121 -