336145573 Daewoo DE12 T TI мануал PDF
336145573 Daewoo DE12 T TI мануал PDF
336145573 Daewoo DE12 T TI мануал PDF
This maintenance manual is designed to serve as a reference for DOOSAN Infracore (here after
DOOSAN’s) customers and distributors who wish to gain basic product knowledge on DOOSAN’s DE
series diesel engines (DE12, DE12T, DE12TI and DE12TIS).
These economical and high-performance diesel engines (6 cylinders, 4 strokes, in-line, direct injection
type) have been so designed and manufactured to be used for overland transport industrial purpose.
That meets all the requirements such as low noise, fuel economy, high engine speed, and durability.
To maintain the engine in optimum condition and retain maximum performance for a long time, CORRECT
OPERATION and PROPER MAINTENANCE are essential.
In this manual, the following symbols are used to indicate the type of service operations to be per-
formed.
Removal Adjustment
Installation Cleaning
Measurement
During engine maintenance, please observe following instructions to prevent environmental damage;
If you have any question or recommendation in connection with this manual, please do not hesitate
to contact our head office, dealers or authorized service shops near by your location for any services.
For the last, the content of this maintenance instruction may be changed without notice for some quality
improvement. Thank you.
1. GENERAL INFORMATION
1.1. General Repair Instructions ..................................................................................................... 1
1.2. Engine Characteristics ............................................................................................................ 2
1.3. Engine Specification ............................................................................................................... 3
1.4. Engine Assembly .................................................................................................................... 8
2. MAJOR MAINTENANCE
2.1. Preventive Maintenance ....................................................................................................... 14
2.2. Diagnosis and Remedy ........................................................................................................ 22
2.3. Engine Inspection ................................................................................................................. 32
• 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 DAEWOO 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 separate 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 a sealer on gaskets to prevent leakage.
11. Carefully observe all specifications for bolts and nuts torques.
12. When service operation is completed, make a final check to be sure service has been done
property.
EA8M1001
1.3.1. Specification
Engine Model
DE12 DE12T DE12TI DE12TIS
Spec.
Engine type 4 cycle in-line, 4 cycle in-line, 4 cycle in-line,
Water-cooled type Water-cooled type Water-cooled type
Naturally aspirated Turbo charged Turbo charged & intercooled
Combustion chamber type Direct injection type
Cylinder liner type Replaceable 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) 6 - 123 x 155
Total piston displacement (cc) 11,051
Compression ratio 17.1 : 1 17.1 : 1 16.5 : 1 16.8 : 1
1,317 x 795 x 1,317 x 847 x
Engine dimension (length x width x height) (mm) 1,368 x 932 x 1,151
1,029 1,064
Engine weight (kg) 872 909 990
Rotating direction (viewed from flywheel) Counter clockwise
Fuel injection order 1-5-3-6-2-4
Fuel injection timing (B.T.D.C static) 12 9 12 1
Injection pump type Mechanical Mechanical Mechanical Electrical
Governor type RFD-C / RLD RFD-C RFD-D RLD-J
Injection nozzle type Multi-hole(5-N0.29) Multi-hole (5-N0.31) Multi-hole(5-N0.33) Multi-hole(5-N0.29)
Fuel injection pressure (kg/cm )
2
1st : 160 1st : 160
220 220
2nd : 220 2nd : 220
Compression pressure (kg/cm2) 28 (at 200rpm)
Intake and exhaust valve clearance(at cold) (mm) 0.3
Open at 18 (B.T.D.C) 18 (B.T.D.C)
Intake valve
Close at 34 (A.B.D.C) 32 (A.B.D.C)
Open at 46 (B.B.D.C) 70 (B.B.D.C)
Exhaust valve
Close at 14 (A.T.D.C) 30 (A.T.D.C)
Lubrication method Full forced pressure feed type
Oil pump type Gear type driven by crankshaft
Oil filter type Cartridge type
Lubricating oil capacity(max./min) (liter) 17/14
Oil cooler type Water cooled
Water pump Centrifugal type driven by gear
Cooling method Fresh water forced circulation
Cooling water capacity (engine only) (liter) 19
Thermostat type Wax pallet type (83 ~ 95 C)
Air compressor type & capacity (cc/rev) Gear driven type, Truck : 220 , Bus : 318
Power steering pump (lit/bar) Bus : 16 / 100 , Truck : 18 / 125
Alternator voltage - capacity (V - A) Truck : 24 - 45 , Bus : 24 - 150
Starting motor voltage - output (V - kW) 24 - 6.0
Air heater capacity (V - A) 22 - 95 (2.1 kW)
Battery capacity (V - AH) 24 - 200
EBICA
/B/C/E/I/ 12 340 / 2,100 135 / 1,260 600-650 2,320±50
L/M
ECIBA
ECICA
340 / 2,100
ECICB 1 145 / 1,260
ECICD
DE12TIS ECIBD 335 / 2,100 600± 25 2,350-2,400 EURO-II
ECICC 1 320 / 2,100 135 / 1,260
ECIBB 1 310 / 2,100 125 / 1,260
ECIBC 1 290 / 2,100 115 / 1,260
ECIBE 1 360 / 2,100 145 / 1,260
* Note : All data are based on operation without cooling fan at ISO 1585(SAE J1349).
1) DE12TIS - 360PS
140
130
370 120
340
310
280
250
220
190
160 160
150
140
EB8O1001
EB8O1
160
150
140
130
360 120
320
280
240
180
200 170
160
150
140
EB8O1002
115
105
95
320
280
240
200
160
155
150
145
EB8O1003
3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19
EQM8018I
7 8 9 10
6
11
5 12
4 13
14
EQM8019I
1) DE12 (Bus)
4 5 6 7 8 20 21
9
3
19
10
2
11 22
1
12 13 14 15 16 17 18
23 24 4 29 30
25 26 27 28
EQM8007I
GENERAL INFORMATION - 10 -
2) DE12TI (Bus)
4 5 6 7 8 20
9
3
19
2 10 21
1 11
12 13 14 15 16 17 18
30
22 23 24 25
31
32
26 27 28 29
EQM8008I
- 11 - GENERAL INFORMATION
3) DE12TIS (Truck)
3 4 5 6 7 8 19
9
2 18
10
1 11 20
21
12 13 14 15 16 17 22 23
26 27 28 29 36 37 38 39
30
25 40
24
35
31 32 33 34
EQM8009I
GENERAL INFORMATION - 12 -
4) DE12TIS (Bus)
4 5 6 7 8 20
9
3
19
10
2
21
11
1
12 13 14 15 16 17 18
22 23 24 25 30
31
32
26 27 28 29
EQM8008I
- 13 - GENERAL INFORMATION
2. MAJOR MAINTENANCE
2.1. Preventive Maintenance
The preventive maintenance means that the operator performs the servicing of engine to obtain
long life and best performance from DAEWOO diesel engine.
• Regarding the cooling water that is to be used for engine, the soft water not the hard water
must be used.he use of proper tools and special tools where specified is important to
efficient and reliable service operation.
• The engine cooling water can be used diluting it with antifreezing solution 40% and the
additive for rust prevention (DCA4) 3 ~ 5 %.
• The density of above solution and additive must be inspected every 500 hours to maintain it
properly.
NOTE :
The proper density control of antifreezing solution and rust preventing additive will be
able to prevent the rusting effectively and maintain the stable quality of engine. For the
improper control might give the fatal damage to the cooling water pump and cylinder
liners, detail care is needed.
• Since DE12/T/TI and DE12TIS (diesel engine of DE12 series) cylinder liner is dry type,
particularly the cooling water control should be applied thoroughly.
• The density of antifreezing solution and additive for rust prevention is able to be confirmed
by the cooling water test kit. (Fleetguard CC2602M)
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.
MAJOR MAINTENANCE - 14 -
(4) Make the numerical value by comparing the test paper which hue has changed with the
color list of label on storage bottle.
(5) By comparing the hue changed into yellowish green or so with the green color indication
of test paper storage bottle, confirm the density. (Then, the density indication must be in
the hue range of 33% to 50%).
(6) The brown at the middle of test paper and the lower pink color indication represent the
additive state for rust prevention, and the proper range is that the meeting numerical
value of brown (vertical) and pink color (horizontal) locates in the range of 0.3 to 0.8 at
the color list of label on the test paper storage bottle.
(7) In case of less than 0.3, replenish the additive for rust prevention (DCA4), and in case of
more than 0.8, pour out the cooling water about 50% and then readjust the density after
refilling with clean fresh water.
-10 80 20
-15 73 27
-20 67 33
-25 60 40
-30 56 44
-40 50 50
- 15 - MAJOR MAINTENANCE
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. Oil in the oil filter should be changed
simultaneously.
Recommend oil
Engine model
SAE No. API No.
DE12/T/TI SAE 15W40 above CD or CE
SAE15W40 ACEA-E2 or ACEA-E3
DE12TIS
SAE10W40 (API CH-4)
* If long oil change intervals are to be used, ACEA-E3 oil must be used.
Bus
DE12TS 17 14 21
Truck
MAJOR MAINTENANCE - 16 -
2.1.4. Oil filter
EQM4010I
4 5
2
6
EA2O4009
EFM1002I
- 17 - MAJOR MAINTENANCE
2.1.7. Intercooler
The intercooler is air to air type and has a large cooling fan capacity. The intercooler life and
performance depends on the intake air condition greatly. Fouled air pollutes and clogs the air
fins of intercooler. As a result of this, the engine output is decreased and engine malfunction
is occurred. So you always check whether the intake air systems like air filter element are
worn or polluted.
Air/air intercooler
with radiator
(combined radiator)
EA5O4003
• After letting the #1 cylinder’s piston come at the compression top dead center by turning the
crankshaft, adjust the valve clearances.
• Loosen the lock nuts of rocker arm adjusting screws and push the feeler gauge of specified
value between a rocker arm and a valve stem and adjust the clearance with adjusting screw
respectively and then tighten with the lock nut.
1) Rotate the crankshaft to overlap the intake and the exhaust valves of #6, then #1 cylinder
become the compression state of top dead center.
2) Therefore adjust the valve clearance corresponding to “ “ of lower figure.
At this time there are no force on the push rods of #1 cylinder.
MAJOR MAINTENANCE - 18 -
3) Rotating the crankshaft by one revolution, #6 cylinder become the compression state of top
dead center.
4) Thereafter adjust the valve clearances corresponding to “ “ of lower figure.
5) After reinsuring the valve clearances, retighten if necessary.
1 2 3 4 5 6
EA8O6001
EFM1004I
Difference
Within L 10 %
between each cylinder
EFM1005I
- 19 - MAJOR MAINTENANCE
2.1.10. Injection nozzle
• If the inspected injection pressure is less than the specified value, adjust using the adjusting
shims.
• 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.
2.1.12. Battery
• Inspect for any leakage of electrolytic solution owing to battery crack, and replace the
battery in case of poor condition.
• Measure the gravity of electrolytic solution, if less than specified value (1.12 ~ 1.28),
replenish.
Viewing
Liquid level liquid level upper limit Isotator
the gravity
indicating line liquid level lower limit
meter
1,100
1,200
1,300 UPPER LEVEL
LOWER LEVEL
EFM1007I E
MAJOR MAINTENANCE - 20 -
2.1.13. Air removal of fuel system
The suction room of fuel injection pump has the function of air removal continuously during
the operation through a relief valve.
In case that the suction room lacks fuel at all, for instance, in case of new installation of
injection pump, after loosening the air removing screws of cartridge filter respectively, remove
the air by operating the manual pump of fuel supply pump until bubble will disappear.
Every time of engine oil replacement, the fuel strainer installed at the fuel supply pump should
be removed and cleaned.
2.1.15. Turbocharger
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 car and so forth, inspect the wiring state being careful for not to get.
- 21 - MAJOR MAINTENANCE
2.2. Diagnosis and Remedy
• The following description summarizes the probable cause of and remedy for general failure
by item.
• DE12TIS inspect the electrical parts problem with SCAN 200 and refer diagnostic manual.
• Immediate countermeasures should be taken before a failure is inflamed if any symptom is detected.
MAJOR MAINTENANCE - 22 -
2. Engine Overheated
Operating state
1. Overload
2. Radiator core clogged
Cooling unit Fuel unit 3. Continuous over-run
Check coolant
Inspect fuel quality Fuel excessive supply
Check fresh
Replace
radiator tank cap External Internal
Clean cooling
Normal
water passage
Engine
disassembly
- 23 - MAJOR MAINTENANCE
3. Output Insufficient
Normal Adjustment
Disassemble injection
pump or engine
MAJOR MAINTENANCE - 24 -
4. Oil pressure lowered
Too low
Normal
Normal
Replace with
Retighten Disassemble engine
Normal recommended oil
Replace or injection pump
Disassemble
engine
- 25 - MAJOR MAINTENANCE
5. Fuel Consumption Excessive
Normal
Oil leakage
Inspect injection nozzle
(injection pressure Adjust Replace
atomizing state etc.)
Retighten Replace
Normal
Normal
Repair Replace
Inspect compressed Check valve
cylinder liner,
pressure clearance
piston ring, piston
Normal
Disassemble
Adjust
injection pump
Normal
Normal
Disassemble engine
(valve assembly, piston,
cylinder liner etc.)
MAJOR MAINTENANCE - 26 -
6. Oil Consumption Excessive
7. Engine Knocking
Unconfirmed Confirm
- 27 - MAJOR MAINTENANCE
8. Battery Discharge
Repair Replace
Normal
Normal Abnormal
Discharging
Disassemble
generator Voltage
regulator
MAJOR MAINTENANCE - 28 -
Condition Causes Remedies
1) Starting difficult
(1) Starting motor trouble • Refer to diagnostics
(2) Fuel system trouble • Refer to diagnostics
(3) Compression pressure lack • Valve’s poor shut, stem distortion Repair or replace
• Cooling
lowered
water pump’s function Repair or replace
• Water
poor
temp. regulator’s operation Replace
• Exhaust
increased
system’s resistance Clean or replace
- 29 - MAJOR MAINTENANCE
Condition Causes Remedies
5) Engine noisy 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
(2) Con-rod and • Lopsided wear of con rod bearing Replace bearing
Con-rod bearing
• Lopsided wear of crank pin Grind crankshaft
MAJOR MAINTENANCE - 30 -
Condition Causes Remedies
7) Oil Consumption
Excessive
(2) Oil level lowered • Looseness of valve stem & guide Replace in set
- 31 - MAJOR MAINTENANCE
2.3. Engine Inspection
After checking the engine for any unusual condition at the idling speed, then turn the key
switch to stop the engine.
* ( ) The engine oil change interval is determine by engine use and oil grade.
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 performances,
it may rather bring early engine failure
MAJOR MAINTENANCE - 32 -
3. DISASSEMBLY AND REASSEMBLY OF MAJOR COMPONENTS
3.1. Disassembly
• Before disassembly, provide parts racks for storage of various tools and disassembled parts.
• Arrange the disassembled parts in the disassembly sequence and use care to prevent any
damage to them.
CAUTION :
When removing radiator filler cap
while the engine is still hot, cover the
cap with a rag, then turn it slowly to
release the internal steam pressure
This will prevent a person from
scalding with hot steam spouted out
from the filler port.
Drain Valve
EA5O4002
EB8O3010
- 33 - ENGINE DISASSEMBLY
3.1.3. Engine oil
EQM3001I
EQM8020I
Engine harness
Water temp. Pre stroke
sensor sensor
ECU connector
1 2
Rack
sensor
Air heater Ne sensor
relay
EQM8004I
EQM3004I
ENGINE DISASSEMBLY - 34 -
3.1.6. V-Belt
Air con.
compressor
EQM8013I
Alternator
EQM8012I
EQM3007I
EQM3005I
- 35 - ENGINE DISASSEMBLY
3.1.9. Fuel filter
EQM3008I
3.1.10. Breather
3.1.11. Intercooler
EA6M2001
EQM3009I
ENGINE DISASSEMBLY - 36 -
3.1.13. Air heater
EQM3010I
NOTE :
Make sure to release the nuts one
after another because the exhaust
manifold will be removed if you
unscrew two nuts simultaneously.
- 37 - ENGINE DISASSEMBLY
3.1.17. Thermostat
• Disassemble
unscrewing
the
the
water
bolts
pipe
and
by
nuts
installed on the cylinder head.
EAMD014I
3.1.18. Starter
EAMD017I
EQM3022S
ENGINE DISASSEMBLY - 38 -
3.1.21. Fuel injection pump
NOTE :
Place the No.1 cylinder in ‘OT’ in exact EAMD021I
NOTE :
Do not interchange the shims as they
must be installed in their original
positions at reassembly
EAMD022I
- 39 - ENGINE DISASSEMBLY
3.1.24. Power steering pump
EQM3020S
EAMD025I
ENGINE DISASSEMBLY - 40 -
3.1.28. Fuel injection pump drive
• Remove the
steering pump.
dowel pin for the
EAMD027I
EAMD028I
EAMD029I
NOTE :
Do not disassemble the nozzle tube if
coolant or gas, etc. does not come
out during engine operation. EAMD030I
- 41 - ENGINE DISASSEMBLY
3.1.32. Cylinder head
EAMD031I
not be re-used.
EA0M4007
EQM3032I
ENGINE DISASSEMBLY - 42 -
3.1.36. Oil pump and pipe
EQM3034I
EAMD036I
EAMD037I
- 43 - ENGINE DISASSEMBLY
• Remove the piston pin snap rings,
take off the piston pin, then
disconnect the connecting rod from
the piston.
EAMD040I
ENGINE DISASSEMBLY - 44 -
3.1.42. Oil seal
EAMD043I
EAMD044I
- 45 - ENGINE DISASSEMBLY
3.1.46. Timing gear case
EAMD046I
EAMD047S
NOTE :
Do not mingle with the metal
bearings and bearing caps randomly. To prevent mixing, temporarily assemble the
metal bearings to the corresponding bearing caps in turn.
ENGINE DISASSEMBLY - 46 -
3.2. Inspection and Measurement
1) Clean the cylinder block thoroughly and make a visual inspection for cracks or damage.
2) Replace if cracked or severely damaged, and correct if slightly damaged.
3) Check oil and water flow lines for restriction or corrosion.
4) Make a hydraulic test to check for any cracks or air leaks.
Hydraulic test
Stop up each outlet port of water/oil passages in the cylinder block, apply air pressure of about
4kg/cm2 against the inlet ports, then immerse the cylinder block in water for about 1 minute to
check any leaks. (Water temperature: 70 ˚C)
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.
cylinder head.
Standard Limit
Thickness : t
114.95 ~ 115.0 mm 113.9 mm
(reference)
• 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.
1) Valve
Clean the valves with clean diesel oil, then inspect them as follows :
Intake
N10.950 ~ N10.970 mm N10.87 mm
valve stem
EFM2036I
Exhaust
N10.935 ~ N10.955 mm N10.84 mm
valve stem
Dimension
Standard Limit
Description
EFM2037I
EA0M4052
Standard Limit
Intake valve 0.04 ~ 0.07 mm 0.2 mm
Exhaust valve 0.06 ~ 0.09 mm 0.25 mm
• Install the valve into the cylinder head valve guide, then check and see if it is centered with
the valve seat using a special tool.
3) Valve seat
Valve depression
Standard Limit
EA0M4046
Intake & 0 ~ 0.03 mm 0.55 mm
Exhaust
- 49 -
INSPECTION & MEASUREMENT
• For removal of the valve seat, apply
arc welding work to two points of valve
Vavle seat
seat insert, and pull out the valve seat insert
insert with inner extractor.
•
Cylinder head
Undercool a new valve seat with dry
ice for about 2 hours and press the
valve seat insert into position in the
cylinder head using a special tool Welding bead EA3M2032
(bench press).
4) Valve spring
• Visual check
Visually check the exterior of the valve springs for damage, and replace if necessary.
• Functional check
- Measure free length and spring
tension with a valve spring tester. 1.0mm or less
(Refer to appendix)
- Measure the spring inclination with
Free length
Square
a square.
- Compare the measured value with
the standard value to determine
whether to replace or repair.
EFM2039I
Standard Limit
Limit 0.2 mm
EDM2037I
Standard Limit
N23.978 ~ N23.959 mm N23.75 mm
EA8M3002
2) Rocker arm
• Visual check
Visually check the face of the rocker arm in contact with the valve stem end for scores and
step wear. If the wear is small, correct it with an oil stone or grinding paper of fine grain size.
Rocker arm with a considerable amount of step wear should be replaced.
• Diameter
bushing
of the rocker arm
EA0M4059
<Clearance>
Standard Limit
0.020 ~ 0.093 mm 0.2 mm
• Clearance
Measure the clearance of the tappet and tappet holes of the cylinder block. If the value is
beyond the specified limit, replace tappets.
Abnormal
EA0M4070
• Outside diameter
With an outside micrometer, measure
the tappet outside diameter If the
measured value is beyond the limit,
replace tappets.
Standard Limit
Tappet
0.035 ~ 0.077 mm 0.15 mm
clearance
feeler gauge
EA0M4073
1) Cam
EA0M4062
Cam journal
diameter (A,B) N59.86 ~N59.88 N59.52
• Cam surface
Inspect the cam face for scratch or damage.
• Slight step wear or damage on the cam face may be corrected with oil stone or oiled grinding
paper. But, replace if severely damaged.
2) Cam shaft
• Clearance between
journal and camshaft bush
camshaft
<Clearance>
Standard Limit
0.05 mm 0.2 mm
EA0M4066
Feeler gauge
Standard Limit
EA0M4067
0.13 ~ 0.27 mm 0.30 mm
1) Defect check
• Visually check the crankshaft journal and crank pins for scores or cracks.
• Using a magnetic particle test and color check, inspect the crankshaft for cracks, and
replace the crankshaft which has cracks.
2) Wear
EAMD057I
Standard Limit
Journal diameter N 95.966 ~ N 95.988 N 94.966 mm
Pin diameter N 82.966 ~ N 82.988 N 81.966 mm
• Standard
• 0.25 (Inside diameter is 0.25 mm lesser than the standard size.)
• 0.50 (Inside diameter is 0.50 mm lesser than the standard size.)
• 0.75 (Inside diameter is 0.75 mm lesser than the standard size.)
• 1.00 (Inside diameter is 1.00 mm lesser than the standard size.)
Undersize bearings are available in 4 different sizes as indicated above, and the
crankshaft can be reground to the above sizes.
NOTE :
When regrinding the crankshaft as
described below, the fillet section ‘R’ "R"
should be finished correctly. Avoid
sharp corners or insufficient fillet.
"R"
3) Crankshaft run-out
Standard Limit
0.1 mm 0.15 mm
1) Visual check
• Visually check the crankshaft bearing and connecting rod bearing for scores, uneven wear
or damage.
Torque 30 kg.m
Standard Limit
0.072 ~ 0.142 mm 0.25 mm
Torque 28 kg.m
Standard Limit
0.049 ~ 0.119 mm 0.20 mm
EAMD060I
• Inspection
Check to see that the bearing
requires a considerable amount of
finger pressure at reassembly
operation.
OA OB
Spread = O A - O B
EDM2047I
• Assemble the
cylinder block.
crankshaft to the
• With a dial
crankshaft end play.
gauge, measure
Standard Limit
0.15 ~ 0.325 mm 0.5 mm
3.2.8. Piston
1) Visual check
• Visually check the pistons for cracks, scuff or wear, paying particular attention to the ring
groove.
EAMD066I
Standard Limit
EAMD067I
N 123 ~ N 123.023 mm N 123.223 mm
• The clearance is computed by subtracting the piston outside diameter from the cylinder liner
inside diameter. Replace either piston or cylinder liner, whichever damaged more, if the
clearance is beyond the specified limit.
1) Visual check
Replace the piston rings with new ones if detected worn or broken when the engine is
overhauled.
Standard Limit
Top ring 0.30 ~ 0.45 mm 1.5 mm
2nd ring 0.35 ~ 0.50 mm 1.5 mm
DE12/T/TI 0.30 ~ 0.50 mm
Oil ring 1.5 mm
DE12TIS 0.40 ~ 0.70 mm
• Replace piston rings with new ones if the gap is beyond the limit
•
feeler
With a feeler gauge, measure side gauge
clearance of each ring, and replace
either the ring or piston if the
measured value is beyond the
specified limit.
Standard Limit
EA0M4032
Top ring -
2nd ring 0.07 ~ 0.102 mm 0.15 mm
2nd ring 0.05 ~ 0.085 mm 0.15 mm
• Replace the piston ring if the measured value is beyond the limit.
Standard
Top ring 2.27 ~ 3.41 kg
2nd ring 2.0 ~ 3.0 kg
Oil ring 4.03 ~ 5.57 kg
1) Wear
Standard Limit
N 44.995 ~ N 45.0 mm N 44.990 mm or less
EA0M4031
2) Clearance
Limit 0.011 mm
3) Condition check
•
EA3M2047
Check the engaged condition of the
piston and piston pin. If it is possible
to force the pin into the piston heated with piston heater, the piston is normal.
When replacing the piston, be sure to replace the piston pin together.
1) Distorsion
• As shown in the figure below, install the connecting rod to the connecting rod tester, and
check for distortion using a feeler gauge.
• If the connecting rod is found distorted, never re-use it but replace with a new one.
Standard Limit
0.05 mm 0.1 mm or less
feeler
gauge
EA0M4034
• Assemble the connecting rod to the crankshaft and measure connecting rod big end side
clearance using a feeler gauge.
• Assemble the connecting rod to the piston and measure connecting rod small end side
clearance.
• If the measured values are beyond the limit, replace the connecting rod.
Limit 0.5 mm
B
(Projection of nozzle) 3.4 ~ 3.5 mm 2.4 ~ 2.5 mm
EQM8010I
• Wash clean all the disassembled parts, particularly oil and water ports, using compressed
air, then check that they are free from restrictions.
• Arrange the general and special tools in order for engine assembly operation.
• Discard used gaskets, seal rings, and consumable parts, and replace with new ones.
• Apply only the specified torque for bolts in the specified tightening order and avoid over-
tightening.
• Be sure to check that all the engine parts operate smoothly after being reassembled.
• After completing the engine reassembly operation, check if there is missing parts or
shortage of parts.
• Cover the floor of the workshop with wood plate or thick paper to prevent damage to the
cylinder head and place the cylinder block with the head fitting surface facing downward.
EDM3053I
ENGINE REASSEMBLY - 62 -
• Apply engine oil to the entire face of
the tappets and slide them into the
tappet holes on the cylinder block.
EDM2060I
3.3.5. Crankshaft
EA0M4083
EA8M3014
- 63 - ENGINE REASSEMBLY
• Semi-tighten a bolt at both sides of
the crankshaft, apply engine oil to
journals and pins, then assemble the
crankshaft with the cylinder block by
tightening the fixing bolts.
EAMD077I
7 6 5 4 3 2 1
EAMD078I
ENGINE REASSEMBLY - 64 -
• Apply oil to the entire part of the
bearing cap bolts, then tighten in
tightening sequence to specified
torque.
Torque 30 kg.m
Torque 12 kg.m
EAMD043I
- 65 - ENGINE REASSEMBLY
3.3.8. Flywheel
Torque 18 kg.m 6 1
2 5
7 3
EAMD097I
Flywheel
Housing
Tolerance
limit
27
27
27
0
EPM2031I
ENGINE REASSEMBLY - 66 -
3.3.10. Timing gear case
EAMD082I
EA8M3004
•
Mark “0”
Check and adjust the amount of
backlash between gears using a EA8M3005
feeler gauge.
- 67 - ENGINE REASSEMBLY
3.3.12. Fuel injection pump drive gear
EAMD027I
3.3.13. Timing gear case cover
ENGINE REASSEMBLY - 68 -
3.3.16. Piston and connecting rod
EAMD088I
- 69 - ENGINE REASSEMBLY
• Identify the mark “Y” or “TOP” on the
ring end to prevent the top and bottom
of the piston ring from being
interchanged and make the marked
portion face upward.
EAMD090I
•
90
O
Torque 28 kg.m
ENGINE REASSEMBLY - 70 -
• Move the bearing cap with hand, and
release and reassemble it if no
movement is detected.
EAMD094I
EAMD036I
- 71 - ENGINE REASSEMBLY
3.3.20. Oil pan
EQM3076I
EB5M3019
EA0M4007
ENGINE REASSEMBLY - 72 -
3.3.22. Nozzle tube
EAMD098I
- 73 - ENGINE REASSEMBLY
• Install the spring, rocker arm, bracket,
rocker arm, spring, washer, and snap
ring in the described sequence.
EA8M3008
TY TY
Use bolt
12.9T 10.9T
•
TOP
ENGINE REASSEMBLY - 74 -
• Coat the head bolts with engine oil,
then tighten them in proper sequence
to the specified torque.
TY TY
Type 12.9T 10.9T
EAMD102I
•
1 4
Adjust the valve clearance as
following guide. 11 14
7 6 5 10
EAMD103I
• After letting the #1 cylinder’s piston come at the compression top dead center by turning the
crankshaft, adjust the valve clearances.
• Loosen the lock nuts of rocker arm adjusting screws and push the feeler gauge of specified
value between a rocker arm and a valve stem and adjust the clearance with adjusting screw
respectively and then tighten with the lock nut.
DE12
DE12T
0.3 mm 0.3 mm
DE12TI
DE12TIS
- 75 - ENGINE REASSEMBLY
• No. 1 Cylinder is located at the side where flywheel was installed.
1 2 3 4 5 6
EA8O6001
specified torque.
• EA8M3007
Install the dust seal with its round
portion facing downward.
EQM3084I
ENGINE REASSEMBLY - 76 -
3.3.27. Oil cooler
EAMD106I
•
EAMD107I
Mount the top/bottom adjusting shims
in the bracket and then mount the fuel
injection pump.
- 77 - ENGINE REASSEMBLY
• Turn the flywheel until No. 1 piston is
placed in the “OT” position of notch
Timing
Check hole
marks on the flywheel, and then turn
again the flywheel clockwise until
showing the notch mark of the right
figure corresponding to the injection
Flywheel
timing is aligned with the pointer ( ) on Injection timing Ring gear
Notch mark
the flywheel housing
Notch mark
EB8O5005
EB8O5005
EQM3020S
ENGINE REASSEMBLY - 78 -
3.3.31. Vibration damper and pulley
• Connect a
expansion tank.
water pipe to the
EAMD112I
- 79 - ENGINE REASSEMBLY
3.3.35. Exhaust manifold
• Semi-assemble
manifold and
the
install the
exhaust
heat
resisting plate.
3.3.36. Turbocharger
EQM3012S
EA8M3012
3.3.38. Starter
EAMD121I
ENGINE REASSEMBLY - 80 -
3.3.39. Intake manifold
•
EQM3009I
Assemble the fuel return hose on the
fuel injection pump.
EAMD120I
EQM3008I
- 81 - ENGINE REASSEMBLY
3.3.42. Cylinder head cover
EQM3104I
3.3.44. Alternator
• Install
bracket.
the alternator mounting
EQM3106I
ENGINE REASSEMBLY - 82 -
3.3.46. V- belt
EQM8013I
Alternator
EQM8012I
EQM3108S
EQM3005I
- 83 - ENGINE REASSEMBLY
3.3.49. Engine control unit : DE12TIS
EQM8020I
Rack
sensor
Air heater Ne sensor
relay
EQM8004I
ENGINE REASSEMBLY - 84 -
3.4. Breaking-In
Because the sliding surfaces of a new engine are not lapped enough, the oil film can be
destroyed easily by overload or overspeed and the engine life-time may be shortened.
Therefore the following things must be obeyed by all means.
• Engine should be run at fast idling until the temperature of the engine becomes normal
operating condition.
During the break-in (the initial running of the engine) period, be particularly observant as
follows :
a) Check engine oil level frequently. Maintain oil level in the safe range, between the “min.” and
“max.” marks on oil level gauge.
NOTE :
If you have a problem getting a good oil level reading on oil level gauge 180˚ and re-
insert for check.
b) Watch the oil pressure warning lamp. If the lamp blinks, it may be the oil pick-up screen is
not covered with oil. Check oil level gauge oil to the oil pan, if required. Do not overfill. If level
is correct and the status still exists, see your DEALER for possible switch or oil pump and
line malfunction.
NOTE :
Oil pressure will rise as RPM increases, and fall as RPM decreases. In addition, cold oil
will generally show higher oil pressure for any specific RPM than hot oil. Both of these
conditions reflect normal engine operation.
c) Watch the engine water temperature gauge and be sure there is proper water circulation.
The water temperature gauge needle will fluctuate if water level in expansion tank is too low.
At the end of the break-in period, remove break-in oil and replace the oil filter cartridge. Fill
oil pan with recommended engine oil. Refer to following table.
- 85 - BREAKING-IN
<Engine Oil capacity>
in Oil pan
Engine
Model Total (lit) API No.
model Max. (lit) Min. (lit)
DE12
Bus API CD grade
DE12T 17 14 21 or
Truck above CE grade
DE12TI
ACEA-E2
or
DE12TIS Bus 17 14 21
ACEA-E3
(API CH-4)
* If long oil change intervals are to be used, ACEA-E3 oil must be used.
BRAKING-IN - 86 -
4. MAINTENANCE OF MAJOR COMPONENTS
4.1. Cooling System
This engine is water-cooling type. Heat from the combustion chamber and engine oil heat are
cooled down by coolant and radiated to the outside, resulting in the normal operation of the
engine.
Looking into the cooling system, the water pumped up by the water pump circulates around
the oil cooler through the water pipe to absorb the oil heat, and then flows through the water
jacket of the cylinder block and water passage of the cylinder head to absorb the heat of the
combustion chamber.
The water absorbing the oil heat and combustion chamber heat goes on to the thermostat
through the water pipe, and circulates to the water pump if water temperature is lower than the
valve opening temperature on the thermostat, while circulating to the radiator at water
temperature higher than the valve opening temperature. At the radiator, the heat absorbed in
the coolant is radiated to cool down and the coolant recirculates to the water pump.
Cylinder head
Radiator
Cylinder block
Air compressor
EQM4001I
• Specification
Description Specification
1. Water pump Type Centrifugal type
Delivery About 350 liter/min
Pumping speed 2,100 rpm
Pumping back pressure 760 mmHg
2. Thermostat Operating temperature 83 ~ 95°C
Fan diameter - Number of blades l700 mm - 9 or l700 mm - 8
3. Cooling fan and belt
Fan belt tension 15 mm / deflection by thumb
• Heat the impeller (5) slightly, then remove it using a puller jig.
• To reassemble the impeller, maintain a constant gap (0.3 ~ 0.6 mm) between the impeller
and pump housing using a feeler gauge.
Thickness
EQM8001I
Specification
Item
In moderate climates In tropical climates
Type Wax-pallet type Wax-pallet type
Open at 83 °C 71 °C
Open wide at 95 °C 85 °C
Valve lift 8 mm or more Truck : 8 mm or more
NOTE :
There are 2 kinds of thermostats according to surrounding and operating conditions.
One is named by 71 °C type and the other is 83 °C.
• Inspecting
(1) Check the wax pallet and spring
for damage.
(2) Put the thermostat in a container of Ruler
Thermometer
water, then heat the water slowly
and check temperature with a
thermometer. If the valve lift is 0.1 Woodplate
mm (starting to open) at
temperature of 83 °C and 8 mm or
more (opening wide) at EFM2055I
temperature of 95 °C, the
thermostat is normal.
spring weakened
correctly
gasket
weakened
connected or broken
cracked
• General descriptions
All the engine oil pumped up from the oil pan by the gear type oil pump is filtrated through
the oil cooler and oil filter, and this filtrated oil is forced through the main oil gallery in the
cylinder block from where it is distributed to lubricate the various sliding parts, and fuel
injection pump in order to ensure normal engine performance.
• Specifications
Rocker arm
Cam shaft
Piston
Air compressor
Water pump
bearing
Turbocharger
EQM4
EQM4005I
• Disassembly
(1) Disassembly of oil pump drive gear
a. Unscrew the screw and
disassemble the oil relief valve.
b. Unfold the washer for the oil
pump drive gear fixing nut and
remove the nut.
c. Disassemble the drive gear.
EQM4006I
EQM4007I
EQM4008I
EQM4009I
b. Measure the inside diameter of the pump body bushing to determine the clearance
between the bushing and shaft, and compare the measured value with the standard
value to determine whether to replace or not.
• Reassembly
(1) For reassembly, reverse the disassembly sequence.
ClearanceThe oil filter mounted in this engine is of cartridge type, so it is necessary to replace
it with a new one at the specified intervals.
EQM4010I
2 3 4 8
1
7
5 6
10
9
11
EQM8002I
Harness
Engine control unit(ECU)
Connector Function
color
Signal name Pin no. pin no.
MEMORY CLEAR
39 - - Engine control unit memory clear switch
SW
CRANK REQ. 40 - Engine cranking signal
GND 42 - - Tachometer gauge ground (-)
A/H LAMP 44 - - Air heater lamp
DIAG LAMP 45 - - Diagnostic lamp
46 - - Engine control unit chassis ground (GND)
ECU GROUND(-) 47 - - Engine control unit ground (-)
ECU GROUND(-) 48 Engine control unit ground (-)
VEHICLE
ENGINE
SIDE
SIDE
C
U
E
EQM8015I
ENGINE
SIDE
VEHICLE
HARNESS
E
VECHILE
INTER CONN.
U VEHICLE
SIDE
BATTERY
EQM8014I
25 12 20
24 11
300
23 10 150
22 9
21 8
20 7
3 X ROCK SENSOR
19 6
1 2 AMP 174257 - 2
18 5
17 4 ENGINE CLAMP POSITION
200
16 3 (F.W.H BREATHER HOSE CLAMP BOLT)
15 2 15
0
14 1
- 100 -
DESCRIPTION CONNECT REMARK
FUNCTION PIN NO. WIRE DIA. MATERIAL CONNECTOR PIN NO. HARNESS CONNECTOR
PRESTROKE ACTUATOR (+) 14 0.85 Y TERLON 5
PIN NO. 14, 1 TWIST
PRESROKE ACTUATOR PRESTROKE ACTUATOR (-) 1 0.85 W TERLON 6
PIN NO. 14 1 SHILD
SHILD WIRE 1 SHILD TERLON
PRESROKE SENSOR 6 0.5 Br AEXBS KOREA LAMP 1 KOREA LAMP
PRESROKE SENSOR (SIG) 7 0.5 Br AEXBS 174264 - 2 2 174264 - 2
PIN NO. 6, 19 SHILD
PRESROKE SENSOR PRESROKE SENSOR (-) 18 0.5 L/R AEXBS 3
PIN NO. 7 SHILD
SHILD WIRE 18 SHILD AEXBS
PRESROKE SENSOR (SHILD) 20 SHILD AEXBS 4
ROCK SENSOR (+5V) 8 0.5 W/Y AEXBS 2
ROCK SENSOR (SIG) 9 0.5 B AEXBS KOREA LAMP 3 KOREA LAMP
RACK SENSOR PIN NO. 8, 9, 21 SHILD
ROCK SENSOR (-) 21 0.5 L AEXBS 174259 - 2 1 174257 - 2
SHILD WIRE 21 SHILD AEXBS
AIR HEATER RELAY AIR HEATER RELAY 12 0.85 R/W AVS KET NO. MO620040 1 KET NO. MC610041
COOLANT WATER RELAY COOLANT WATER SENSOR (SIG) 5 0.5 Y/R AVS 1
AMP 85202 - 1
(AIR HEATER) COOLANT WATER SENSOR (GND) 24 0.5 R/Y AVS 2
NE (PICK-UP SENSOR (SIG) 10 0.5 W/L AEXBS 2
KOREA LAMP KOREA LAMP
NE (PICK-UP) SENSOR NE (PICK-UP SENSOR (GND) 23 0.5 R/G AEXBS 3 PIN NO. 10, 23 SHILD
174359 - 2 174357 - 2
NE (PICK-UP SENSOR (SHILD) 23 SHILD AEXBS 1
EQM8003I
4.3.3. Engine electrical components (Fuel injection pump)
EA2M4002
Connect Actuator
Harness
terminal terminal Remarks
color
no. no.
1 4 Green Actuator drive(-)
2 5 Yellow Actuator drive(-) EA2M4004
Black/
3 GND Actuator drive(-)
white
Pre stroke
4 3 Black
sensor (GND)
Pre stroke
5 2 White
sensor (signal)
Pre stroke
6 1 Blue
sensor (OSC)
Terminal Harness a)
resistance(a
Red(OSC) ~
2 and 3
White(MDL)
EA2M4005
Black(GND) ~
1 and 3
White(MDL)
Black(GND) ~
1 and 2
Red(OSC)
Terminal Harness a)
Resistance(ka
Yellow(SIG) ~
2 and 3 2.1 ~ 2.5
Black(GND)
EQM4065I
• Temporarily tighten
actuator’s five bolts.
the pre-stroke
NOTE :
EA2M4007
When installing the actuator, turn it as far
as possible clockwise (viewed from the
drive side) to facilitate later adjustment.
EA2M4008
EA2M4009
c)
Temperature (c a)
Resistance(ka
20 2.27 ~ 2.73
40 1.059 ~ 1.281
60 0.538 ~ 0.650
EB808006
80 0.322 ~ 0.298
5V OUT
PS OUT
RACK OUT
POWER
RTD ADV
NORMAL
EA2M4011
EA2M4012
CAUTION :
Leave the power switch OFF to
prevent the pre-stroke actuator from
overheating.
EA2M4013
EA2M4015
• Turn the target dial, and adjust the rack sensor output to 3 -0.02 V.
• Turn the pump test stand’s flywheel and confirm that the NO 1 cylinder’s pre-stroke does not
exceed 3.4 mm.
If the above results cannot be obtained, repeat all procedures from “Timing rod assembly”.
NOTE :
The values at left are only examples.
Refer to the data sheet.
EA2M4018
EA2M4017
NOTE :
When the sleeve flange is turned as
shown in the figure at left (right helix
EA2M4021
plunger), the injection quantity
increases.
EA2M4023
EA2M4024
EA2M4025
NOTE :
If not as specified, add or remove
shims until it is as specified.
EA2M4026
NOTE :
Before installing the bobbin in the
joint, apply grease to the 0-ring.
EA2M4027
• Read the specified output voltage and the specified rack position from the rack position, voltage
graph in the calibration data.
EA2M4028
NOTE :
The values at left vary with the pump.
Refer to the data sheet at adjustment,
EA2M4029
EA2M4030
• When a SFC code is set, the ECU will illuminate the malfunction indicator lamp on the
instrument panel and save the code in memory.
• The system fault codes can be read by using either the malfunction indicator lamp or a
SCAN 200.
• The ECU system has built-in diagnostics for trouble shooting. The system has a dash
mounted malfunction indicator lamp for indication of system problems.
• Engine control system related problems that affect emissions or drive ability of the
vehicle will set a system fault code and illuminate the malfunction indicator lamp.
• System Fault Codes can be cleared from memory with a SCAN 200 or by turning the
ignition key to the ON position and operating the memory clear switch pin no. 39.
2) SCAN 200
Inspect the electrical parts problem with SCAN 200 and refer diagnostic manual.
Diagnosis
port
EA2M5001 HA2M5001
Pause
1 sec 1 sec 0.5 sec 3 sec
Key-on
Key-off
0.5 sec
EQM8016I
Key-on
Key-off
0.5 sec
EQM8017I
No
No
No
Does SCAN 200 display Yes 1) Check the contact of ECU connector.
voltage more than 24 ? 2) Inspect the ECU or require after service.
No
Does SCAN 200 display Yes 1) Check the contact of ECU connector.
resistance 400~600 ? 2) Inspect the ECU or require after service.
No
Does SCAN 200 display Yes 1) Check the contact of ECU connector.
resistance correct ? 2) Inspect the ECU or require after service.
No
No
No
1) This fault code occur initial can not engine starting in 2.5sec
No
Yes ECU
2) Probe the NE pick-up sensor voltage more than
0.6 at between pin No. 10 and pin No 23
1) Refer to the fault code No. 16 at NE pick-up sensor.
Yes
The fuel system consists of the fuel tank, injection pump, injection nozzle, fuel filter, and fuel
lines such as pipes and hoses necessary to connect those components.
1 2 5
4
3 7
1a
12
10
9 11
EQM4011I
The components relating to the injection pump should be serviced at regular intervals as the
plunger and delivery valve may be worn after a given length of time for use and cause the
deterioration of the engine.
Make sure that servicing should be performed at the professional maintenance shop as
authorized by Bosch or Zexel Company.
For adjustment of fuel injection volume, refer to the ‘Specifications of fuel injection pump’
described on the following pages.
(A) Test condition for Nozzle & Holder ass’y 105160-4361 Opening pressure :175 bar
Fuel injection pump Fuel Injection pipe (IDBOD-L) - N2.0 B N6.0 - 650 mm
Test oil ISO4113 Temperature :40 L 5 C
(B) Engine standard 65.10101-7296 Nozzle (5 B N0.29)
Nozzle & holder ass’y
parts 65.10102-6045 Opening pressure : 220 kg/cm2
65.10301-6151
Fuel Injection pipe (IDBOD-L) N1.8 B N6 - 550 mm
65.10301-6152
Rack diagram and setting valve at each point
Injection Q`ty on RIG
Rack Pump
RACK LIMIT CR=9.5 –0.05
Check (mm3 / 1,000st) Pressure
position speed
E
A
point (mmHg)
(mm) (rpm) Test condition for inj. pump
B
9.4
8.9
8.4
6.7
or more
EQM4012I
E - 100 100 or more -
(B) Test condition for Nozzle & Holder ass’y 105160-4361 Opening pressure :175 bar
Fuel injection pump Fuel Injection pipe (IDBOD-L) - N2.0 B N6.0 - 650 mm
Test oil ISO4113 Temperature :40 L 5 C
(B) Engine standard 65.10101-7296 Nozzle (5 B N0.29)
Nozzle & holder ass’y
parts 65.10102-6045 Opening pressure : 220 kg/cm2
65.10301-6151
Fuel Injection pipe (IDBOD-L) N1.8 B N6 - 550 mm
65.10301-6152
Rack diagram and setting valve at each point
RACK LIMIT
Injection Q`ty on RIG
Rack Pump
Check (mm3 / 1,000st) Pressure
position speed
point (mmHg)
(mm) (rpm) Test condition for inj. pump
B
12.3
12.1
12.0 A
11.3
C
Rack position (mm)
A 12 700 99 L 2 -
10.5
or more
B 12.3 1,100 95 L 3 -
8.1 - 00.1
6.5 +- 0.1
C 11.3 500 81 L 2 -
250 380 500 +- 15 700 1100 1210 D 8.5 250 145 L 1.5 -
290 (1120)
EQM4013I E - 100 95 L 3 -
(C) Test condition for Nozzle & Holder ass’y 105160-4351 Opening pressure :175 bar
Fuel injection pump Fuel Injection pipe (IDBOD-L) - N2.0 B N6.0 - 650 mm
Test oil ISO4113 Temperature :40 L 5 C
(B) Engine standard 65.10101-7300 Nozzle (5 B N0.31)
Nozzle & holder ass’y
parts 65.10102-6046 Opening pressure : 220 kg/cm2
65.10301-6151
Fuel Injection pipe (IDBOD-L) N2.2 B N6.0 - 650 mm
65.10301-6152
Rack diagram and setting valve at each point
5.2
5.2
D
B 10.9 1,100 152 L 3 -
3.9
C - 500 (97 L 2) -
250 380 390-10 500–15 680+20 1150+20 1205–5 D 5.2 250 14.5 L 1.5 -
1170
Injection pump speed (rpm)
EQM4014I
E - 100 100 or more -
600
Rack position (mm)
E
7.1
600
A 9.2 1,050 154 L 2
Rack position (mm)
R2+1.5 or more
(R2-3.6)–0.5
C - 100 100 -
Pressure
position speed
point
0.5–0.1
(mmHg)
D
R1
C
A
(mm) (rpm) Test condition for inj. pump
Rack position (mm)
600
A R1 1,050 171 L 2
R2+1.5
or more
B
I
13.6
101
10.25
A 14.5 630 166 L 2
or more
101
B 15.4 1050 (159 L 3)
or more
200 630 1050 1190
B
15.4
A
14.5
Rack position (mm)
I
13.6
10.25
EQM8022I
I
12.2
101
A 15.0 630 181 L 2
10.25
or more
101
B 15.9 1050 (171 L 3)
or more
100 630 1050 1190
B
15.9
A
15.0
Rack position (mm)
I
12.2
10.25
EQM8023I
I
13.3
10.25 101
A 15.2 630 196.5 L 2
or more
101
B 16.1 1050 (183 L 3)
or more
100 630 1050 1190
B
16.1
A
15.2
Rack position (mm)
I
13.3
10.25
EQM8024I
I
13.45
103
A 15.7 630 207 L 2
10.25
or more
103
B 16.6 1050 (192 L 3)
or more
100 630 1050 1190
B
16.0
A
15.7
Rack position (mm)
I
13.45
10.25
EQM8025I
Priming pump
Check valve
Check valve
Inlet Outlet
side side
Tappet
Piston
Cam shaft
EQM40
EQM4019I
EQM4020I
The fuel pressurized as the cam rotates on flows through the check valve on the outlet side as
shown in (B). If the feeding pressure increases abnormally, the spring is compressed, resulting in
interrupting further delivery of fuel as shown in (C).
This feed pump is mounted with a priming pump designed to permit manual feeding of fuel from
the fuel tank with the injection pump mounted in the engine. During the manual feeding operation,
air must be bled from the fuel lines.
When using the priming pump, fix it securely to prevent the possible entry of moisture or other
foreign substances in the inside of feed pump.
In addition, a strainer is fitted into joint bolt on the inlet side of the fuel feed pump to filtrate any
foreign substances possibly mixed in fuel.
2) Disassembly
• Take off the priming pump (25), plug (16), both gaskets (18), spring (15), and check valve (14).
• Take off the prig (7), gasket (8), spring (6), and piston (5) on the piston side.
• Pull out the snap ring (20) holding the tappet (10).
• Disassemble the snap ring, then take off the tappet (10) and push rod (1).
3) Inspection
• If the check valve is damaged or scored on its seat face, replace it with a new one.
• Replace the push rod if excessively worn, and replace together with the pump housing if
required. The inspection for wear should be performed in the same procedure as for suction
pressure test described below.
4) Reassembly
Reassembly operation is performed in reverse order of disassembly. All the gaskets must be
replaced with new ones at reassembly.
NOTE :
Check the item no. 30 before assembling it whether it is the fuel strainer bolt.
Clean it when fuel filter cartridge is replaced.
5) Testing
(1) Suction capacity test
Connect one end of a hose to the inlet
Outlet hose
side of the feed pump and immerse the
other end of it into the fuel tank as
Feed pump
illustrated.
Hold the feed pump in position about 1 m
above the level of fuel in the fuel tank.
Operate the tappet at the rate of 100 rpm
Inlet hose
and check to see if fuel is drawn in and
delivered for 40 seconds or so.
Fuel tank
EQM4022I
EAMC016I
Feed pump
EQM4023I
EQM4024I
EQM4024I
1. Cap nut
2. Adjusting screw
3. Spring
4. Push rod
5. Connector
6. Retaining nut
7. Needle valve
8. Nozzle
9. Nozzle holder
EQM4025S
(2) Reassembly
EQM4026S
(3) Adjustment
EAMC022S
(1) Disassembly
31
1. Nozzle holder body
30
2. Push rod 2
3. Primary spring
7
4. Adjusting screw 1
6. Gasket 6
7. Cap nut 4
10. Adjusting shim
10
11. Secondary spring
11
12. Spring seat 12
3
13
13. Lift pin
15 14
14. Pin 16
15. Spacer A
16. Pin
17. Retaining nut
17
30. Gasket
31. Eye bolt
EQM4029I
EQM4
A. Nozzle
NOTE :
Use the plate assembly (157944-
9520) in fixing a nozzle holder having
a flange. A nozzle holder without
flange should be directly installed
EQM4030I
onto a vise.
EQM4031I
EQM4032I
EQM4033I
A
16
EQM4034I
NOTE :
While tightening the cap nut, keep
checking to see if the lock pin comes
all the way into the nozzle.
NOTE :
Tighten the retaining nut until it
resists hand tightening, then further
tighten it using a torque wrench.
EQM4036I
(2)
80
20
1010). 0
100
EQM4039I
EQM4040I
EQM4041I
EQM4042I
NOTE : EQM4045I
NOTE 1 :
Fix the dial gauge so that a stroke of
2 mm or so can be measured.
NOTE 2 :
Overtightening the nut may cause a
sticking of the dial gauge seat.
EQM4046S
NOTE :
This testing is to be made in order to
check the nozzle seat portion for
unusual wear or whether the nozzle 0
Tester pressure EQM4048I
assembly is a standard item.
kgf / cm 2
EQM4049I
Amount of lift
0
Tester pressure EQM4050I
EQM4051I
NOTE :
Locate the point of primary opening
pressure + approx. 10kgf/cm2 while
dropping the pressure.
0
Primary opening pressure
Tester pressure EQM4050I
EQM4052I
EQM4053I
Amount of lift
the needle valve.
b. Release the nozzle tester handle to +0.05
0 80
100
0
EQM4055I
0
90 300
10 200
80
20 100 400
70
30
500
0
60
40
50
EQM4056I
7
Torque 6.0 ~ 8.0 kg.m
EQM4036I
Inspection at completion
a. Assemble the nozzle holder to a nozzle
tester and check the primary opening
60
40
80
20
EQM4039I
A
NOTE :
If only a nozzle is replaced, the amount of
pre-lift will deviate from the specified
value. EQM4060I
Air pressure
at compressor Approx. 1.15 kg/cm2 Approx. 1.2 kg/cm2 Approx. 1.3 kg/cm2
At outlet
maximum Approx. 20.0 Approx. 22.0 Approx. 22.5
Air suction volume
output m3/min m3/min m3/min
Speed of turbine
Approx. 90,000 rpm Approx. 96,000 rpm Approx. 94,000 rpm
revolution
Max. allowable
temperature of exhaust 750 C 750 C 750 C
gas at turbine inlet
Lubricating system External oil supply External oil supply External oil supply
Weight 14 kg 14 kg 14 kg
2) Operating principle
Oil inlet
Turbine wheel and
shaft assembly Compressor
housing
Exhaust pipe
Exhaust gas discharge Fresh air inlet
EAOM8001
The turbocharger is a system designed to make use of the engine exhaust gas energy to
charge high-density air into the cylinders, thereby to increase the engine output.
16
4
15
11
1
2
10
6
18
17
3
5
13
14 12
23
24
25,26 23
21
20
9
8
23
24
22
19
EQM8026I
The engine output is determined by the fuel delivery volume and engine efficiency.
To burn the supplied fuel completely to change into effective power for the engine, the volume
of air enough to burn the fuel completely should be supplied into the cylinders.
Therefore, the engine output is determined substantially by the cylinder capacity, and a greater
volume of compressed air is charged into cylinders of given capacity, the greater engine output
can be obtained as a greater volume of air charged into the cylinders burns so much more fuel.
As explained, the compressing of air to supply into the cylinders is called “Supercharging” and
the making use of the energy of exhaust gas discharged from the combustion chamber to
charge the compressed air into the cylinders is called “Turbocharging”.
4.5.3. Functions
1) Turbine
Exhaust gas discharged from the combustion chamber distributes its own energy to the
turbine blades while passing the inside of the turbine housing, with the result that the turbine
shaft can get rotating force. This is the operating principle of ‘turbine’, which is mounted with
seal rings and heat protector to prevent exhaust gas from affecting the bearings adversely.
2) Compressor
The compressor, which is connected to the turbine over the one and same shaft to form a
rotating body, takes in and compresses ambient air with rotating force transmitted from the
turbine shaft. Then, the compressed air is delivered to the intake stake. This is the operating
principle of the compressor.
3) Bearings
(1) Thrust bearing
The turbine wheel creates thrust force. Therefore, exercise care so that the shaft is not
deviated from its the original position due to this thrust.
(2) Journal bearing
This journal bearing of floating type forms a dual oil film on both the inside and outside
of the bearing so that the bearing can rotate independently. As the dual oil film plays a
role as a damper, the sliding speed of the bearing surface becomes lower than the
rotating speed of the shaft, resulting in assurance of stability in its movement.
4) Sealing-Compressor shaft
The compressor is of a dual construction type composed of seal plate and seal ring to
prevent the leak of compressed air or lubricating oil.
Immediately 1) Run the engine at idle for 5 1) Applying load abruptly If load is
after starting minutes after starting off. abruptly applied with the engine
and turbocharger rotating
unsmoothly, such parts that a
sufficient amount of oil has not
reached can be seized up.
2) Check each part for leakage of oil, 2) Leakage of oil, gas, and air
gas, and air, and take proper (especially, oil leak) causes drop in
measure. oil pressure and loss of oil results
in seizure of the bearing.
During operation Check the followings:
1) Oil pressure At idle: 0.8 kg/cm2 or 1) Excessively low oil pressure
more At full load: 3.0 ~ 4.8 kg/cm2 causes unusual wear or seizure of
the bearing. Too high pressure
2) If unusual sound or vibration is causes oil leakage.
heard or felt, reduce engine 2) The engine is operated continuously
revolutions slowly and locate the with unusual sound or vibration not
cause. corrected, it can be damaged
beyond repair.
When stopping 1) Run the engine at idle for 5 1) If the engine is put to a stop after
the engine minutes before stopping. being operated at high load, heat
from the red-hot turbine blades is
transmitted to the bearing portion
and burns oil to cause seizure of the
bearing metal and rotating shaft.
As the condition of turbocharger depends greatly on how well the engine is serviced, it is very
important to maintain the engine in accordance with the specified maintenance procedure.
1) Intake system
Pay particular attention to the air cleaner when servicing the intake system.
In the case of wet-type air cleaner, if the level of oil surface is lower than specified, cleaning
effect is poor; if too high, the cleaner draws in oil to foul the case.
Especially, if the rotor is fouled, the sophisticatedly-tuned balance is broken to create
vibration and to cause seizure and unusual wear to the bearing.
Therefore, it is very important to use a good quality air cleaner all the time.
In the case of dry-type air cleaner, it is essential to clean it to reduce intake resistance as
much as possible.
2) Exhaust system
Pay particular attention to prevent gas leaks and seizure when servicing the exhaust system
because leakage of exhaust gas from discharge pipes, turbocharger fixing portions, etc.
lowers charging effect.
As such components as turbine chamber that becomes red-hot during operation use heat
resisting steel nuts, do not interchange these nuts with ordinary steel nuts. In addition, apply
anti-seizure coating to fixing nuts on the portions as designated.
3) Fuel system
If the full load stopper regulating the maximum injection volume and the maximum speed
stopper regulating the maximum speed in the fuel injection pump are adjusted without using
a pump tester, the turbocharger rotates at excessively rapid speed and may suffer damage.
Besides of it, if spray pattern from the fuel injection nozzles is bad or the injection timing is
incorrect, temperature of exhaust gas rises up to affect the turbocharger adversely. To avoid
such trouble, be sure to make a nozzle test.
4) Lubricating system
Pay particular attention to oil quality and oil filter change intervals when servicing the
lubricating system. Deteriorated engine oil affects adversely not only the engine but torso the
turbocharger. Suggested engine oils for the turbocharger-mounted engine are as follows :
Recommend oil
Engine model
SAE No. API No.
DE12/T/TI SAE 15W40 above CD or CE
SAE 15W40
DE12TIS ACEA-E2 or ACEA-E3 (API CH-4)
SAE 10W40
* If long oil change intervals are to be used, ACEA-E3 oil must be used.
Make it a rule to check the turbocharger assembly for condition and contamination periodically.
Dial gauge
Magnetic vise
Oil outlet
Oil inlet
EA8M4004
(3) If the measured axial and radial plays are beyond the limit of wear, replace or repair the
turbocharger.
• Before reassembling the turbocharger onto the engine, inject new oil in the oil inlet port and
lubricate the journal and thrust bearings by rotating them with hand
• Clean not only the pipes installed between the engine and oil inlet port but also the oil outlet
pipe and check them for damage or foreign matters.
• Assemble each joint on the intake duct and air cleaner securely to prevent air leaks.
• Be sure to use heat resisting steel bolts and nuts. Do not interchange them with ordinary steel
bolts and nuts when performing reassembly operation. Apply anti-seizure coating to the bolts
and nuts.
• Assemble each joint on the exhaust pipes securely to prevent gas leaks.
2. Excessive white smoke 1) Oil leak into turbine and compressor Disassemble/repair
or replace
3. Low engine output 1) Gas leak at each part of exhaust system Check and correct
3) Seized up Disassemble/repair
or replace
D2366
EF.123-015
DE12/T/TI
3 Injection pump setting ass’y
EF.123-156 DE12TIS
CR : made USA
EF.123-127
(up to 2000. Apr.)
4 Oil seal insert ass’y (Front)
NOK : made Japan
EF.123-173
(From 2000. may.)
CR : made USA
EF.123-053
(up to 2000. Apr.)
5 Oil seal insert ass’y (Rear)
NOK : made Japan
EF.123-194
(From 2000. may.)
EF.123-079 DE12/T/TI/TIS
14 Piston sleeve
EF.120-208 Use all engine
1st : 6 kg•m
2nd : 180°
10.9T Dodecagon
Finished : 150°
(angle torque)
1st : 6 kg•m
12T 2nd : 90° + 90°
Dodecagon
Finished : 30°
(angle torque)
1st : 15 kg•m
Connecting rod bearing cap bolt M16 B 1.5 12.9T 2nd : 22 kg•m
3rd : 30 kg•m
1st : 15 kg•m
Crankshaft main bearing cap bolt M16 B 1.5 12.9T 2nd : 25 kg•m
3rd : 30 kg•m
Balance weight fixing bolt M14 B 1.5 10.9T 14.0 kg•m Split type
Injection pump driving gear nut M24 B 1.5 8.8T 25.0 kg•m
APPENDIX - 160 -
• Standard bolt tightening torque table
Refer to the following table for bolts other then described above
Degree of strength
Diameter 3.6 4.6 4.8 5.6 5.8 6.6 6.8 6.9 8.8 10.9 12.9
B (4A) (4D) (4S) (5D) (5S) (6D) (6S) (6G) (8G) (10K) (12K)
pitch Limit value for elasticity (kg/mm ) 2
(mm) 20 24 32 30 40 36 48 54 64 90 108
Tightening torque (kg•m)
M5 0.15 0.16 0.25 0.22 0.31 0.28 0.43 0.48 0.5 0.75 0.9
M6 0.28 0.30 0.45 0.4 0.55 0.47 0.77 0.85 0.9 1.25 0.5
M7 0.43 0.46 0.7 0.63 0.83 0.78 1.2 1.3 1.4 1.95 2.35
M8 0.7 0.75 1.1 1 1.4 1.25 1.9 2.1 2.2 3.1 3.8
M8 B 1 0.73 0.8 1.2 1.1 1.5 1.34 2.1 2.3 2.4 3.35 4.1
M10 1.35 1.4 2.2 1.9 2.7 2.35 3.7 4.2 4.4 6.2 7.4
M10 B 1 1.5 1.6 2.5 2.1 3.1 2.8 4.3 4.9 5 7 8.4
M12 2.4 2.5 3.7 3.3 4.7 4.2 6.3 7.2 7.5 10.5 12.5
M12 B 1.5 2.55 2.7 4 3.5 5 4.6 6.8 7.7 8 11.2 13.4
M14 3.7 3.9 6 5.2 7.5 7 10 11.5 12 17 20
M14 B 1.5 4.1 4.3 6.6 5.7 8.3 7.5 11.1 12.5 13 18.5 22
M16 5.6 6 9 8 11.5 10.5 17.9 18.5 18 26 31
M16 B 1.5 6.2 6.5 9.7 8.6 12.5 11.3 17 19.5 20 28 33
M18 7.8 8.3 12.5 11 16 14.5 21 24.2 25 36 43
M18 B 1.5 9.1 9.5 14.5 12.5 18.5 16.7 24.5 27.5 28 41 49
M20 11.5 12 18 16 22 19 31.5 35 36 51 60
M20 B 1.5 12.8 13.5 20.5 18 25 22.5 35 39.5 41 58 68
M22 15.5 16 24.5 21 30 26 42 46 49 67 75
M22 B 1.5 17 18.5 28 24 34 29 47 52 56 75 85
M24 20.5 21.5 33 27 40 34 55 58 63 82 92
M24 B 1.5 23 25 37 31 45 38 61 67 74 93 103
Others : 1. The above torque rating have been determined to 70% or so of the limit value for bolt
elasticity.
2. Tension is calculated by multiplying tensile strength by cross section of thread.
3. Special screws should be tightened to 85% or so of the standard value.
For example, a screw coated with MoS2 should be tightened to 60% or so of the standard
value.
- 161 - APPENDIX
• Maintenance specification table (unit : mm)
Measure unworn
Inside diameter of
N123 ~ N123.023 N123.223 Replace liner portion beneath the
Cylinder liner for wear
rim of the upper side
Permissible weight
± 15 g 96 g
Major difference of each piston
Install ring by
Direction of ring gap - -
120 C
APPENDIX - 162 -
(unit : mm)
- 163 - APPENDIX
(unit : mm)
APPENDIX - 164 -
(unit : mm)
- 165 - APPENDIX
(unit : mm)
APPENDIX - 166 -