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Daewoo DE12 Shop Manual
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Daewoo DE12 Shop Manual

Daewoo DE12 Shop Manual

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DE12, DE12T &
DE12TI & DE12TIS
DIESEL ENGINE
Shop Manual
65.99892-8030B
Daewoo reserves the right to improve our products in a continuing process to provide the best possible
product to the market place. These improvements can be implemented at any time with no obligation to
change materials on previously sold products. It is recommended that consumers periodically contact their
distributors for recent documentation on purchased equipment.
This documentation may include attachments and optional equipment that is not available in your
machine's package. Please call your distributor for additional items that you may require.
Illustrations used throughout this manual are used only as a representation of the actual piece of
equipment, and may vary from the actual item.
65.99892-8030B Shop Manual

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Summary of Contents for Daewoo DE12

  • Page 1 Shop Manual 65.99892-8030B Daewoo reserves the right to improve our products in a continuing process to provide the best possible product to the market place. These improvements can be implemented at any time with no obligation to change materials on previously sold products. It is recommended that consumers periodically contact their distributors for recent documentation on purchased equipment.
  • Page 2 FOREWORD This manual has been prepared to help you use and maintain the DE series diesel engines (DE12, DE12T, DE12TI and DE12TIS) safely and correctly. These economical and high-performance diesel engines(6 cylinders, 4 strokes, in-line, direct injection type) have been designed and manufactured to be used for overland transport or industrial pur- pose.
  • Page 3 CONTENTS 1. General information ....................... 1 1.1. Engine characteristics 1.4. Engine performance curve 1.2. Main data and specifications 1.5. Exterior view of engine 1.3. Engine specification(’98 type) 2. Major maintenance ......................22 2.1. Preventive maintenance 2.2. Diagnostics and troubleshooting for the engine 3.
  • Page 4 Due to the application of OMEGA combustion system and optimal ultilization of intake and exhaust port configuration within the cylinder head, the DE12 series engines discharge a very low level of hazardous exhaust gases such as smoke, nitrogen oxide, hydrocarbon, or carbon monoxide and thus ensure high performance and low fuel consumption.
  • Page 5 1.1.2. Wastegated turbocharging system 1) What is the wastegated turbocharging system? Turbocharger is a system designed to pressurize the intake air to increase engine output and decrease fuel consumption by using the energy of exhaust gas discharged from the engine. However, the turbocharger has a weak point at low engine speed, its performance may drop, thus performance at low speed is relatively low.
  • Page 6 1.2. Main data and specifications Engine Model DE12 DE12T DE12TI DE12TIS Type In-line, 4-stroke, vertical type Combustion chamber type OMEGA Combustion bowl Fuel injection Direct injection type B stroke-No. of cylinders 123mm B 155 - 6 Bore Total displacement 11,051cc Compression ratio 17.1:1...
  • Page 7 1.3. Engine specification(’98 type) Item DE12-228 DE12TI-280 DE12TI-310 DE12TIS Manufacturer Mounting location Under Seat Starting type SELF Engine type Diesel 4 Cycle Turbocharged & Intercooled Cylinder(No. arrangement) In-line, vertical Combustion chamber type Direct injection Valve position Diameter x stroke 123x155 Compression ratio 17.1...
  • Page 8 Item DE12-228 DE12TI-280 DE12TI-310 DE12TIS Turbocharger type Exhaust gas driven Intercooler type Air cooled Cooling type Forced water circulation Engine Coolant capacity 19(engine only) Cooling system Water pump type Centrifugal Thermostat type Wax pellet Fuel pump type Plunger Fuel filter type...
  • Page 9 1.4. Engine performance curve 1.4.1. DE12 1000 1200 1400 1600 1800 2000 2200 2400 Revolution(rpm) Performance criteria ISO 1585(SAE J1349) Output(Max.) 235 ps/2,200 rpm 81.5 kg . m/1,400 rpm Torque(Max.) 160 g/ps . h Fuel consumption ratio(min.) EQM1004I - 6 -...
  • Page 10 1.4.2. DE12(’98 type) 1000 1200 1400 1600 1800 2000 2200 2400 Revolution(rpm) Performance ISO 1585(SAE J1349) Output(Max.) 228 ps/2,200 rpm 80 kg . m/1,400 rpm Torque(Max.) 155 g/ps . h Fuel consumption ratio(min.) EQM1005I - 7 -...
  • Page 11 1.4.3. DE12T 1 000 1400 1600 1800 1200 2000 2200 2400 Revolution(rpm) Performance ISO 1585(SAE J1349) Output(Max.) 300 ps/2,200 rpm 110 kg . m/1,300 rpm Torque(Max.) 155 g/ps . h Fuel consumption ratio(min.) EQM1006I - 8 -...
  • Page 12 1.4.4. DE12TI 1 000 1400 1600 1800 1200 2000 2200 2400 Revolution(rpm) Performance ISO 1585(SAE J1349) Output(Max.) 340 ps/2,100 rpm 135 kg . m/1,260 rpm Torque(Max.) 147 g/ps . h Fuel consumption ratio(min.) EQM1007I - 9 -...
  • Page 13 1.4.5. DE12TI(280 ps : ’98 type) 1000 1200 1400 1600 1800 2000 2200 2400 Revolution(rpm) Performance ISO 1585(SAE J1349) Output(Max.) 280 ps/2,100 rpm 115 kg . m/1,260 rpm Torque(Max.) 145 g/ps . h Fuel consumption ratio(min.) EQM1008I - 10 -...
  • Page 14 1.4.6. DE12TI(310 ps : ’98 type) 1000 1200 1400 1600 1800 2000 2200 2400 Revolution(rpm) Performance ISO 1585(SAE J1349) Output(Max.) 310 ps/2,100 rpm 125 kg . m/1,260 rpm Torque(Max.) 145 g/ps . h Fuel consumption ratio(min.) EQM1009I - 11 -...
  • Page 15 1.4.7. DE12TIS ISO 1585 N . m kg . m ps kW 1400 1200 120 1000 g/kW . h g/ps . h 1000 1200 1400 1600 1800 2000 2200 Revolution(rpm) Performance ISO 1585(SAE J1349) Output(Max.) 340 ps/2,100 rpm 140 kg . m/1,260 rpm Torque(Max.) 143 g/ps .
  • Page 16 1.5. Exterior view of engine 1.5.1. DE12- for Bus 1. Cylinder block 2. Flywheel housing 3. Breather 4. Oil filler pipe 5. Vibration damper 6. Flywheel 7. V-pulley 8. Cylinder head 9. Oil filter 10. Oil cooler 11. Oil pan 12.
  • Page 17 1.5.2. DE12- for Truck 1. Cylinder block 2. Flywheel housing 3. Breather 4. Oil filler pipe 5. Vibration damper 6. Flywheel 7. Idle pulley 8. Cylinder head 9. Cylinder head cover 10. Oil filter 11. Oil cooler 12. Oil pan 13.
  • Page 18 1.5.3. DE12T- for Bus 1. Cylinder block 2. Flywheel housing 3. Breather 4. Oil filler pipe 5. Vibration damper 6. Flywheel 7. V-pulley 8. Cylinder head 9. Oil filter 10. Oil cooler 11. Oil pan 12. Oil dipstick 13. Cooling water pipe 14.
  • Page 19 1.5.4. DE12TI(340 ps)- for Bus 1. Cylinder block 2. Flywheel housing 3. Breather 4. Oil filler pipe 5. Vibration damper 6. Flywheel 7. V-pulley 8. Cylinder head 9. Oil filter 10. Oil cooler 11. Oil pan 12. Oil dipstick 13. Cooling water pipe 14.
  • Page 20 1.5.5. DE12TI(280 ps : ’98 type)- for Bus 1. Cylinder block 2. Flywheel housing 3. Breather 4. Oil filler pipe 5. Vibration damper 6. Flywheel 7. V-pulley 8. Cylinder head 9. Oil filter 10. Oil cooler 11. Oil pan 12. Oil dipstick 13.
  • Page 21 1.5.6. DE12TI(310 ps : ’98 type)- for Bus 1. Cylinder block 2. Flywheel housing 3. Breather 4. Oil filler pipe 5. Vibration damper 6. Flywheel 7. V-pulley 8. Cylinder head 9. Oil filter 10. Oil cooler 11. Oil pan 12. Oil dipstick 13.
  • Page 22 1.5.7. DE12TI - for Truck 19 24 30 20 1. Cylinder block 2. Flywheel housing 3. Breather 4. Oil filler pipe 5. Vibration damper 6. Flywheel 7. Idle pulley 8. Cylinder head 9. Cylinder head cover 10. Oil filter 11. Oil cooler 12.
  • Page 23 1.5.8. DE12TIS - for Bus 24 32 19 27 28 23 30 1. Cylinder block 2. Flywheel housing 3. Breather 4. Oil filler pipe 5. Vibration damper 6. Flywheel 7. Crank shaft pulley 8. Cylinder head 9. Cylinder head cover 10.
  • Page 24 1.5.9. DE12TIS - for Truck 20 26 27 28 1. Cylinder block 2. Flywheel housing 3. Breather 4. Oil filler pipe 5. Vibration damper 6. Flywheel 7. Idle pulley 8. Cylinder head 9. Cylinder head cover 10. Oil filter 11. Oil cooler 12.
  • Page 25 2. Major maintenance 2.1. Preventive maintenance 2.1.1. Cooling water 1) Check the coolant level of the radiator by removing the radiator filler cap, and add coolant if necessary. 2) Check the pressure valve opening pressure using a radiator cap tester. Replace the radiator filler cap assembly if the measured value does not reach the specified limit.
  • Page 26 (First oil change : 1,000km running) • Suggested engines oils Engine Model SAE NO. API NO DE12, DE12T,DE12TI 15W40 CD grade or above DE12TIS 15W40 CG grade 2.1.4. Oil filter 1) Check for oil pressure and oil leaks, and repair or replace the oil filter if necessary.
  • Page 27 2.1.7. Valve clearance 1) Turn the crank shaft so that the piston in No. 1 cylinder reaches the TDC on compression stroke, then adjust the valve clearance. 2) After releasing the lock nut for the rocker arm adjusting screw, insert a feeler gauge of speci- fied thickness into the clearance between the rocker arm and valve stem, and adjust the clearance with the adjusting screw.
  • Page 28 2.1.10. Fuel injection pump 1) Check the fuel injection pump housing for cracks or breaks, and replace if damaged. 2) Check and see if the lead seal for idling control and speed control levers have not been removed. 2.1.11. Battery 1) Check the battery for damage or leaking of battery fluid(electrolyte) from cracks on the bat- tery.
  • Page 29 2.2. Diagnostics and trouble shooting for the engine 2.2.1. Diagnostics 1. Engine won’t start Starter does not turn Starter turns but engine does not start Check battery fluid and specific gravity Engine Fuel Normal Too low Check air cleaner Check fuel level Replenish or recharge Normal Fouled...
  • Page 30 2. Engine overheating Cooling system Fuel system Operating conditions 1. Overload 2. Clogged radiator core 3. Continued overrunning Check coolant level Check fuel quality Normal Too low Check fan belt for tension, wear, or breaks Clean or replace with the specified fuel Normal Repair or replace Check radiator cap...
  • Page 31 3. Lack of power Engine Chassis Fuel system Others Check for clutch slip Check fuel line for air Check air cleaner Adjust or replace clutch Check fuel feed pump Normal Clean or replace Normal Clean or replace Check engine control rod, link and cable Check fuel filter element and overflow valve Normal...
  • Page 32 4. Low oil pressure Check if oil pressure gauge indicates exactly Check oil level Normal Too low Check cooling water temperature Refill with recommanded oil Normal Too high Check oil quality Refer to ‘Engine overheating’ Normal Check oil pressure relief valve Water, fuel, etc.
  • Page 33 5. High fuel consumption Causes according to operating conditions 1. Overload 2. Frequent use of low gear position at high speed 3. Frequent use of high gear position at low speed 4. Clutch slip 5. Too low tire inflation pressure Check fuel leakage Normal Oil leakage...
  • Page 34 6. Excessive oil consumption Causes according to operating conditions 1. Too high lub. oil level 2. Continuous driving at low speed or with excessive cold engine Check oil leakage Check air cleaner Clean or replace Normal Oil leak Check oil quality External Internal Replace with suggested lub.
  • Page 35 7. Engine knocks(excessive) Check fuel and oil burning(Check carbon deposit from exhaust gas) Not identified Identified Check compression pressure Overhaul engine Normal Too low Check injection timing Check valve clearance, cyl. head gasket for damage Normal Adjust Normal Replace or adjust Check fuel quality Overhaul engine Use suggested fuel...
  • Page 36 8. Dead or weak battery Battery Harness, switch Alternator Check battery fluid level Check wiring connections Check fan belt for for short, etc deflection, damage, etc. Repair or replace Normal Check battery fluid specs. Damaged battery case Battery discharged Battery overcharged Replenish Replace Recharge...
  • Page 37 2.2.2. Trouble shooting Complaint Cause Correction 1) Difficulty in engine starting (1) Trouble in starter (See <2.2.1>) (2) Trouble in fuel system (See <Section 4.3 Fuel system>) Check valve and valve seat, (3) Lack of compression Valves holding open, skewed valve stem then repair or replace pressure Valve springs damaged...
  • Page 38 Complaint Cause Correction 5) Engine noises It is important to correctly locate the causes of noise since generally nois- es may originate from various engine components such as rotating parts, sliding parts, etc. (1) Crankshaft Oil clearance excessive due to Replace bearings and grind worn bearings or crankshaft crankshaft...
  • Page 39 Complaint Cause Correction 7) High oil consumption (1) Oil leaking into Clearance between cylinder liner Replace combustion chamber and piston excessive Piston rings and ring grooves Replace pistons and piston worn excessively rings Piston rings broken, worn, or sticking Replace piston rings Piston rings gaps set incorrectly Correct Piston skirt portion broken, worn...
  • Page 40 3. Disassembly and reassembly of major components 3.1. Disassembly 3.1.1. General precautions 1) Maintenance operation should be carried out in a bright and clean place. 2) Before disassembly, provide parts racks for storage of various tools and disassembled parts. 3) Arrange the disassembled parts in the disassembly sequence and take care to prevent any damage to them.
  • Page 41 3.1.5. Cooling fan 1) Remove the flange fixing bolts, then take off the flange and cooling fan. EQM3004I 3.1.6. Oil level gauge guide tube 1) Loosen the flange nut installed on the ladder frame to remove the guide tube. EQM3005I 3.1.7.
  • Page 42 3.1.9. Fuel filter 1) Remove fuel hoses connected to the fuel injection pump, take off the bracket fixing bolts, then disassemble the fuel filter. 3.1.10. Breather 1) Loosen the clamp screw to remove the rubber hose. EQM3008I 3.1.11. Injection pipe 1) Unscrew the hollow screws to disas- semble the fuel return pipe.
  • Page 43 3.1.14. Turbocharger (for DE12T / DE12TI / DE12TIS only) 1) Release the clamp screw of the rubber hose connected to the intake manifold, and take off the intake pipes both simul- taneously. 2) Unscrew the exhaust pipe bracket fix- ing bolts, release the nuts installed on the turbocharger, then disassemble the exhaust pipe.
  • Page 44 3.1.18. Fuel injection pump 1) Remove the oil supply pipe and return pipe connected to the fuel injection pump. 2) Unscrew the bolts connecting the cou- pling and drive shaft, loosen the injec- tion pump attaching bolts, then disas- semble the injection pump. Note : Place the No.1 cylinder in the exact 'OT' position to disassem- EQM3016I...
  • Page 45 3.1.21. Power steering pump 1) Remove the oil hoses. 2) Unscrew the hex bolts and remove the steering pump. EQM3020S 3.1.22. Water pump 1) Remove the water pipe connected to the expansion tank 2) Remove the water pipe and hoses con- nected to the water pump.
  • Page 46 3.1.25. Timing gear case cover 1) Disassemble the oil seal using an oil seal removing jig. 2) Remove the cover fixing bolts and dis- assemble the cover from the timing gear case. EQM3024I 3.1.26. Idle gear 1) Unscrew the idle gear fixing bolts and disassemble the thrust washer and idle gear.
  • Page 47 3.1.29. Rocker arm assembly 1) Unscrew the rocker arm bracket bolts and remove the rocker arm assembly. 2) Take off the snap rings to remove the washers and rocker arm, then unscrew the bracket fixing bolts to take off the bracket and springs.
  • Page 48 3.1.33. Oil cooler 1) Remove the water pipe connected to the water pump. 2) Unscrew the oil cooler cover fixing bolts and disassemble the oil cooler assem- bly from the cylinder block. 3) Unscrew the oil cooler fixing bolts and remove the oil cooler from the oil cooler cover.
  • Page 49 3.1.37. Piston and connection rod 1) Disassemble the pistons by two hands while turning the crankshaft. 2) Unscrew the conn. rod fixing bolts and take off the pistons and conn. rods in the direction of piston. EQM3035I 3) Remove the piston pin snap rings, take off the piston pin, then disconnect the conn.
  • Page 50 3.1.39. Flywheel 1) Position the engine so that the head installing surface of the cylinder block faces down. 2) Unscrew the flywheel fixing bolts and fit a dowel pin. 3) Install flywheel disassembling bolts in the bolt holes machined on the flywheel, and disassemble the flywheel.
  • Page 51 3.1.43. Crankshaft gear and oil pump idle gear 1) Loosen the socket head bolts and take out the oil pump idle gear. 2) Use a puller to remove the crankshaft Puller gear. EQM3043S 3.1.44. Timing gear case 1) Unscrew the case fixing bolts and dis- assemble the timing gear case.
  • Page 52 3.2. Inspection 3.2.1. Cylinder block 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.
  • Page 53 3.2.3. Valve and valve guide 1) Inspecting the valve Clean the valves with clean diesel oil, then inspect them as follows: (1) Measure the valve stem outer diam- eter at 3 positions(top, middle, and bottom). If the amount of wear is beyond the limit(0.18mm), replace the valve.
  • Page 54 3) Inspection and correction of valve seat (1) Measure contacting face between the intake valve seat and exhaust valve seat for valve seat wear, and replace if the measured value exceeds the specified limit. (2) Install the valve into the valve seat on the cylinder head, and check the amount of depression of the valve EQM3049I...
  • Page 55 3.2.4. Rocker arm shaft assembly 1) Measurement of rocker arm shaft (1) Place the rocker arm shaft on two V- blocks and inspect the shaft for bend using a dial gauge. If the amount of this run-out is small, press the shaft with a bench press to correct the run-out.
  • Page 56 3.2.5. Cam shaft 1) Inspection of cam (1) Measure the cam height with a micrometer and replace the camshaft if the measured value is beyond the specified limit. (2) Inspect the cam face for scratch or damage. Slight step wear or damage on the cam face may be corrected with oil EDM2045I stone or oiled grinding paper.
  • Page 57 3.2.6. Crank shaft 1) Inspection for scores or cracks (1) Visually check the crank shaft journal and crank pins for scores or cracks. (2) Using a magnetic power and color check, inspect the crank shaft for cracks, and replace the crank shaft which has cracks. 2) Checking crank shaft for wear (1) With an outside micrometer, measure the diameter of the crank shaft journals and pins in the directions as shown, and compare the measured values to determine the amount of...
  • Page 58 3) Measurement of crankshaft run-out (1) Support the crankshaft on V-blocks. (2) Turn the crankshaft with a dial indi- cator placed on the surface plate and take the amount of crank shaft run- out. EDM2040S <Figure 3-14> Measuring crank shaft run-out EDM2041S <Figure 3-15>...
  • Page 59 (3) Compare the two values obtained through measurement of bearing inside diameter with the outside diameters of crankshaft journals and pins to determine the oil clearance. (4) If the clearance deviates from the specified range, have the crankshaft journals and pins ground and install undersize bearings.
  • Page 60 (3) Conn. rod bearing crush can be checked as follows: Install the bearing and cap in the conn. rod big end, retighten the bolts to specified torque, unscrew out one bolt completely, then measure the clearance between the bearing cap and conn.
  • Page 61 (3) The clearance is computed by sub- tracting the piston outside diameter from the cylinder liner inside diame- ter. Replace either piston or cylinder liner, whichever damaged more, if the clearance is beyond the specified limit. Liner Standard Limit Cylinder line +0.005 l123 inside diameter...
  • Page 62 Dimensions Standard(mm) Limit(mm) Descriptions Top ring 2nd ring 0.07~0.102 0.15 Oil ring 0.05~0.085 0.15 4) With a tension tester, measure piston ring tension. Replace the piston ring if the measured value is beyond the limit. 3.2.10. Piston pin 1) Measure the amount of wear on the pis- ton pin (1) Measure the amount of wear on the piston pin at the points as shown.
  • Page 63 3.2.11. Connecting rod 1) Check the connecting rod for distortion. As shown in the figure right, install the conn. rod to the conn. rod tester, and check for distortion using a feeler gauge. If the conn. rod is found distort- ed, never re-use it and replace it with a new one.
  • Page 64 3.3. Reassembly 3.3.1. General precautions 1) Wash clean all the disassembled parts, particularly oil and water ports, using compressed air, then check that they are free from restrictions. 2) Arrange the general and special tools for engine assembly operation. 3) To wet each sliding part, prepare clean engine oil. 4) Prepare service materials such as sealant, etc.
  • Page 65 3) Wet the cam bush inside diameter and cam shaft with oil, and carefully assem- ble them while turning the cam shaft. 4) Check to see that the cam shaft rotates smoothly. EDM2060I 3.3.5. Crank shaft 1) Install the main bearing machined with two holes in the cylinder block so that the key is aligned with the key groove, then Oil port and passage...
  • Page 66 5) Install the bearing and thrust washers to the bearing cap and apply oil to the bear- ing and thrust washers. EQM3057I 6) Install the bearing cap by matching the cylinder block No. with the bearing cap 7) Apply oil to the entire part of the bearing cap bolts, then tighten in tightening sequence to specified torque(30kg •...
  • Page 67 3.3.7. Rear oil seal 1) Apply lubricating oil to the outside of the oil seal and flywheel inside diameter and fit them over the crank shaft, then assemble the oil seal using an oil seal fit- ting jig. EQM3061I 3.3.8. Flywheel 1) Install a guide bar into a bolt hole on the crank shaft, and lift the flywheel to align the dowel pin with the pin hole on the fly-...
  • Page 68 3.3.10. Fuel injection pump drive gear assembly 1) Mount gasket by aligning the bolt holes with the pin holes on the bearing hous- ing. 2) Tighten up the fixing bolts in the direction of fuel injection pump. EQM3065I 3.3.11. Timing gear 1) Install the oil pump idle gear onto the No.
  • Page 69 3.3.13. Front oil seal 1) Apply lubricating oil to the outside of the oil seal and timing gear case inside diameter and fit them over the crank shaft, then assemble the oil seal using an oil seal fitting jig. EQM3068I 3.3.14.
  • Page 70 4) Install the piston ring in the piston using piston ring pliers. 5) Identify the mark "Y" or "TOP" on the ring end to prevent the top and bottom of the piston ring from being inter- changed and make the marked portion face upward.
  • Page 71 12) Move the bearing cap with hand, and release and reassemble it if no move- ment is detected. EQM3073I 3.3.16. Ladder frame 1) Cut out the gasket protruding from the joints of the timing gear case, case cover, and flywheel housing. 2) Apply silicon to each joint and attach gasket to the cylinder block.
  • Page 72 3.3.19. Intake and exhaust valves 1) Identify the marks of "IN" and "EX" impressioned on the valve head before assembling the valve with the valve head. 2) With a valve stem seal fitting jig, assemble the valve stem seal with the valve guide.
  • Page 73 3.3.21. Rocker arm assembly 1) Apply lubricating oil to the rocker arm bush and shaft, and assemble the inter- mediate bracket with the rocker arm using fixing bolts. 2) Semi-install valve clearance adjusting bolts onto the rocker arm. 3) Install the washer, rocker arm, spring, rocker arm, washer, bracket, spring, washer, and snap ring in the described EQM3079I...
  • Page 74 6) Coat the push rod with engine oil and insert it into the push rod hole. 7) Mount the rocker arm assembly on the cylinder head and tighten the rocker arm bracket fixing bolts to specified torque(4.4kg • m). 8) Adjust the valve clearance. •...
  • Page 75 3.3.24. Water pipe and thermostat 1) Install the water pipe onto the cylinder head. 2) Install the thermostat in the housing. 3) With socket head bolts, install the ther- mostat housing onto the water pipe. EQM3084I 3.3.25. Oil cooler 1) Install the oil cooler onto the oil cooler cover.
  • Page 76 4) Tighten the fixing bolts in a diagonal sequence to specified torque (4.4kg • m). 5) Turn the flywaheel until No. 1 piston is placed in the "OT" position, and then Injection timing notch mark turn again the flywheel clockwise until, Flywheel of notch marks on the flywheel, the notch mark under the figure corre-...
  • Page 77 3.3.29. Vibration damper and pulley 1) Install the vibration damper on the crank shaft pulley. 2) Install the crank shaft pulley assembly on the crank shaft, then tighten the bolts and thrust washers. (bolt tightening torque : 13.4kg • m) EQM3092S 3.3.30.
  • Page 78 3.3.33. Exhaust manifold 1) Install the exhaust manifold gasket over the stud bolts by aligning the gasket with the exhaust port on the cylinder head so that the face and back of the gasket can be positioned correctly. 2) Semi-assemble the exhaust manifold and install the heat resisting plate.
  • Page 79 3.3.36. Intake manifold 1) Fit a gasket on the intake manifold before assembling the intake manifold. 2) Mount the air heater gasket on the intake manifold, then assemble the air heater with the intake manifold. 3) Connect the air hose to the boost com- pensator mounted on the fuel injection pump.
  • Page 80 3.3.40. Air-conditioning compressor 1) Install the A/C compressor mounting bracket on the timing gear case. 2) Install the alternator mounting bracket on the timing gear case, then install A/C compressor fixing bolts. 3) Tighten the fixing bolts. EQM3104I 3.3.41. Alternator 1) Install the alternator mounting bracket with a fixing bolt onto the cylinder head.
  • Page 81 3.3.44. Fan guide 1) Install the three fan guide brackets. 2) Install the fan guide to the bracket. 3.3.45. Oil level gauge 1) Assemble the oil level gauge to the lad- der frame. EQM3108S 3.4. Breaking-in 3.4.1. Preparations for breaking-in 1) Fill 20M of new engine oil through the oil filler cap.
  • Page 82 4. Maintenance of major components 4.1. Cooling system 4.1.1. General descriptions and main data 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.
  • Page 83 4.1.2. Water pump 1) Loosen the bolt (14) to disassemble the housing cover (13). 2) Heat the impeller (5) slightly, then remove it using a puller. 3) Remove the mechanical seal. 4) Remove the shaft and bearing assembly from the housing. 5) With a press, remove the spline shaft and bearing.
  • Page 84 Thickness 0.3 ~ 0.6 Par latex coating 13 12 2(Bead) EQM4003I 1. Water pump housing 8. Spacer 2. Pipe 9. Ang. contact ball 3. Shaft 10. Stop ring 4. Mechanical seal 11. Spline shaft 5. Impeller 13. Cover, water pump housing 6.
  • Page 85 4.1.3. Thermostat 1) General descriptions and main data To radiator The thermostat maintains a constant temperature of coolant(90 ~95c) and improve thermal efficiency of the engine by preventing heat loss. Namely, when temperature coolant is low, the thermostat valve is Bypass closed to make the coolant bypass to valve...
  • Page 86 4.1.4. Diagnostics and troubleshooting Complaints Possible causes Corrections 1. Engine (1) Lack of coolant (1) Replenish coolant overheating (2) Radiator cap pressure valve spring (2) Replace cap weakened (3) Fan belt loosened or broken (3) Adjust or replace fan belt (4) Fan belt fouled with oil (4) Replace fan belt (5) Thermostat inoperative...
  • Page 87 4.2. Lubricating system 4.2.1. General descriptions and main data 1) 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, fuel injection pump, and air compressor in order to ensure normal engine performance.
  • Page 88 4.2.2. Oil pump 1) Disassembly (1) Disassembly of oil pump drive gear a. Unscrew the screw and disassem- ble the oil relief valve. b. Loosen the washer for the oil pump drive gear fixing nut and remove the nut. c. Disassemble the drive gear. EQM4006I <Figure 4-6>...
  • Page 89 (3) Measuring clearance between drive shaft and bushing a. Measure the outside diameter of the drive shaft and driven shaft, and replace if the mea- sured values are less than the limit (N16.95mm). 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.
  • Page 90 4.2.4. Diagnostics for oil Complaints Possible causes Corrections Oil consumption (1) Poor oil (1) Use suggested oil excessive (2) Oil seal or packing leaky (2) Replace cap (3) Pistons or piston rings worn (3) Replace pistons and/or piston rings (4) Cylinder liner worn (4) Replace cylinder liner (5) Piston rings sticking (5) Replace pistons and/or piston rings...
  • Page 91 4.3. Fuel system 4.3.1. General descriptions 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. EQM4011I <Figure 4-11> Diagram of fuel system 1.

  • Page 92: Table Of Contents

    1) DE12 (1) DE12(A) (a) Main data and specifications Part No. : 65.11101-7260(106671-9170) Model : PE6P type Governor : RFD+C type Timer : SD type, range of operation: 5.5°/600-1100 rpm Plunger : 65.11125-0010 Delivery valve : 65.11108-6009 Fuel feed pump : 65.12101-7013 Pre-stroke : 4.7L0.05mm...
  • Page 93 (c) Adjusting governor ±0.05 RACK LIMIT CR=9.5 or more ±15 ±5 1150 1205 1170 EQM4012I Injection pump speed (rpm) - 90 -...
  • Page 94 (2) DE12(B) (a) Main data and specifications Part No. : 65.11101 - 7296 Model : PE6P type Governor : RLD+J type Timer : SD type, range of operation: 6°/600-950 rpm Plunger : 65.11125-0021 Delivery valve : 65.11108-6019 Fuel feed pump : 65.12101-7027...
  • Page 95 (c) Adjusting governor RACK LIMIT 12.3 12.1 12.0 11.3 10.5 or more Damper spring set - 0.1 1100 1210 (1120) EQM4013I Injection pump speed (rpm) - 92 -...
  • Page 96 2) DE12T (1) DE12T(A) (a) Main data and specifications Part No. : 65.1101-7261(106671-9170) Model : PE6P type Governor : RFD+C type Timer : SD type, range of operation: 3°/700-1100 rpm Plunger : 65.11125-0010 Delivery valve : Fuel feed pump : 65.12101-7013 Pre-stroke : 4.2L0.05mm Rotating direction...

  • Page 97: Or More

    (c) Adjusting governor 0.05 Rack limit CR=9.5 10.05 RACK LIMIT CR=9.5 or more ±15 ±5 1150 1205 1170 Pump speed(rpm) EQM4014I - 94 -...

  • Page 98: Nozzle Holder Assembly 105780-8140

    3) DE12TI (1) DE12TI-280 (a) Main data and specifications Part No. : 65.11101 - 7296 Model : PE6P type Governor : RFD+D type Timer : SPG type, range of operation: 3°/700-1100 rpm Plunger : 65.11125-0010 Delivery valve : 65.11108-6009 Fuel feed pump : 65.12101-7013 Pre-stroke : 4.2L0.05mm Rotating direction...
  • Page 99 (c) Adjusting governor ±0.1 BOOST COMPENSATOR STROKE:1.6 ±0.1 8.2=R1 R2+1.5 or more 5.1=R2 4.0=R4 ±0.5 (R2-3.6) ±15 ±25 ±15 ±10 (850) (250) 1100 (1185) Injection pump speed (rpm) EQM4016I - 96 -...
  • Page 100 (2) DE12TI-310 (a) Main data and specifications Part No. : 65.11101 - 7297 Model : PE6P type Governor : RFD+D type Timer : SPG type, range of operation: 3°/700-1100 rpm Plunger : 65.11125-0010 Delivery valve : 65.11108-6009 Fuel feed pump : 65.12101-7013 Pre-stroke : 4.2L0.05mm...
  • Page 101 (c) Adjusting governor ±0.1 BOOST COMPENSATOR STROKE:2.6 ±0.1 9.2=R1 R2+1.5 5.1=R2 3.0=R4 ±0.5 (R2-3.6) ±15 ±15 ±25 ±10 (870) (250) 1100 (1185) Injection pump speed (rpm) EQM4017I - 98 -...
  • Page 102 (3) DE12TI(A) (a) Main data and specifications Part No. : 65.1101-7287(106671-9130) Model : PE6P type Governor : RFD+D type Timer : SD type, range of operation: 3°/700-1100 rpm Plunger : 65.11125-0010 Delivery valve : 65.11108-6009 Fuel feed pump : 65.12101-7013 Pre-stroke : 4.2L0.05mm Rotating direction : C.W.
  • Page 103 (c) Adjusting governor ±0.1 BOOST COMPENSATOR STROKE:2.5 Boost compensator stroke : 2.5 L 0.1mm. ±0.1 R2+1.5 ±0.5 (R2-3.6) ±15 ±15 ±25 ±10 (850) (250) 1100 (1185) Pump speed(rpm) EQM4017I - 100 -...
  • Page 104 4) DE12TIS (1)DE12TIS (a) Main data and specifications Part No. : 65.11101-7661(108622-4000) Model : HD-TICS Governor : RLD+J type Timer : Dummy timer + electronically controled Plunger Delivery valve : 65.11108-6009 Fuel feed pump : 65.12101-7013 Pre-stroke : 6.3L0.05mm Rotating direction : C.W.
  • Page 105 (c) Adjusting governor ±0.1 BOOST COMPENSATOR STROKE:3.8 R1-0.55 R1-0.9 R1-1.5 R1-1.85 R2-2.0 ±10 ±10 ±10 790 850 1100 (1185) (250) Injection pump speed (rpm) EA2M4001 - 102 -...
  • Page 106 4.3.3. Fuel feed pump 1) General descriptions and construction The P-type injection pump is mounted with K-ADS or KP type feed pump. These pumps have the same basic construction and operation, and the general descriptions of the KP type pump are given below: The following figures show its construction and operation.
  • Page 107 Inlet side Outlet side Interruption EQM4020I This feed pump is mounted with a priming pump designed to permit manual feeding of fuel from the fuel tank with the injection pump mounted in the engine. During the manual feeding operation, air must be bled from the fuel lines. When using the priming pump, fix it securely to prevent the possible entry of moisture or other foreign substances inside of feed pump.
  • Page 108 2) Disassembly Fuel tank side strainer bolt (MESH 50) Fuel filter side EQM4021S <Figure 4-14> Exploded view of fuel feed pump (1) Clamp the feed pump with a vise and disassemble the plugs(30, 32) and gaskets(35, 36). (2) Take off the priming pump(25), plug(16), both gaskets(18), spring(15), and check valve(14). (3) Take off the plug(7), gasket(8), spring(6), and piston(5) on the piston side.
  • Page 109 5) Testing Outlet hose (1) Suction capacity test Connect one end of a hose to the inlet Feed pump side of the feed pump and immerse the other end of it into the fuel tank as illustrated. Inlet hose Hold the feed pump in position about 1m above the level of fuel in the fuel tank.
  • Page 110 4.3.4. Injection nozzle 1) General descriptions Pressurized fuel delivered from the fuel injection pump is sprayed into the combustion cham- ber past the injection nozzle at proper spray pressure and spray angle, then burnt completely to achieve effective engine performance. (1) At valve closed (2) At valve opened EQM4024I...
  • Page 111 (2) Reassembly a. After removing carbon deposit, Replace 4~5kg • m gaskets submerge the nozzle in diesel oil and clean it. b. Replace all the gaskets with new Replace gaskets ones. c. Assemble the parts and tighten Replace them to specified torque. gaskets Locating pin EQM4026S...
  • Page 112 3) 2-spring type (1) Disassembly EQM4029I <Fig 4-23> Exploded view of 2-spring 1. Nozzle holder body 13. Lift pin 2. Push rod 14. Pin 3. Primary spring 15. Spacer 4. Adjusting screw 16. Pin 6. Gasket 17. Retaining seat 7. Cap nut 30.
  • Page 113 (2) Inspection and adjustment Adjusting the primary opening pres- sure a. Install the plate of plate assembly (157944 -9520) onto a vise. Note: Use plate assembly (157944-9520) in fixing a nozzle holder having EQM4030I flange. A nozzle holder with- <Figure 4-24> Installing plate out flange should be direct- ly installed onto a vise.
  • Page 114 e. Assemble the pin(14), lift piece(13), and spacer(15) with the nozzle holder body. (Figure 4-27) EQM4033I <Figure 4-27> Installing pin, lift piece, and spacer f. Install the pin(16) and nozzle(A) onto the spacer. EQM4034I <Figure 4-28> Installing pin and nozzle g.
  • Page 115 h. Be sure to follow the specified torque rating when tightening the adjusting retaining nut. Specified torque 59~78N•m (6.0~8.0kg•m) EQM4036I <Figure 4-30> Fixing the nozzle i. With the cap nut facing upward, install the nozzle holder on the plate. (Figure 4-31) EQM4037I <Figure 4-31>...
  • Page 116 l. Assemble the nozzle and nozzle holder assembly to the nozzle tester (105785-1010). (Figure 4-33) EQM4039I <Figure 4-33> Nozzle test, nozzle and nozzle holder assembly m. Adjust the primary opening pres- sure to the specified pressure using the adjusting screw(4). (Figure 4-34) EQM4040I <Figure 4-34>...
  • Page 117 • Inspecting the needle valve for full lift a. Install gasket(30) and plug (31) onto the adjusting retaining nut (7). (Figure 4-36) EQM4042I <Figure 4-36> Installing gasket and plug b. Install the nozzle holder on the plate with the cap nut facing upward. c.
  • Page 118 e. Assemble the pin(157892-4200 or 157892-4300) dial gauge (157954-3800). (Figure 4-39) Part No. L (mm) 157892-4200 157892-4300 EQM4045I Note: "L" means the length of the pin <Figure 4-39> Installing pin except the threaded portion. f. Install the dial gauge on the holder assembly so that the pin is brought into Dial gauge contact with the upper end of the push...
  • Page 119 g. Assemble the nozzle and nozzle hold- er assembly to the nozzle tester and zero the dial gauge. h. Operate the nozzle tester, bleed the retaining nut, and check for fuel leak- age. (Figure 4-41) EQM4047I <Figure 4-41> Air in the retaining nut i.
  • Page 120 • Inspection of pre-lift a. If the nozzle tester handle is released with the needle valve engaged in a full lift condition, the tester pressure drops, being accompanied by decrease in the needle valve lift value(indicated value on the dial gauge). (Figures 4-43 and kgf / cm 4-44) EQM4049I...
  • Page 121 Measuring point for pre-lift Take the indicated value on the dial gauge at a point of primary opening pres- sure + approx. 10kgf/cm Note: Locate the point of primary opening pressure approx. 10kgf/cm while dropping the pressure. Primary opening pressure Tester pressure EQM4052I <Figure 4-46>...
  • Page 122 c. Take the indicated value on the pres- sure gauge at the point of time when the needle of the dial gauge indicates the specified needle valve lift value(in general, pre-lift "M" + 0.05mm). (Figure 4-50) EQM4055I <Figure 4-49> Checking the secondary opening pressure by means of cover method EQM4056I <Figure 4-50>...
  • Page 123 • Adjusting secondary opening pressure a. In the event that the measured value deviates from the specified limit, read- just the primary opening pressure if the amount of deviation is small. (to the standard range of the primary opening pressure) (Figure 4-51) •...
  • Page 124 4.3.5. DE12TIS fuel injection pump inspec- tion & adjustment only 1) Pre-stroke actuator inspection drive shaft. Replace the drive shaft if the ball section is bent,worn or damaged. EA2M4002 2) Electrical components (1) Check the resistances between the prestroke actuator terminals shown in the figure at left using a circuit tester.
  • Page 125 (3) Check the resistances between each of the rack sensor terminals shown in the figure using a circuit tester. Their resistances at 25˚C are shown in the table below. Ω) Wire color Resistance( Red(OSC)~White(MID) 92.5~101.5 Black(GND)~White(MID) 92.5~101.5 EA2M4005 Also, check that resistance between the terminals and the hous-...
  • Page 126 (2) Confirm that the actuator’s pre-stroke position sensor plate moves smooth- ly when moved with a finger, as shown at left. EA2M4008 (3) Install the actuator cover on the actu- ator and tighten the bolts to the spec- ified torque. Specified torque : 4.9~6.9 N•m(0.5~0.7 kgf•m) EA2M4009...
  • Page 127 4) Pre-stroke actuator adjustment (1) Adjustment checker (including control unit) This control unit is used especially for adjustment of TICS pumps. In addition to the control unit, a constant voltage power supply and a digital voltmeter(both commercially available) are necessary. The figure below shows the names and functions of each control panel switch, dial and ter- minal.
  • Page 128 5) Wiring harness (1) The wiring harness layout is as shown below. EA2M4012 (2) Position each switch on the check- er(407980-2090) as shown at left. COUTION : Leave power switch OFF to pre- vent the pre-stroke actuator from over- heating. EA2M4013 (3) Reinstall measuring...
  • Page 129 (6) Set the constant voltage power sup- ply at 24 V. (7) Turn on the digital voltmeter’s power switch. EA2M4015 (8) Turn the checker’s power ON. (9) Trun the ‘Normal-Act Off’ switch to ‘Normal’ (10) Turn the target dial until the fuel stops flowing.
  • Page 130 (7) The relationship between pre-stroke and pre-stroke sensor output is shown at left. COUTION : The values at left are only examples. Refer to the data sheet. EA2M4018 7) Injection quantity adjustment setting the control rod’s ‘0’ position (1) Remove measuring device (105782-4371) from the No.1 cylinder...
  • Page 131 8) Injection quantity adjustment When adjusting the TC(S) HD type pump’s fuel injection quantity, operate the pre-stroke actuator with the pre- stroke set as specified. (1) Turn the ‘Normal-Act OFF’ switch to the ‘Normal” position and rotate the target dial to set the sensor output to 2.62 0.01 V, corresponding to a pre- EA2M4017...
  • Page 132 9) Rack sensor adjustment (1) Rack limiter adjustment Secure the control rod in the position where the fuel quantity ‘I’ is obtained. EA2M4023 (2) Install the block and measure the dis- tance ‘X’. EA2M4024 (3) Install the joint and measure the dis- tance ‘Y’.
  • Page 133 (5) Screw in the bobbin until the edge of the bobbin contacts the bottom of the joint. Note : Before installing the bobbin in the joint, apply grease to the O-ring. EA2M4027 10) Rack sensor adjustment (1) Secure the control lever in the full speed position.
  • Page 134 11) Ecu circuit diagram 5A ECU POWER PREST ACT. POWER KEY ON S/W ENGINE PREST. ACTUATOR ENGINE HARNESS PREST. SENSOR CONNECTOR RACK SENSOR PRE-HEATER COOLING WATER TEMP. SENSOR ENGINE SIDE VEHICLE SIDE VEHICLE SENSOR K-Line Scan-Scope VEHICLE GROUND HARNESS EA2M4031 1.
  • Page 135 • Retaining nut a. Take out the dial gauge, nut, holder and gasket from the cap nut(7). b. Remove the adjusting retaining nut and gasket, and install the original retaining ring nut(17:SW19mm). (Figure 4-53) Retaining nut tightening torque 59~78 N•m (6.0~8.0kgf•m) EQM4036I <Figure 4-53>...
  • Page 136 4.3.6. Diagnostics and troubleshooting Complaints Possible causes Corrections 1. Engine won’t start (1) Fuel pipes clogged or air into pipe line Correct 1) Fuel not being pumped (2) Feed pump valve defective Replace out from feed pump (3) Feed pump piston or push rod sticking Disassemble, correct 2) Fuel not being injected (1) Fuel filter element restricted...
  • Page 137 Complaints Possible causes Corrections 6. Engine output (1) Supply of fuel insufficient Check feed pump unstable (2) Air in fuel Bleed (3) Water in fuel Replace fuel (4) Operation of plungers unsmooth Disassemble, correct (5) Movement of control rack sluggish Disassemble, correct (6) Nozzles defective Disassemble, correct...
  • Page 138 4.4. Turbocharger 4.4.1. Main data and specifications 1) Main data and specifications Model Specifications Air pressure at compressor outlet About 1,257kg/cm Gauge At maximum output Air suction volume About 19.0m /min Speed of turbine revolution About 95,000rpm Maximum allowable speed 110,000rpm Max.
  • Page 139 3) Construction EQM4062S Turbine housing Bearing Compressor housing Plug Thrust collar Elbow Arm and valve Screw Clamp Bush Thrust bearing Hose Crank Thrust space Piston Retaining ring Piston ring Bracket, body V-band Seal ring Cove Wheel Seal ring Retainer Piston ring Rear plate Gimble Wheel shroud...
  • Page 140 4.4.2. General descriptions 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 the greater volume of compressed air is charged into the cylinders of given capacity, the greater engine output can be obtained as a greater volume of air charged into the cylinders burns so...
  • Page 141 4.4.4. Precautions for operation 1) Precautions for operation of engine The following precautions should be observed when starting, operating, or stopping the engine: Complaints Possible causes Corrections When starting 1) Check oil level 2) Crank the engine with starter to 2) Abrupt starting of the engine the engine check the increase in oil pres-...
  • Page 142 4.4.5. Walk-around check and servicing 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;...
  • Page 143 4.4.6. Periodical checking and servicing Make it a rule to check the turbocharger assembly for condition and contamination periodically. 1) Guide for checking the rotor for rotating condition The inspection of the rotor assembly for rotating condition should be performed by the degree of unusual sound.
  • Page 144 (3) If the measured axial and radial plays are beyond the limit of wear, replace or repair the turbocharger. 3) Guide for disassembling/cleaning and checking the turbocharger First, disassemble the turbocharger from the engine and clean/check it with the oil inlet and outlet plugged with tape and so on.
  • Page 145 Pole, press ON/OFF key once more. In this case to change the screen, press any key. DAEWOO HEAVY INDUSTRIES LTD. Press any key if ok marks are displayed EA2M5002 EA2M5002 to the system check and memory check items of the scan pole screen.
  • Page 146 [ NORMAL ] [ FAULT ] If Daewoo vehicle model was not matched with communication protocol or any error occurred, then above FAULT message is displayed. If NORMAL message displayed, then program goes on next screen. And the right screen will be displayed as COMMUNICATION CHECK a result of unit check.
  • Page 147 5.3. Self-Diagnosis(current) If user selects the SELF-DIAGNOSIS DIAGNOSIS (CURRENT) diagnosis item menu when prestroke C15. PRESTROKE ACTUATOR POWER ERROR C22. FUEL RACK SENSOR ERROR acturator and fuel rack sensor fail, then HELP ERASE PRINT following screen is displayed Repair Hint Fail code erase Fail item printing * SELF-DIAGNOSIS (PAST) FUNCTION IS SAME.
  • Page 148 5.4. Sensor data If user selects the SENSOR DATA SENSOR DATA DIAGNOSIS ITEM SELECT menu 01 ENGINE RPM....... RPM 02 FUEL RACK SENSOR......V screen then display as follows. 03 PRESTROKE TARGET...... V 04 PRESTROKE ACTUAL....... V Displayed sensor data can scroll to use 05 WATER TEMP.SENSOR....
  • Page 149 FULL 5.4.3 function Press the F2 function key then FULL SENSOR DATA FULL SCREEN 22 sensors data is displayed on the ENG.RPM HEATER L RACK SEN HEATER R screen. But the full screen does not dis- P.TARGET play regular sensor data value P.ACTUAL W.T.S °C...
  • Page 150 5.5. Actuator test If user selects the ACTUATOR TEST ACTUATOR TEST item in DIAGNOSIS ITEM, user can see 1. PRESTROKE ACTUATOR TEST 2. TACHO METER TEST item as shown on the right : 3. AIR HEATER LAMP TEST 4. AIR HEATER RELAY TEST 5.DIAGNOSTICS LAMP TEST Press Key,refer to the item.
  • Page 151 5.6.1 Flight record basic application is the function which checks to occur fail condition sometimes.This FLIGHT RECORD function is very useful to search fail of vehicle cause of using analysis of record data. SELECT 5.6.2 function To select a record item, press the FLIGHT RECORD SELECT F1 key.
  • Page 152 TIME 5.6.4 function User must adjust a interval of recording FLIGHT RECORD time use the TIME F3 key before 01 ENGINE RPM......RECORD 05 WATER TEMP.SENSOR..RECORD flight record started. 06 RACK SENSOR OFFSET..RECORD 07 PRESTROKE OFFSET..RECORD The time change interval is 0.1 sec and IME INTERVAL : 0.1 sec the time range is 0.1 sec ~ 10.0 sec.
  • Page 153 PRINT 5.6.7 function User can print the recorded data to press the : F6 function key. Before printing Scan PRINT Pole must be connected with printer via PC connection cable. Printer is option. 5.6.8 D12TIS diagnosis & repair hint CODE Fault Point Regular Specification Repair Hint...
  • Page 154 CODE Fault Point Regular Specification Repair Hint ENGINE SPEED Error in engine RPM 1.Check the signal between SENSOR ERROR sensor pin No.10 pin and pin No.23 of ECU 2.Check the resistance of pick-up sensor : 2.5`0.5K 3.Check if cable is short or open 4.Check the contracts of connector PRESTROKE Error in prestroke...
  • Page 155 5.6.9. Special tools Description Part No. Illustration Nozzle tube Insert ass’y DPN-5337 Nozzle tube Extracter ass’y EF.123-082 EF.123-015 (DE12/T/TI) Inj, pump setting ass’y EF.123-156 (DE12TIS) Oil seal insert ass’y(FR) EF.123-126 Oil seal insert ass’y(RR) EF.123-053 Oil seal puller ass’y(FR) EF.123-052...
  • Page 156 Description Part No. Illustration Oil seal puller ass’y(RR) EF.123-048 Cylinder pressure tester EU.2-0531 adapter Cylinder liner puller ass’y EU.123-087 Stem seal insert EF.123-066 Valve clearance adjust ass’y EU.2-0131 Valve cottor extracter ass’y EF.123-065 EA2M5003 - 153 -...
  • Page 157 6. Maintenance specifications 6.1. Tightening torque 6.1.1. Major part tightening torque Part Dia.Bpitch(mm) Grade Tightening torque Cylinder head bolt M14B1.5 12.9T 24.5 Conn. rod bearing cap bolt M16B1.5 12.9T Crankshaft main bearing cap bolt M16B1.5 12.9T Balance weight fixing bolt M14B1.5 10.9T Flywheel fixing bolt...
  • Page 158 6.1.3. Standard bolt tightening torque table Refer to the following table for bolts other than described above. Degree of strength 10.9 12.9 Diameter (4A) (4D) (4S) (5D) (5S) (6D) (6S) (6G) (8G) (10K) (12K) pitch Limit value for elasticity (kg/mm (mm) Tightening torque (kg•m) 0.15...
  • Page 159 6.2. Maintenance specification table Nominal Standard value Limit for Assembly Part Check items Correction Remarks value for assembly Measure unworn portion beneath Inside diameter of cyl. liner for wear 123~123.025 123.22 Replace liner the rim of the upper side Projected portion of liner 0.03~0.08 Cylinder block...
  • Page 160 Nominal Standard value Limit for Assembly Part Check items Correction Remarks value for assembly N96 g6 Axial run-out of journal and pin 0.05 Correct with a grinder In horizontal and vertical directions N83 g6 N96 g6 95.966~95.988 N94.966 Replace crank shaft Outside diameter of journal N83 g6 82.966~82.988 N81.966 Replace crank shaft Outside diameter of pin...
  • Page 161 Nominal Standard value Limit for Assembly Part Check items Correction Remarks value for assembly Between crank gear & idle gear Idle 0.10~0.20 Replace gear Between idle gear & cam shaft gear 0.10~0.20 Outside diameter of intake valve stem 10.950-10.970 10.87 Replace valve guide together Replace valve &...
  • Page 162 Nominal Standard value Limit for Assembly Part Check items Correction Remarks value forassembly Correct or replace if severely Contacting face of valve stem & rocker arm pitted on tip of arm and stem Valve Valve Clearance between rocker arm shaft & rocker arm bush 0.020~0.093 Replace bush or shaft System...
  • Page 163 Nominal Standard value Limit for Assembly Part Check items Correction Remarks value forassembly Radiator & water pump for corrosion, damage & improper connecting Correct or replace Test for leakage(air pressure) kg/cm 1.0332 Submerge in water and replace if air bubbles found Radiator Pressure valve for opening pressure kg/cm Negative pressure valve for opening pressure mmHg...
  • Page 164 Nominal Standard value Limit for Assembly Part Check items Correction Remarks value for assembly Run-out of shaft 0.1 or more Replace rotor Rotor Bearing for noise Replace bearing Slip ring face for fouling Correct with sandpaper if fouled or damaged Brush length mm Alternator Brush Brush &...
  • Page 165 Nominal Standard value Limit for Assembly Part Check items Correction Remarks value for assembly Operating voltage V Magnetic switch Holding voltage V Correct or replace if excessively Pinion stroke +1.0 or less worn or damaged Starter Gap between pinion and ring gear Unload speed(24V, 70A or less) rpm 4,000 or more Perform-...

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