FOREWORD This manual is designed to serve as an instruction for the Operation & Maintenance of marine propulsion engines (L136/T/TI/086TI) and marine auxiliary engines (AD136/T/TI/086TI), combined in one book. The first half is explained for operation and the latter half is described for maintenance like disassembling, inspecting and re-assembling etc in order to help an understanding for the maintenance procedure more easily.
CONTENTS Operation Parts 1. Specification ......................................................................................................................... 1 1.1. Engine Specification 1.3. Engine Performance Curve 1.2. Engine Aspects 1.4. Engine Model & Serial Number 2. Safety Regulations .............................................................................................................. 8 2.1. General Notes 2.4. Regulations Designed to Prevent Pollution 2.2.
1. Specification 1.1. Engine Specification 1.1.1. L136/T/TI Model Spec. Units L136 L136T 4 cycle, in line, direct- injection, water cooled naturally aspirated Engine type Rating output (B.H.P) Displacement PS(kW)/rpm L136TL 160(118)/2,200 200(147)/2,200 240(177)/2,500 mm Valve clearance at cold mm In. : 0.3 , Ex. : 0.3 Low idling rpm rpm 725 ± 25 No load max. rpm rpm 6- 111 x 139 below 2,400 Mean effective press. (Initial ) kg/cm Mean piston speed m/sec. 2 Compression ratio 8.
1.1.2. L086TI Model Spec. L086TI Units L086TIH L086TIM L086TIL 4 cycle, in line, direct- injection, water cooled Engine type with wet-turbo charger & inter-cooler Rating output (B.H.P) Displacement PS(kW)/rpm 285(210)/2,100 300(221)/2,300 cc 360(265)/2,500 8,071 Cylinder No. - bore( ) x stroke mm Valve clearance at cold mm In. : 0.3, Ex. : 0.3 Low idling rpm rpm 750 ± 25 No load max. rpm rpm 6- 111 x 139 below 2,310 below 2,530 below 2,750 Mean effective press.
1.1.3. AD136 / T / TI / 086TI Model Spec. Units AD136 AD136T AD136TI 4 cycle, in line, 4 cycle, in line, 4 cycle, in line, 4 cycle, in line, direct- injection, direct- injection, direct- injection, direct- injection, water cooled with water cooled with water cooled water cooled with turbo charger & wet-turbo charger turbo charger naturally aspirated inter-cooler & inter-cooler Engine type 50 Hz Rating output (B.H.
1.2. Engine Aspects 1.2.1. Engine Sectional Drawing 26 25 20 8 28 19 7 18 3 2 27 4 22 14 16 5 6 1 17 15 9 13 12 21 23 11 10 24 EC5OM100 1. Cylinder block 11. Camshaft 21. Oil pump 2. Cylinder head 12. Vibration damper 22. Oil cooler 3. Cylinder head cover 13. Camshaft pulley 23. Oil pan 4. Cylinder liner 14. Piston 24. Oil suction pipe 5. Flywheel housing 15. Connecting rod 25. Water pump 6. Flywheel 16. Piston pin 26. Sea water pump 7. Rocker arm 17.
1.2.2. Engine Assembly 6 5 3 14 7 15 27 26 8 13 2 21 9 22 12 19 11 10 1 20 23 24 25 4 16 17 18 EC5OM099 1. Crank pulley 10. Oil pan 19. Thermostat housing 2. Expansion tank 11. Injection pump ass’y 20. Breather ass’y 3. Fuel filter 12. Oil guide tube & level gauge 21. Exhaust manifold 4. Oil cooler cover 13. Water pump 22. Oil filler cap 5. Intake manifold 14. Fresh water filler cap 23. Exhaust outlet pipe 6. Intercooler 15. Sea water pump 24. Turbocharger(wet) 7.
1.3. Engine Performance Curve 1.3.1. L136 / L136T / L136TI /L136TL 100 Fuel Consumption 1000 1500 2000 170 160 150 Full Load e ang nR ratio Ope Propulsion Curve 200 100 2500 1000 1500 2000 300 Full Load 200 e ang nR ratio Ope 100 400 300 200 Full Load 100 ratio Ope Propulsion Curve 170 160 150 Fuel Consumption Engine Speed (r.p.m) 400 Propulsion Curve 170 160 150 Fuel Consumption 2500 1000 Engine Speed (r.p.m) 1500 2000 e ang nR 2500 1000 Engine Speed (r.p.
1.4. Engine Model & Serial Number The engine serial number is inscribed on the engine as illustrated. This number is required when requesting warranty and ordering parts. It is also referred to as engine model and serial number because of their location. Note : The engine model Name Plate name (L136/T/TI/086TI) is described in Engine Plate EC5OM138 the name plate on the cylinder block. • Engine serial No. (Example : L086TI) EBPKM300001 Serial No.
2. Safety Regulations 2.1. General Notes Day-to-day use of power engines and the service products necessary for running them presents no problems if the persons occupied with their operation, maintenance and care are given suitable training and think as they work. This summary is a compilation of the most important regulations. These are broken down into main sections which contain the information necessary for preventing injury to persons, damage to property and pollution.
• Do not touch the engine hot parts(Exh. Manifold & turbocharger connection pipes, Inter cooler & heat exchanger connection pipes..etc) with bare hands when it is warm from operation risk of burns. • Exhaust gases are toxic. Comply with the installation instructions for the installation of DAEWOO marine diesel EC2OM010 engines which are to be operated in enclosed spaces. Ensure that there is adequate ventilation and air extraction.
• When using compressed air, e.g. for cleaning the heat exchanger, wear goggles. • Keep service products (anti-freeze) only in containers which can not be confused with drinks containers. • Comply with the manufacturer’s instructions when handling batteries. CAUTION :Accumulator acid is toxic and caustic. Battery gases are explosive. 2.2.3. When carrying out checking, setting and repair work • Checking, setting and repair work must be carried out by authorized personnel only.
2.4. Regulations Designed to Prevent Pollution 2.4.1. Engine oil, filter element, fuel filter • Take old oil only to an oil collection point. Take strict precautions to ensure that oil does not get into the drains or into the ground and sea. • The drinking water supply may be contaminated. • Oil and fuel filter cartridges are classed as dangerous waste and must be treated as such. 2.4.2. Coolant • Treat undiluted anti-corrosion agent and / or antifreeze as dangerous waste.
3. Commissioning and Operation 3.1. Inspections Before Operation 3.1.1. Lubricating oil • The notches in dipstick must indicate the oil level between max. and min. permissible. • The measurement of the oil level must be done on a even water line and in 10 minutes after engine operating. • Examining the viscosity and thecontamination of the oil smeared at the dipstick, replace the engine oil if EA4O4001 necessary.
3.1.3. Sea water pump The rotating direction of the pump impeller determines the location of the pump’s intake and discharge ports. OUT IN IN OUT EA7O3005 EA7O3005 • Over-tightened belt or gear load will reduce the bearing life of the sea water pump. • Do not run sea water pump at dry for more than 20 seconds. • Make sure that all valves / cocks in the sea water circuit are opened before run. • If there is a risk of freezing weather, drain the water by loosening bolts of end cover.
3.1.7. Gauge Panel Check the all gauges of the panel whether the function is in normal or not. • L136 1 4 5 7 1 10 2 8 9 ENGINE SPEED 10 ENG OIL PRESS CHARGE WATER TEMP 6 PRE HEAT WATER TEMP 5A OFF HEAT 2A ACC START ENG STOP START SWITCH EB1M3001 1 Case, Gauge 5 Gauge, Water Temp 8 Connector 2 Panel, Gauge 6 Key Switch Ass’y 9 Button, Engine Stop 4 Meter, Tacho 7 Hour Meter 10 Fuse Holder • L136T/TI/086TI 4 6 2 3 11 5 1 CHARGE WATER TEMP ENG.
3.1.8. Engine Stop & Warning Devices L136/T/TI/086TI gauge panel is equipped with warning lamps and an audible alarm to alert the operator as follows. 1) Engine Stop Device (Stop solenoid) Engine stop solenoid is operated with warning lamps and buzzer sound at the same time as follows. • When the engine oil pressure is less than 0.5 kg/cm • When the engine water temperature is more than 100 °C.
3.2. Starting 3.2.1. Operation 1 After checking the warning lamps of the gauge panel and the NEUTRAL position of reduction gear control lever, turn the key switch to the START position to crank the engine, at once. Behavior - When the key switch is placed in the START position. 3.2.2. Operation 2 After the engine is cranked, convert the key switch to the ACC position quickly. Behavior - As the engine is cranked, don’t fix the key switch too long (over 5 seconds) in the START position.
Initional Break-In of DAEWOO Marine Engines (Load) 100% 75% 50% Fast Idle 25% Idle 0 3 min. 5 5 2 2 30 5 30 min. 5 52 30 5 30 5 10 5 30 min. 5 30 30 30 30 min. 3 2 Repeat again Repeat again Up to 2 hours Up to Next 8 hours Repeat again Repeat again And then Next 10 hours During 20 hours Last additional 30 hours Total 50 hours Initial Break-In of DAEWOO marine Engines Running Time EC5OM126 3.3.1.
3.3.3. Final 10 hours During the final 10 hours of break-in, it is permissible to operate at full throttle for five to ten minutes at a time. After warming engine to operating temperature, momentarily reduce then increase engine speed. Continue to operate at approximately three-fourths throttle. Occasionally reduce engine speed to idle to provide cooling periods. Note : Do not run engine at a constant rpm for prolonged periods of time during the breakin period. 3.3.4.
3.4. Inspection After Starting During operation the oil pressure in the engine lubrication system must be monitored. If the monitoring devices register a drop in the lube oil pressure, switch off the engine immediately.And the charge warning lamp of the alternator should go out when the engine is running. • Do not disconnect the battery or pole terminals or the cables.
3.6. Operation in Winter Time Pay special attention to the freezing of cooling water and the viscosity of lubricating oil. 3.6.1. Prevention against the freeze of cooling water When not using anti-freeze, completely discharge the whole cooling water after engine running. The freeze of cooling water causes the fatal damages of the engine. Because the anti-freeze is used to prevent coolant from freeze and corrosion, it is always to be filled with the anti-freeze 35 ~ 40 % of the engine whole coolant. 3.6.2.
4. Maintenance and Care 4.1. General Instructions 1. Before performing service operation, disconnect the grounding cable from the battery for reducing the chance of cable damage and burning due to short-circuiting. 2. Use covers to prevent the disassembled parts and components from damage or pollution. 3. Engine oil and anti-freeze solution must be handled with care. They can cause damage for painted parts. 4.
4.2. Periodical Inspection & Maintenance In order to insure maximum, trouble-free engine performance at all times, regular inspection, adjustment and maintenance are vital before occurring any problems. • Daily inspections in below figure should be checked every day. • The following maintenance details should be executed thoroughly at regular internals.
4.3. Cooling System 4.3.1. Coolant level check and refill • Replenish the deficient coolant in the expansion tank every day before running. The coolant must be changed at intervals of 1,200 hours operation or six months whichever comes first. If the coolant is being fouled greatly, it will lead engine overheat or coolant blow off from the expansion tank. • Clean fresh water should be used for engine coolant.
4.3.2. Contamination check of the coolant and the quantity of the anti-freeze We recommend the engine coolant for DAEWOO marine engines should be mixture of fresh water and additional agent (35 ~ 40% anti-freeze and 3 ~ 5% anti-corrosion agent). Check the quantity of the anti-freeze every 600 hours. From time to time, refill the anti-freeze as much as required. You can check the quantity of anti-freeze and anti-corrosion agent by using a FLEETGUARD test kit simply as follow. (Fleetguard CC2602M : DHI No.
(1) Compare the end pad “a)” color of the strip % GLYCOL / FREEZEPOINT (℃) (End Pad) 25% 33% 40% 50% 60% with color blocks of a row at the upper part of the standard color chart (below of the letter “GLYCOL/FREEZE POINT”). Same -12°-15° -15°-18° -18° -21° -21°-23° -23°-29° -29° -34° -34°-43° -43°-51℃ -51° -12° color in the block of the row means the content of anti-freeze in the SCA Units per Litre coolant. (Normal range is between 33% and 50%.
2) Quantity of anti-freeze The anti-freeze, 35 ~ 40% of the whole coolant, is always to be used to prevent the cooling system from the corrosion. And in winter the amount of anti-freeze shown in the following table should be used in accordance with the ambient temperature. As the individual freezing points corresponding to the proportions of antifreeze in the table are subject to change slightly according to the kind of antifreeze, you must follow the specifications provided by the antifreeze manufacturer.
4.3.4. V-belt check and adjustment (1) Visual check Check the belt for cracks, oil, overheating and wear. (2) Tension check By the finger-pressure, the belt is pressed by 10 ~ 15mm between the 10mm water pump pulley and the alternator pulley in normal condition. Water pump For the adjustment of the tension, loosen the adjusting bolts which support Alternator the alternator, adjust the tension and tighten the bolts again.
• Inspection (1) Check the wax pallet and spring for damage. (2) Put the thermostat in a container of water, then heat the water slowly Bar and check temperature with a Thermometer thermometer. If the valve lift is 0.1 mm (starting to open) at temperature of 71 °C and 8 mm or Wood plate more (opening wide) at temperature of 85 °C, the thermostat is normal.
• Impeller disassembly (1) Remove end cover screws, end cover and o-ring. (2) Grasp the hub of impeller with water pump pliers and withdraw it by twisting to the rotating direction of the sea water pump body or remove it using two drivers like upper figure. (3) Detach the cam unscrewed a bolt and clean the sealant of cam and body bore. EB4O401L (4) Remove the wear-plate. EB4O402L • Impeller assembly (1) Install wear-plate in body bore, aligning slot in wear-plate with dowel pin in body.
4.4. Lubrication System 4.4.1. Oil level check • The notches in dipstick must indicate the oil level between high and low permissible when the vessel is in the water and with its normal trim. • The oil level should be checked with the engine horizontal and only after it has been shut down for about 10 MAX minutes. • Examining the viscosity and MIN the EA6O5001 contamination of the oil smeared at the dipstick, replace the engine oil if necessary.
4.4.2. Lubrication oil exchange Engine oil and the oil filter are important factors affecting engine life. They affect ease of starting, fuel economy, combustion chamber deposits and engine wear. The first engine oil change should be after 50 hours of operation and next exchange will be performed every 250 hours. At the end of the break-in period (50 hours), change the engine oil and replace the oil filter cartridge to new one.
Engine oil viscosity - ambient temperature SAE 20, 20W Single grade SAE 30 SAE 10W Ambient -30 C temp (-20 F) SAE 40, 50 -15 C (-0 F) -0 C (-32 F) Multi grade 15 C (60 F) 25 C 30 C (80 F) (90 F) SAE 10W - 30 SAE 15W - 40 SAE 10W - 40, 20W - 40, 20W - 50 SAE 5W - 20 EA4M1008 4.4.3. Oil filter cartridge replacement Every time oil exchanges, replace the oil filter cartridge. • Drain engine oil by loosening the drain plug on the filter head.
4.4.5. Cylinder compression pressure check • Stop the engine after warming up, and take out nozzle holder assembly. • Install the special tool (compression gauge adapter) at the nozzle holder hole, and connect the compression pressure gauge there. Standard value Limit value Difference between each cylinder 24 ~ 28kg/cm2 24kg/cm2 or less EB4O403L Within ± 10 % Test Condition * Cooling water temperature 20°C, Engine rotation 200rpm (about 10 revolutions) 4.5. Intake & Exhaust System 4.5.1.
4.5.2. Air filter element cleaning & change The engine life and performance depends on the intake air condition greatly. A fouled air filter element results decreased intake air amount that leads decreased engine output and finally may cause an engine malfunction. Further, a damaged air filer element results wear on the cylinder component or the valve mechanism etc. leading increased engine oil consumption and decreased engine output, finally leads to shorten the engine life.
4.5.3. Inter-cooler cleaning Inter-cooler depends on the intake air conditiongreatly. The fouled air pollutes and clogs the air fins of the inter cooler. As a result of this, theengine output is decreased and the engine malfunction may be occurred. Therefore alwayscheck weather the intake air systems like air filter element are worn or polluted. EC5OM106 The inter-cooler has to be removed from theengine for cleaning.
take care to see that only the compressor wheel is immersed and that the turbocharger is supported on the bearing casing and not on the wheel. 4.5.5. Exhaust gas check Exhaust gas depends on much or less of it shows whether combustion condition of the engine is good or not. If exhaust gas is any abnormal condition like excessive smoke, white smoke, black smoke, the engine should be serviced maintenance from specialist. 4.6.
NOTICE : A galvanized steel tank should never be used for fuel storage, because fuel oil reacts chemically with the zinc coating to form powdery flakes which can quickly clog the fuel filters and damage the fuel pump and injection nozzles. • How to select fuel oil Fuel quality is an important factor in obtaining satisfactory engine performance, long engine life, and acceptable exhaust emission levels. DAEWOO engines are designed to operate on most diesel fuels marketed today.
Note : The cloud point should be 6 °C (10 °F) below the lowest expected fuel temperature to prevent clogging of fuel filter by crystals. 4.6.3. Water separator cleaning DAEWOO recommends the fuel water separator to install between fuel tank and fuel injection pump strongly. Condensation formed in a partially filled tank promotes the growth of microbial organisms that can clog fuel filters and restrict fuel flow and cause the engine power decrease before.
4.6.5. Fuel injection timing check (by authorized specialist personnel) Check the fuel injection timing every year. Refer to details in “6.3.27. Injection pump & timing “ Caution : • Check the fuel injection pump housing for cracks or breaks, and replace if damaged. • Check whether the lead seal for idling control and speed control levers have been removed or not. • No alterations must be made to the injection pump. If the lead seal is damaged the warranty on the engine will become null and void.
4.8. Cylinder 4.8.1. Valve clearance adjustment Usually should check the valve clearance of intake & exhaust every 1,000 hours after engine operation. Refer to "6.3.26. Valve clearance adjustment" details. The valve clearances should be adjusted at the times of the following situations. • After initial 50 hours operation. • When the engine is overhauled and the cylinder heads are disassembled. • When severe noise comes from valve train.
4.9. Engine Preservation Points for a Long Time Preserved engine for a long time should be prevented from corrosion or entering faulty matters. Especially the external and internal major components of the engine are likely to corrode. Please take care of the engine to maintain its good performance as follows. • Drain the engine coolant completely and fill flesh water into the engine. Then run it sufficiently until washing out the engine coolant line.
4.10. Management for Sunken Engine If the engine is sunk in sea water, remove the moisture of all engine parts as soon as possible and ask after service of your DAEWOO dealer at once. All parts of the engine should be disassembled to remove the salty moisture. After this, engine oil should be applied onto the parts at once. Finally check whether the components of the engine are dried, eroded away or damaged especially components of the fuel system. These actions must be finished quickly without delay.
5. Main Accessory Parts 5.1. Reduction Gear Refer to “reduction gear manual” provided with engine separately for detail operation and maintenance of reduction gear. 5.1.1. Construction and operation The reduction gear is used for high-speed engine and consists of 4 major components such as input shaft, gear shaft, output shaft, and housing. The clutch for forward and reverse movements is composed of a hydraulic wet-type and multiplate type.
5.1.2. Characteristics The hydraulic-type clutch is composed of forward main body, reverse main body, output shaft, and selector valve.. The selector valve assembly installed on the external part is a device designed to control forward, neutral, and reverse movements and also it can be remote-controlled. The oil pumped up at the pump supplies hydraulic pressure for the clutch assembly, lubricating portions on gear and bearings, and cooling system.
(4) Emergency bolt The emergency bolt is designed to couple the clutch mechanically when the clutch indicates abnormal condition or slip at clutch coupling operation. The reverse clutch pack has no emergency bolt. When using the emergency bolt, first loosen the tightening bolts to remove the control block, tighten the 8mm wrench bolt on the forward disc pack using a 5mm L-shaped wrench, then reassemble the control block in the reverse order. Be sure to use this emergency bolt literally in case of emergency.
5.2.2. For small cross drive power The figure is applicable to the drive arrangement (No supporting bearing on front side of PTO pulley) in which the Engine distance between the end face of the engine pulley and the Crank V-pulley, PTO pulley MAX. 170mm (6.7 in) dia. centerline through pulley groove is not greater than 60mm. The distance is indicated as L in the figure. L EA4O7002 Model L mm Belt driven side load(kW) L136 L136T rpm 35 40 60 L136TI 50 L086TI 62 1,600 5.3.
5.4. Electric System 5.4.1. Alternator Terminal R Terminal L Terminal P Terminal B Terminal E EFM5001I The alternator is fitted with integral silicon rectifiers. mounted A on transistorized the alternator P regulator limits B the L alternator voltage evenly. The alternator I.C Regulator should be operated with the regulator and R F battery connected in circuit to avoid the Body damage of the rectifier and regulator.
• Inspection points on the voltage regulator Resistance Value Resistance Value Terminal Terminal (KΩ) + - L E about 2 R E about 53 F E about 50 L F about 50 R L R F (KΩ) + - E R about 50 L R about 168 F R ∞ ∞ ∞ (2) Precautions in use • Pay attention to dropping the battery voltage capacity when they are left for long time even without use.
5.4.2. Starter Motor The starter motor is installed on the flywheel housing. When the starter key switch is turned on, the starter motor pinion flies out and engages the ring gear of the flywheel. Then the main contact is closed, current flows, and the engine is started. After the engine starts, the pinion automatically returns to its initial position as soon as the starter key switch is released. Otherwise, the starter motor may be damaged or burned out.
6. Disassembly and Assembly of Major Components 6.1. Disassembly 6.1.1. General precautions • Maintenance operation should be carried out in a bright and clean place. • Before disassembly, provide racks for arrangement of various tools and disassembled parts. • Arrange the disassembled parts in the disassembly sequence and use care to prevent any damage to them. 6.1.2.
6.1.5. Alternator • Remove the electric wires and the alternator fixing bolt and then disassemble the cover and alternator. • Remove the tension adjusting bolt and bracket. EC5OM109 6.1.6. Fuel filter • Remove fuel hoses connected to the fuel injection pump, take off the filter housing fixing bolts, then disassemble the fuel filter. EC5OM110 6.1.7. Breather • Loosen the clamp screw to remove the rubber hose and the breather after unscrew. EB1M3006 6.1.8.
6.1.9. Air cleaner • Remove the air filter element. • Loosen the clamp, then remove the air cleaner. EB1M3008 6.1.10. Turbo charger Turbo Charger • Loosen the clamp screw of the rubber hose connected to the inter cooler, and take off the intake pipes both simultaneously. • Unscrew the exhaust pipe flange fixing bolts and the nuts installed on theturbocharger, then take out the exhaust pipe.
6.1.12. Stop solenoid • Remove the cable from the fuel stop lever to the stop solenoid. • Disassemble the stop solenoid. EC5OM114 6.1.13. Injection pipe • Unscrew the hollow screws to disassemble the fuel return pipe. • Remove the nuts installed on the fuel injection pump nozzles, then and the injection disassemble the injection pipe. EAMD011I 6.1.14. Intake manifold • Remove the hoses connected to the injection pump and fuel filter and intake manifold.
6.1.16. Heat exchanger • Loosen the clamp on the rubber hoses connected to the inter cooler and cooling water pipe of the heat exchanger, and remove the inter cooler then take off the rubber hoses. • After remove the inter cooler, unscrew the heat exchanger fixing bolts, then detach the heat exchanger. EC5OM117 6.1.17. Exhaust manifold • Remove the cooling water pipes on the front and upper side and then exhaust outlet pipe.
6.1.20. Water pump • Remove rubber the expansion tank and hose connected to the expansion tank. • Remove the water pipe and hoses connected to the oil cooler. • Unscrew the water pump fixing bolts and remove the water pump. EB1M3017 6.1.21. Injection pump (A) L086TI • Remove the oil supply pipe and the return pipe connected to the fuel injection pump. • Unscrew the bolts connected the coupling and drive shaft, disassemble the injection pump mounting bolts, then detach the injection pump.
(B) L136/T/TI • Put the piston (No.1) of the engine to O.T position, then remove the timing gear case cover, and engrave a line on the both flanges as the figure. (This is only for no engraved line before.) • Remove the injection pump, Engrave 표시선Line EB4O601L To exchange the injection pump for new one, put the piston (No.1) of the engine to O.T position, then mark the line marking temporary by using oil paint at the geared point between injection pump gear and idle gear separately.
6.1.24. Timing gear case cover • Disassemble the oil seal using the removing jig. • Unscrew the cover fixing bolts and disassemble the cover from the timing gear case. EAMD025I 6.1.25. Idle gear • Unscrew the idle gear fixing bolts and disassemble the thrust washer and idle gear. • Disassemble the idle gear pin using a rubber hammer to prevent them from damaging. ENM3032S 6.1.26.
6.1.28. Rocker arm assembly • Unscrew the rocker arm bracket bolts and remove the rocker arm assembly. • Take off the snap rings to remove the washers and rocker arm, then unscrew the bracket fixing bolts to take off the bracket and springs. • Take out the push rods. EAMD029I 6.1.29. Injection nozzle • Take off the injection pipes between the injection pump and injection nozzles. • Remove the nozzle holder assembly using the nozzle removing jig.
6.1.31. Valve & stem seal • Compress the valve spring retainer using a jig and take off the valve cotter pins. • Disassemble the valve springs and retainers. • Take off the valves. • Remove and discard the used valve compress the 스프링 분해 spring 지그 stem seals in order not to be re-used. EA0M4007 6.1.32. Oil cooler • Unscrew the oil cooler cover fixing bolts and disassemble the oil cooler tube assembly from the oil cooler housing. Oil cooler EC5OM132 6.1.33.
6.1.35. Relief valve • Unscrew the relief valve housing fixing bolts • Disassemble the relief valve from the housing. Relief valve EB1M3019 6.1.36. Piston and connecting rod • Disassemble the pistons by two cylinders while turning the crankshaft. • Unscrew the connecting rod fixing bolts and take off the pistons and connecting rods in the direction of piston upper side. EAMD037I • Remove the piston pin and snap rings, then disconnect the connecting rod from the piston.
6.1.37. Cylinder liner • Take off the cylinder liner. EAMD040I 6.1.38. Flywheel • First remove two fixing bolts of the flywheel and install the two dowel pins in the bolt hole. • Unscrew the last flywheel fixing bolts, and then detach the flywheel with care. EB1M3020 6.1.39. Oil seal • Take off the rear oil seal using an oil seal disassembling jig. 6.1.40. Flywheel housing • Loosen the housing fixing bolts, then disassemble the flywheel housing.
6.1.41. Cam shaft and tappet • Remove the camshaft gear and thrust washer. • Take out the camshaft with care not to damage it and inner bearings. • Take out the tappets by hand. EAMD044I 6.1.42. Crankshaft gear and oil pump idle gear • Loosen the socket head bolts and take out the oil pump idle gear. • Use a puller of special tool to remove the crankshaft gear. 6.1.43. Timing gear case • Unscrew the case fixing bolts and disassemble the timing gear case. EAMD046I 6.1.44.
6.1.45. Oil spray nozzle • Unscrew the fixing bolt and remove the oil spray nozzles.
6.2. Inspection 6.2.1. Cylinder block 1) Clean the cylinder block thoroughly and check a visual inspection for cracks or damage. 2) Replace if cracked or severely damaged, and correct if slightly damaged. 3) Check the oil and water passing lines for restriction or corrosion. 4) Make a hydraulic test to check for any cracks or air leaks.
3) Flatness Measure the flatness of the intake and exhaust manifold face mounted on the cylinder head using a straight edge and a feeler gauge. Standard Limit 0.05 mm 0.2 mm 4) Hydraulic test Hydraulic test for the cylinder head is same as that for cylinder block. 6.2.3. Valve & valve guide 1) Valve Clean the valves with clean diesel oil, then inspect them as follows : • Valve stem outer diameter Measure the valve stem outer diameter at 3 positions (top, middle, and bottom).
2) Valve guide • Install the valve into the valve guide and measure the clearance between them by valve movement. If the clearance is excessive, measure the valve and replace either the valve or Measuring position the valve guide, whichever worn more. EA0M4052 Standard Limit 0.030 ~ 0.065 mm 0.15 mm Exhaust valve 0.045 ~ 0.080 mm 0.
• For removal of the valve seat, apply arc welding work to two points of valve Valve seat insert seat insert, and pull out the valve seat insert with inner extractor. Cylinder head Welding bead EA3M2032 • For assembling of a new valve seat, by putting it among the dry ices of an ice box previously for about 2 hours for the cold shrinkage, and press it in the cylinder head by a special tool.
• Valve Spring Inclination Use a surface plate and a square to measure the valve spring inclination.If the measured value exceeds Inclination the specified limit, the valve spring must be Standard Limit 1.8 mm 2.7 mm Valve spring inclination Free length replaced. Square EJM2050I • Valve Spring Tension Use a spring tester to measure the valve spring tension if the measured value is less than the specified limit, the valve spring must be replaced.
• Rocker arm shaft diameter With an outside micrometer, measure the rocker arm shaft diameter at the point where the rocker arms have been installed. Replace the rocker arm if the amount of wear is beyond the specified limit. Standard 23.939 ~ 23.96 mm Limit 23.75 mm EA8M3002 2) Rocker arm • Visual check Visually check the face of the rocker arm in contact with the valve stem end for scores and step wear. If the wear is small, correct it with an oil stone or grinding paper of fine grain size.
• Visual check of tappet Visually check the face of the tappets in contact with the cam for pitting, scores or cracks, and replace if severely damaged. If the amount of unevenness (1) 요철 cracks or pitting is small, correct with Crack (2) 균열 Normal (3) 정상 an oilstone or grinding paper. abnormal (4) 비정상 EA0M4070 • Outside diameter With an outside micrometer, measure the tappet outside diameter. If the measured value is beyond the limit, replace tappets. Standard 19.944 ~ 19.
6.2.5. Camshaft 1) Cam • Cam lobe height Use a micrometer to measure the cam lobe height and journal diameter. If the measured number is less than the specified limit, the camshaft must replaced. Items Cam lobe Intake height (C) Exhaust Standard Limit 49.15 mm 48.85 mm 49.32 49.00 mm I II A C B D I II B A EA0M4062 Cam journal 57.86 ~ diameter (A, B) 57.52 mm 57.88 mm • Cam surface Inspect the cam surface for scratch or damage.
• Run-out Support the camshaft on two V blocks and check for run-out using a dial indicator. Correct or replace the cam shaft if the amount of run-out is beyond the value indicating need for servicing. Standard Limit 0.05 mm 0.2 mm EA0M4066 3) Camshaft end play • Push the thrust plate toward the cam gear. • With a feeler gauge, measure the clearance between the thrust plate and camshaft journal. • If the end play is excessive, replace the thrust plate. Standard Limit 0.28 ~ 0.43 mm 0.
Standard Journal diameter Pin diameter Limit A 83.966 ~ 83.988 83.000 mm 70.971 ~ 70.990 70.000 mm B B B B A EFM2047I * Undersize bearings available Standard 0.25 (Inside diameter is 0.25 mm lesser than the standard size.) 0.50 (Inside diameter is 0.50 mm lesser than the standard size.) 0.75 (Inside diameter is 0.75 mm lesser than the standard size.) 1.00 (Inside diameter is 1.00 mm lesser than the standard size.
6.2.7. Crankshaft bearing and con- rod bearing 1) Visual check Visually check the crankshaft bearing and the connecting rod bearing for scores, uneven wear or damage. 2) Oil clearance between crankshaft and bearing. • Main bearing clearance Install the main bearing in the cylinder block, tighten the bearing cap to specified torque, then measure the inside diameter. Torque 30 kg.m Crank journal Diameter 83.966~83.
Compare the two values obtained through measurement of connecting rod bearing inside diameter with the outside diameters of the crankshaft pins to determine the oil clearance. Standard Limit 0.049 ~ 0.119 mm 0.20 mm EAMD060I If the clearance deviates from the specified range, polish the crankshaft journals and pins ground and install undersized bearings.
• Crankshaft bearing crush Install the bearing and cap in the cylinder block, retighten the bolts to specified torque, only unscrew out one bolt completely, then measure the clearance between the bearing cap and cylinder block using a feeler gauge. Standard 0.19 ~ 0.
6.2.8. Piston 1) Visual check Visually check the pistons for cracks, scuff or wear, paying particular attention to the ring groove. 2) Clearance between the piston and cylinder liner • With an outside micrometer, measure the piston outside diameter at a point Position of measuring outside diameter 13mm away from the lower end of piston skirt at right angle against direction of the piston pin hole. Standard 110.801 ~ 110.
6.2.9. Piston rings 1) Visual check Replace the piston rings with new ones if detected worn or broken when the engine is overhauled. 2) Piston ring gap • Insert the piston ring into the upper portion of the cylinder liner bore and then it should be positioned at a right angle against the cylinder liner wall surface. • Measure the piston ring gap with a feeler gauge. Standard Limit Top ring 0.40 ~ 0.65 mm 1.5 mm 2nd ring 0.40 ~ 0.65 mm 1.5 mm Oil ring 0.30 ~ 0.60 mm 1.
6.2.10. Piston pin 1) Wear Measure the amount of wear on the piston pin at the points as shown. If the measured values are beyond the limit (0.005 mm or greater), replace the pin. Standard Limit 41.944 ~ 42.000 mm 41.940 mm or less EA0M4031 2) Clearance Measure the clearance between the piston pin and connecting rod bush, and replace either of them, whichever damaged more, if the measured value is beyond the limit. Standard Limit 0.009 ~ 0.015 mm 0.
6.2.11. Connecting rod 1) Distortion Check the connecting rod for distortion. As shown in the figure below, install the connecting rod to the connecting rod tester, and check for distortion using a feeler gauge. If the connecting rod is found distorted, never re-use it but replace with a new one. 2) Holes alignment (parallelism) Measure the alignment of the connecting rod small bushing hole and the connecting rod big end hole. At this time also, use both connecting rod tester and feeler gauge.
6.3. Engine Re-assembly 6.3.1. General precautions • Clean all the disassembled parts, particularly oil and water ports, using compressed air, then check that they are free from restrictions.I • Arrange the general and special tools in order to engine assembly operation. • To lubricate each sliding part, prepare the clean engine oil. • Prepare maintenance materials such as sealant, gaskets, and etc. • Discard used gaskets, seal rings, and consumable parts, and replace with new ones.
• Apply engine oil to the entire face of the tappets and slide them into the tappet holes on the cylinder block. • Wet the cam bush inside diameter and camshaft with oil, and carefully assemble them while turning the camshaft. • Check to see that the camshaft rotates smoothly. EDM2060I 6.3.5.
• Semi-tighten a bolt at both sides of the crankshaft, apply engine oil to journals and pins, then assemble the crankshaft with the cylinder block by tightening the fixing bolts. EAMD075S • Install the oiled thrust washers with the oil groove facing outward of the bearing. • Install the bearing and thrust washers to the bearing cap and apply oil to the bearing and thrust washers. EAMD077I • Install the bearing cap by matching the cylinder block number compare with the bearing cap number.
• Apply oil to the entire part of the bearing cap bolts, then tighten in tightening sequence to specified torque. 30 kg.m Torque EAMD079I • After semi-tightening both bolts evenly, tighten them diagonally specified torque using a torque wrench as follows. (1) First stage : Coat engine oil over the bolts. (2) Second stage : Temporary assemble the bolts about 1 ~ 2 threads (3) Third stage : With impact wrench, tighten up to about 15 kg.
6.3.7. Rear oil seal • Apply lubricating oil to the outside of the oil seal and flywheel housing inside diameter and fit them over the crank shaft, then assemble the oil seal using an oil seal fitting jig. 6.3.8. Flywheel • Install a guide bar into a bolt hole on the crank shaft, and lift the flywheel to align the dowel pin with the pin hole on the flywheel for temporary assembly operation.
6.3.10. Injection pump drive gear • Mount the gasket by aligning the bolt holes with the pin holes on the bearing housing. • Tighten up the fixing bolts in the direction of fuel injection pump. EB1M3023 6.3.11. Timing gear • Install the oil pump idle gear into the No.7 bearing cap. • Install a thrust washer over the Idle gear pin camshaft and assemble the cam gear by aligning it with camshaft key groove. Torque 2.2 kg.
• Check and adjust the amount of backlash between gears using a feeler gauge. Items Standard Limit Cam gear & idle gear 0.16 ~ 0.28 mm 0.35 mm Crank gear & idle gear 0.16 ~ 0.28 mm 0.35 mm Injection pump & idle gear 0.16 ~ 0.28 mm 0.35 mm 6.3.12. Timing gear case cover • Install the dowel pin on the timing gear case. • Mount a gasket by aligning the fixing bolt holes with those on the gasket. • Align the dowel pin with the cover pin hole, then install the cover with light tap.
6.3.15. Piston and connecting rod • Use a piston heater to heat the piston approximately 100 °C ~ 212 °F for 5 minutes. • Align the piston pin hole with the connecting rod small end bush oiled and press the piston pin (by lightly tapping with a rubber hammer) to assemble the connecting rod into the piston.
• Identify the mark “Y” on the piston ring end to prevent assembling the bottom of the piston ring is being interchanged with its top faced marked “Y”. Note : Be sure to make the piston ring end marked face(“Y”) upward. "Y" marked from piston ring manulacturing company EAMD090I • Adjust the angle among individual 45 piston ring gaps to 90° and fit a piston 2nd ring gap assembling jig onto the piston, Use (0.35~0.50mm) O 45 O Top ring gap (0.30~0.
(1) First stage : Coat engine oil over bolts (2) Second stage : Temporary screw the bolt about 1 ~ 2 threads (3) Third stage : With torque wrench, tighten at about 10 kg.m (4) Fourth stage (5) Fifth stage : With torque wrench, tighten up to about 15 kg.m : Finally, tighten in the specified torque 18kg.m with torque wrench . 18 kg.m Torque • Move the bearing cap with hand, and release and reassemble it if no movement is detected. EAMD094I 6.3.16.
6.3.18. Oil pan • Mount gasket and put the oil pan thereon. • Align the bolt holes with gasket holes to prevent damage to the gasket and tighten bolts to specified torque. Torque 2.2 kg.m EAMD034I 6.3.19. Vibration damper and pulley • Assemble the vibration damper on the Crankshaft pulley. • Install the crankshaft pulley assembly on the crankshaft, then tighten the bolts and thrust washers. Torque 13.4 kg.m 6.3.20.
• Check the inside of combustion chamber for foreign substances, and carefully mount the cylinder head on the cylinder block by aligning the dowel pin in the pin hole. Be careful not to damage the head gasket. If the dowel pin is not in alignment, lift the cylinder head again and then remount it. EAMD102I • Coat the head bolts with engine oil, then tighten them in proper sequence to the specified torque according to bolt tightening order.
6.3.21. Intake and exhaust valves • Identify the marks of “IN” and “EX” impressed on the valve head before assembling the valve in the head. • With a valve stem seal fitting jig, assemble the valve guide and stem seal. • After installing valve springs and spring retainer, press the retainer with a jig, then install cotter pin. • Tap the valve stem lightly with a rubber hammer to check that the valve is assembled correctly. compressor the spring EA0M4007 6.3.22.
6.3.23. Injection nozzle • Install the dust seal with its round portion facing downward. • Mount a seal ring on its position of the cylinder head and then assemble the nozzle holder. • Be sure to follow the specified torque. EB1M3024 7.0 kg.m Torque 6.3.24. Valve clearance adjustment • Cylinder No. 1 begins from the rear side where the flywheel is mounted but cylinder No. 6 begins from the front side of the engine on the contrary. Flywheel Intaek Valve 1 Exhaust Valve 2 3 Cylinder No.
• Adjust valve clearance with a feeler gauge and tighten the fixing nuts to specified torque. 4.4 kg.m Torque EA0O4014 6.3.25. Injection pipe • Semi-assemble the nuts at both ends of the fuel injection pipe and tighten them up one by one to specified torque. 2.9 ~ 3.2 kg.m Torque • Tighten the hollow screws to assemble the fuel return pipe. • Assemble the fuel return hose on the fuel injection pump. 6.3.26.
6.3.27. Injection pump & injection timing (1) Fuel injection pump (A) L086TI, AD086TI • Install the injection pump bracket in the cylinder block. • After measuring the amount of runout with an alignment setting jig, disassemble the bracket, adjust the shims, then reassemble it. Run out • Mount 0.2 mm or less the top/bottom adjusting shims in the bracket and then EAMD107I mount the fuel injection pump. • Tighten the fixing bolts in a diagonal sequence to specified torque. Torque 4.4 kg.
Then assemble the injection pump gear by aligning with the oil paint marking lines as figure. marking ENM3032S (2) Injection timing • Turn the crank shaft until cylinder No. 6 is placed in the overlap TDC and Timing check hole then turn again the flywheel clockwise until the notch mark corresponding to the injection timing degree its model is aligned with hole center( ) in the fly- wheel as right figure. Refer to “ 1. Engine specification ” for each model.
(A) L086TI, AD086TI • After letting the cylinder No. 6 at overlap TDC position, adjust the injection timing degree of the engine. • After that, turn the injection pump until the notch mark of the pump indicator plate mounted is aligned with the notch mark of the drive shaft flange as right figure. • Tighten the coupling housing fixing EQM3089S bolts and nuts to specified torque. 6.0 kg.m Torque • Tighten the coupling housing fixing bolts and nuts to specified torque. Torque 7.5 ~ 8.5 kg.
• Turn the crank pulley clockwise slowly on pumping the priming pump to be continues simultaneously and you can see the point that fuel falls down by one drop per every 5 or 6 seconds from the fuel pipe No. 1. This point is the very fuel injection timing degree. EA9M3016 • After confirming the fuel injection timing, reassemble the holder and inner Holder 홀 더 parts including seat, spring and delivery valve. 시 트 Seat 4 ~ 4.5 kg.m Holder Torque A Spring Delivery 딜리버리 Valve 밸브 • Connect the No.
• Connect the cooling water pipes to the water pump and the heat exchanger. 6.3.29. Water pump • Mount a new gasket. • Install the water pump on the cylinder block and tighten the assembling bolts with specified torque. 2.2 kg.m Torque • Connect cooling water pipe and the expansion tank each other. EB1M3017 6.3.30. Sea water pump • Mount a new gasket. • Install the sea water pump on the timing gear case cover and tighten the assembling bolts with specified torque. Torque 4.4 kg.m EC5OM120 6.3.
6.3.32. Thermostat • Install the thermostat. • Fit the new gasket on the thermostat housing, then assemble the thermostat housing with mounting bolts. • Assemble the hose clamps in both sides of the heat exchanger and cooling water pipe EC5OM116 6.3.
6.3.35. Stop solenoid (L086TI) • Assemble the brackets on the injection pump body. • Install the stop solenoid and tighten the fixing bolts. • Connect the tie rod to fuel feed pump and stop solenoid. EC5OM114 6.3.36. Injection pipe • Semi-assemble nuts at both ends of the fuel high pressure pipe and tighten them up one by one to specified torque. Torque 3.0 kg.m • Tighten the hollow screws to assemble the fuel return pipe. • Assemble the fuel return hose to the EAMD120I fuel injection pump. 6.3.
6.3.39. Turbocharger • Insert a new gasket on the exhaust outlet pipe and mount the turbocharger. • Install the oil supply & return pipe. • Clamp the rubber hose connected to the air inlet pipe of the inter cooler, and assemble the cooling water inlet & outlet pipe. EC5OM130 6.3.40. Air cleaner • Assemble the air cleaner and tighten the bolt and nut of clamp properly • Finally install the air filter element. EB1M3008 6.3.41.
6.3.43. Alternator • Install the alternator mounting bracket. • Assemble the alternator and protector. EC5OM109 6.3.44. V - Belt • Install the V-belt on the crank pulley and alternator. • Adjust the V-belt tension using the tension adjusting bolt. EB1M3003 6.4. Break-in After Maintenance Because the sliding parts of a new or an overhauled engine are not lapped enough, the oil film can be destroyed easily by overload or over-speed and the engine life time may be shorten.
7. Main Parts Maintenance 7.1. Lubricating System Lubricating oil pumped by the gear oil pump in the oil pan is filtrated in the oil filter through oil cooler. This filtrated oil passed on the main oil gallery of the cylinder block where is distributed to lubricate the various sliding parts, fuel injection pump, and turbo-charger etc also in order to ensure normal engine performance. 7.1.1.
(2) Remove the oil pump cover fixing nuts and disassemble the oil pump cover. The oil pump cover is fixed with the two dowel pins. (3) Disassemble the drive and driven gear. EAMC005I • Inspection and correction (1) With steel ruler and feeler gauge, measure the axial end play of the oil pump gear. Replace if the measured value is beyond the limit. Limit 0.025 ~ 0.089 mm EAMC006I (2) With a feeler gauge, measure the amount of backlash between the oil pump drive gear and driven gear.
• Re-assembly (1) For re-assembly, reverse the disassembly sequence. 7.2. Cooling System 7.2.1. Cooling water pump • Loosen the bolt (8) and remove the pulley (12). • Unscrew the socket bolt (7) and detach the housing cover (5). • After heating on the impeller (3) a little remove the impeller using a special jig. • Detach the mechanical seal (4). • Heat on the hub (9) little by little and then remove the hub using a removing jig. • After detach the snap ring (11) remove the unit bearing shaft.
7.3. Fuel System 7.3.1. Injection pump The components relating to the injection pump should be serviced at regular intervals as the plunger and delivery valve may be worn after a given length of time for use and cause the deterioration of the engine. Make sure that servicing should be performed at the professional maintenance shop as authorized by Bosch or Zexel Company. For adjustment of fuel injection volume, refer to the ‘Specifications of fuel injection pump’ described on the following pages.
(3) Rack Diagram Idling serve 아이들링 서브spring 스프링 Rack position (MM) 14 14 or more 14 또는than 14이상 C Stroke start 스트로크 스타트 Governor spring 가버너 스프링 셋트set 아이들링 Idling serve 서브Spring 스프링setting 셋팅 10.5 7.7 6.9 6.
2) L136T, AD136T (1) Main Specification Fuel Injection Pump : 65.11101-7271A Model Type : PES6AD Governor Type : RSV Fuel Feed Pump : 105210-4830 Cam Lift : 11 mm Injection Timing : BTDC 18° ±1° Injection Order : 1-5-3-6-2-4 Rotating Direction : Clockwise (Viewed at driving gear side) (2) Calibration Data (A) Test condition for injection pump Nozzle & Holder Ass’y 105780-8140 Injection pipe(ID ,OD ,L) - Test oil (B) Engine standard parts Opening pressure :175kg/cm2 8.
(3) Rack Diagram 14 또는 14이상 or more than 14 C ±1.0mm 부스터 보점 스타트 : 1.0 Booster compensating start : 1.0 ± 1.0 mm Rack position (MM) A Governor spring setting 가버너 스프링 셋팅 11.2 ±5 10.5 C (7.7) Idling serve Spring setting 아이들링 서브 스프링 셋팅 B Q = 17±1.3 ㎟/st R2 (7.0) R1 -0.
3) L136TI, AD136TI (1) Main Specification Fuel Injection Pump : 65.11101-7341 Model Type : PES6AD Governor Type : RSV Fuel Feed Pump : 105210-5610 Cam Lift : 12 mm Injection Timing : BTDC 14° ±1° Injection Order : 1-5-3-6-2-4 Rotating Direction : Clockwise (Viewed at driving gear side) (2) Calibration Data (A) Test condition for injection pump Nozzle & Holder Ass’y 105160-4370 Injection pipe(ID ,OD ,L) - Test oil (B) Engine standard parts Opening pressure : 175kg/cm2 8.
(3) Rack Diagram or more14.0 than이상 14 E Rack position (MM) C ±0.1 mm Booster보정 compensating : 1.5 부스터 스타트 : 1.5stroke 13.1±0.1 12.5 B ±0.1 mm A D Idle serve, spring set셋트 아이들링 스브, 스프링 10.0±0.1 C 7.8 6.25±0.1 6.00±0.
4) L086TIH, AD086TI (1) Main Specification Fuel Injection Pump : 65.
(3) Rack diagram 14 C A RACK POSITION, mm 12 랙 10 위 8 치 6 D B (mm) 4 2 0 INJECTION PUMP SPEED, rpm 분사펌프 속도(rpm) EB1M4001 (4) Boost compensator pressure 13.0 RACK POSITION, mm P2 12.0 랙 위 11.0 치 P1 (mm) 10.0 9.
5) L086TIM (1) Main Specification Fuel Injection Pump : 65.
(3) Rack diagram E 14 C A RACK POSITION (mm) 12 랙 10 위 8 치 6 D B (mm) 4 2 0 200 400 600 800 1000 1200 1400 분사펌프 속도(rpm) PUMP SPEED (rpm) EB1O4001 (4) Boost compensator pressure 14 RACK POSITION (mm) P1 12 랙 위 P2 10 치 (mm) 8 6 0 200 400 600 800 1000 1200 부양PRESSURE 압력 (mmHg) BOOST (mmHg) EB1O4002 - 117 -
7.3.2. Electric governor system 1) AD136 / T / TI Governor system for fuel injection pump consists of “Integral Actuator” and “ Speed Control Unit”. (1) ACAD176 Series Electric Actuator • Introduction The ACD176 SERIES electric actuator is designed to mount directly on a Bosch “A” size fuel injection pump, with a left hand rack, in place of the mechanical governor. When the ACE176 is installed on the fuel pump, an optimum performance, long life fuel control system results.
Environmental Operating Temperature ....................................................... -40 to +95 °C (-40 to +200 °F) Relative Humidity ............................................................................................. up to 100 % Vibration .................................................................................................. 20 g, 20 - 500 Hz Shock ....................................................................................................... 20 g @ 11 msec.
4. Remove both of the actuator covers. DO NOT remove or loosen the lever(16) from the actuator shaft. Place the o-ring seal(4) into the groove on the mounting face of the actuator. Apply a small amount of grease to the o-ring to hold it in place. 5. Swing the armature out of the actuator so that the lever(16) is out of the way. Guide the actuator over the rack and onto the lower mounting retainer studs.
Caution : Adjusting the fuel pump is an essential part for performance and endurance of engine, therefore operation and maintenance should be performed only by specialized engineer. Figure 1 ACD176 Fuel Rack Force vs. Stroke WIRNING The ACD176 actuator is pre-wired for 12 or 24V DC operation. Use the included cable harness to connect the actuator to the speed control unit. The cable may be lengthened as necessary to fit the specific application. Use the comparable size wire to extend the cable harness.
EA4O9101 - 122 -
2) AD086TI Governor system for fuel injection pump consists of “Integral Actuator” and “Speed Control Unit”. (1) Integral Actuator Adjust linkage length so that when fastened to the operating lever the fuel rack is approx. 0.5-1.0mm away from its extreme stop position Emergency mechanjcal stop Upper chamber Engine oil lubricated Linkage length L Extreme stop position of fuel rack Injection pump Operating lever Fuel rack Electromechanical chamber Completety enclosed, and seated Operating lever The G.
No. Description Q’ty Remark No. Description Q’ty Remark 1 Stop lever(emergency) 1 20 actuator spring 1 2 pump gasket 1 21 gasket,lower cover 1 3 washer 4 22 lower cover 1 4 allen screw 4 7 ~ 9 N.m 23 washer 8 5 ball link 2 * 24 allen screw 6 6 stop nut 2 3.5 ~ 4.0 N.
(2) Speed control unit for governor system (All) a) Introduction Series speed control unit is an all electronic device designed to control engine speed with fast and precise response to transient load changes. This closed loop control, when connected to a proportional electric actuator and supplied with a magnetic speed sensor signal, will control a wide variety of engines in an isochronous or droop mode. The speed control unit are the engine STARTING FUEL and SPEED RAMPING adjustments.
The stability adjustment, when advanced clockwise, increases the time rate of response of the governor system to match the various time constants of a wide variety of engines. The speed control unit is a PID device, the “D”, derivative portion can be varied when required. (See Instability section.) During the engine cranking cycle, STARTING FUEL can be adjusted from an almost closed, to a nearly full fuel position.
c) Specification PERFORMANCE Isochronous Operation/steady State Stability ± 0.25% or better Speed Range/Governor 1 K ± 7.5 KHz continuous Speed Drift with Temperature ± 1% Maximum Idle Adjust CW 60% of set speed Idle Adjust CCW Less than 1,200 Hz. Droop Range 1 ± 5 % regulation* Droop Adj. Max. (K-L Jumpered) 400 Hz ± 75 Hz per 1.0 A change Droop Adj. Min. (K-L Jumpered) 15 Hz ± 6 Hz. per 1.0 A change Speed Trim Range ± 200 HZ Remote Variable Speed Range Terminal Sensitivity 500 ± 7.
d-1) Wiring Diagram and Outline (AD034TI, AD136/T/TI) 6.25 154 9.5 15 1 2 3 4 5 6 7 8 Over Speed Run 9 Crank Overspeed Run Crank Speed D1 139 ON OFF Stability Starting Fuel GHANA CONTROL MADE IN KOREA Speed Ramping D2 ON OFF Idle Idle Speed Trim Actuator B C D E F G Droop Droop Battery + AUX 10V H J K L M N P 15 A Test Gain GOVERNOR CONTROLLER MODEL : DWC-2000 INPUT : DC24V PARTS No. : 65.11220-7006 SERIAL No. : Pick-Up Reset 10V POWER AUX.
d-2) Wiring Diagram and Outline (AD086TI) 6.00 (152) 5.25 (133) O 0.27 (7) C2 ON SOFT COUPLING OFF C1 OFF LEAD CIRCUIT ON OVERSPEED OVERNORS MERICA GA C 1 2 3 RESET TEST OVERSPEED ORP SPEED CONTROL UNIT SPEED MODEL : ESD5550 S/N GAIN STABILITY 6.00 (152) 6.05 (165) MADE IN AGAWAM, MA U.S.
Caution : An overspeed shutdown device, independent of the governor system, should be provided to prevent loss of engine control which may cause personal injury or equipment damage. Do not rely exclusively on the governor system electric actuator to prevent overspeed. A secondary shutoff device, such as a fuel solenoid must be used. e) Functions of the Control unit 1. STARTING FUEL : When starting engine at first, it controls the amount of starting fuel.
g) Adjustments (Used new controller) 1. Before Starting Engine 1 The GAIN and STABILITY adjustments are set to mid position. 2 STARTING FUEL : FULL CW (Maximum Fuel) 3 SPEED RAMPING : FULL CCW (Fastest) 4 IDLE : FULL CW (Idle speed increase position) 5 Place the engine in idle by connecting Terminals M & G. 2. After Starting Engine When starting engine at first, actuator activates forward “maximum fuel” position. After starting engine, adjust to maintain idle speed.
5. Starting Fuel Adjustment The engine’s exhaust smoke at start-up can be minimized by completing the following adjustments. 1 Place the engine in idle by connecting Terminals M & G. 2 Adjust the IDLE speed for as low a speed setting as the application allows. 3 Adjust the STARTING FUEL CCW until the engine speed begins to fall, Increase the STARTING FUEL slightly so that the idle speed is returned to the desired level. 4 Stop the engine.
8. Accessory input The Auxiliary Terminal N accepts input signals from load sharing units, auto synchronizers, and other governor system accessories, accessories are directly connected to this terminal It is recommended that this connection from accessories be shielded as it is a sensitive input terminal.
h) System Trouble shooting 1. System Inoperative If the engine governing system does not function, the fault may be determined by performing the voltage tests described in Steps 1, 2, 3, and 4.Be careful of the meter polarities measuring. Should normal values be indicated as a result of following the trouble shooting steps, the fault may be with the actuator or the wiring to the actuator See the actuator publication for testing details.
2. Unsatisfactory Performance If the governing system functions poorly, perform the following tests. SYMPTOM TEST PROBABLE FAULT Engine overspeeds 1. Do not crank. Apply DC power to the governor system. 2. Manually hold the engine at the desired running speed. Measure the DC voltage between Terminals A(-) & F(+) on the speed control unit. 1. Actuator goes to full fuel. Then, disconnect speed sensor at Terminals C & D. If actuator still at full fuel speed control unit defective.
4. Electromagnetic Compatibility (EMC) The governor system can be adversely affected by large interfering signals that are conducted through the cabling or through direct radiation into the control circuits. All speed control units contain filters and shielding designed to protect the units sensitive circuits from moderate external interfering sources.
5. Instability Instability in a closed loop speed control system can be categorized into two general types. 1 PERIODIC appears to be sinusoidal and at a regular rate. 2 NON-PERIODIC is a random wandering or an occasional deviation from a steady state band for no apparent reason Switch C1 controls the “Lead Circuit” found. The normal position is “ON “ Move the switch to the “OFF” position if there is fast instability in the system.
7.3.3. Fuel feed pump 1) General descriptions and construction The P-type injection pump is mounted with NP-FP or KD-PS type feed pump. These pumps have the same basic construction and operation, and the general descriptions of the KD type pump are given below: The figures show its construction (right figure) and operation (below figure).
(A) Inlet side (B) Outlet side (C) Interruption EQM4020I This feed pump is mounted with a priming pump designed to permit manual feeding of fuel from the fuel tank with the injection pump mounted in the engine. During the manual feeding operation, air must be bled from the fuel lines. When using the priming pump, fix it securely to prevent the possible entry of moisture or other foreign substances in the inside of feed pump.
2) disassembly • Clamp the feed pump with a vise and disassemble the plugs (30, 32), strainer (31) and gaskets (35, 36). • • • • Take off the priming pump (25), plug (16), both gaskets (18), spring (15), and check valve (14). Take off the plug (7), gasket (8), spring (6), and piston (5) on the piston side. Pull out the snap ring (20) holding the tappet (10). Disassemble the snap ring, then take off the tappet (10) and push rod (1).
5) Testing (1) Suction capacity test Connect one end of a hose to the inlet side of the feed pump and immerse the Outlet hose other end of it into the fuel tank as Feed pump illustrated. Hold the feed pump in position about 1 m above the level of fuel in the fuel tank. Operate the tappet at the rate of 100 rpm and check to see if fuel is drawn in and Inlet hose delivered for 40 seconds or so. Fuel tank EQM4022I (2) Delivery test Make a test with the feed pump mounted on a pump tester as illustrated.
7.3.4. Fuel injection nozzle The injection nozzle assembly consists of the nozzle body and needle valve assembly. Pressurized fuel delivered from the fuel injection pump is sprayed into the combustion chamber past the injection nozzle at proper spray pressure and spray angle, then burnt completely to achieve effective engine performance.
(1) Disassembly • Clamp the nozzle holder in a vise and remove the cap nut. • Loosen the adjust screw lock nut and remove the adjust screw then detach the spring and push-rod • Clamp the nozzle holder body with the nozzle side up in a vise. • With a wrench remove the nozzle nut using care not to drop the nozzle. Remove the nozzle carefully not to drop the needle valve. 1 4 3 노즐 홀더 쉼 코일 스프링 2 가이드 부쉬 6 7 조정 와셔 1. Nozzle Holder 노 즐 2. Guide bush 5 3. Coil spring 유니언 너트 4. Shim 5.
(2) Adjustment • Remove the cap nut and assemble a nozzle to a nozzle tester. • With the adjusting screw loosened, operate the nozzle 2 ~ 3 times to bleed it. • Operate the nozzle tester lever at the specified rate. • Adjust the injection pressure to the standard pressure using the adjusting screw. • EFM2056I After adjusting the injection pressure, tighten the cap nut to specified torque. • Re-check the injection pressure and see if the spray pattern is normal.
(4) Re-assembly • • • After removing carbon deposit, submerge the nozzle in diesel oil and clean it. Replace all the gaskets with new ones. Assemble the parts and tighten them to specified torque. Items Torque (kg.m) Nozzle holder cap nut 7 Nozzle cap nut 6~8 Injection pipe cap nut 2.9 ~ 3.2 Injection pump delivery valve holder 2.5 ~ 3.0 7.4.
7.4.2. Turbo charger assembly 1) L136T / TI : TO4E55 20 21 22 14 3 6 7 8 4 18 13 17 2 15 12 19 16 5 1 9 10 23, 24, 25 11 EB7O7017 1. Turbine Shaft 10. Bolt 19. Heat Plate 2. Thrust Bush 11. Clamp 20. Compressor Housing 3. Oil Shut Off 12. Bearing Housing 21. Clamp 4. Lock Nut 13. Retainer Ring 22. Bolt 5. Seal Ring 14. Seal Plate 23. Liquid Gasket 6. Seal Ring 15. Thrust Bearing 24. Loctite 7. Seal Ring 16. Journal Bearing 25. Liquid Anti-Burn Agent 8. Compressor Seal 17.
2) L086TI (HX35) EA7M4003 2. Center housing rotating assembly 31. Oil slinger 57. Bolt, turbine housing 4. Bearing Housing 32. O ring seal, bearing housing 58. Screw thrust bearing 5. Turbine housing 33. Oil baffle 59. Bolt compressor cover 6. Assembly turbine wheel 36. Thrust collar 61. Lock nut, 7. Compressor wheel 38. Heat shield 8. Compressor housing 40. Lock plate compressor 62. V-band lock nut 11. Journal bearing 41. O ring seal, compressor 64. Ring retainer bearing 12.
7.4.3. Inspection As the condition of turbocharger depends greatly on how well the engine is serviced, it is very important to maintain the engine in accordance with the specified maintenance procedure and pay particular attention to checking oil & air leaks, unusual sound on running. 1) Checking of the rotor for rotating condition The inspection of the rotor assembly for rotating condition should be performed by the degree of unusual sound on running.
3) Precautions for reassembling the turbocharger onto the engine For re-assembly of the turbocharger or handling it after re-assembly operation, be sure to observe the following precautions : Especially, pay attention to prevent foreign matters from entering the inside of the turbocharger. (1) Lubricating system • Before reassembling the turbocharger onto the engine, inject new oil in the oil inlet port and lubricate the journal and thrust bearings by rotating them with hand.
• Center housing rotating assembly (H2D) EA7M4005 • Watercooled bearing housing (5) This can have additional water feed drain plug fittings. Special attention should be made to the position of these fittings as this may be specific for each application. EA7M4006 2) Disassembly • Before disassembling the turbocharger, scribe the parts listed below to help in alignment during assembly. EA7M4007 • Secure the turbine housing (5) in a vice.
• Gently remove the compressor cover (8), and fitted, remove the O ring seal (41). Caution : The compressor wheel blades can be easily damaged when the compressor housing is removed. EA7M4009 • Loosen and remove the 6 bolts (57) and clamp plates (88). EA7M4010 Caution : The turbine blades can be easily damaged when the turbine housing is removed. EA7M4011 • Locate the Center Housing Rotating Assembly (CHRA) onto a 19mm socket clamped in the jaws of a vice or a suitable fixture.
• Remove the compressor wheel lock nut (61). Note : Left hand thread. EA7M4013 • Remove the compressor wheel (7). EA7M4014 • Remove the remaining CHRA from the socket and gently slide the shaft and wheel (6) from the bearing housing (4). EA7M4015 • Discard the two piston ring seals (13). Caution : Care should be taken not to score the assembly turbine wheel shaft.
• Remove the heat shield (38). EA7M4017 • Place the bearing housing on a flat surface and using a flat screwdriver, remove the insert retaining ring (66). EA7M4018 • Using two flat screwdrivers, gently remove the oil seal plate (43). EA7M4019 • Remove the oil slinger (31).
• Remove and discard the piston ring seal (16). EA7M4021 • Remove and discard the O ring seal (32). EA7M4022 • Remove the oil baffle (33). EA7M4023 • Remove and discard the 3 flat head screws (58). Remove the thrust bearing (12).
• If fitted remove the thrust bearing spacer (44). Remove the thrust collar (36). Also remove flat retaining ring (77) if fitted. EA7M4025 • Using circlip pliers, remove and discard the two circlips (64) and the journal bearing (11) from the compressor end. EA7M4026 • Turn the bearing housing over and repair the process. EA7M4027 3) Cleaning With the turbocharger completely dismantled for overhaul, soak all the components in a noncaustic metal cleaner to loosen deposits.
Caution : Shot blasting specific areas for long periods of time may effect component balance. The surface adjacent to the turbine and compressor wheels on the stationary housings must be clean, smooth and free from deposits. 4) Inspection Caution : Do not attempt to straighten the turbine shaft. (a) Place the shaft on a vee block, using a dial gauge rotate the turbine wheel and check for movement on the dial gauge. Replace the assembly turbine wheel if it is bent. Max shaft bend allowed 0.025 mm (0.
• Turbine Housing (5) Inspect the profile for damage caused by possible contact with the rotor. Check all threads for damage. Inspect the outer and internal walls for cracks or flaking caused by overheating also check mounting flanges for signs of distortion. Replace with new if any of the above are visible. EA7M4030 • Compressor Housing (8) Inspect the profile for damage due to possible contact with the rotor. Check the V-band groove. Replace with new if any of the above is visible.
• Oil slinger (31) Inspect and replace if the piston ring seal groove walls are scored or damaged. Also check for signs of rubbing on the flat surfaces. EA7M4034 • Oil seal plate (43) Inspect the seal bore, replace if scored or damaged. EA7M4035 • Heat shield (38) Check and replace if the heat shield id distorted or if signs of rubbing or cracking are visible.
Rotor balance limits (Max.) g.mm oz. ins. Turbine end 2.2 0.003 Compressor end 4.4 0.006 • Make sure that the circlips are always fitted with the bevelled edge facing the journal bearing. Caution : Circlips (64). Premature failure will result if the circlips are fitted incorrectly. EA7M4038 • Place the bearing housing (4) on a bench with the turbine end facing uppermost. Fit the inner circlip (64) with the bevelled edge facing upwards.
• Install the heat shield (38). EA7M4041 • Install the two new piston ring seals (13) to the assembly turbine wheel (6). EA7M4042 • Lubricate the shaft using clean engine oil. Caution : Align the piston ring seals (13) so the gaps is positioned 180 ° from the oil drain hole. Gently press down on the turbine wheel - a slight rotation of the wheel will EA7M4043 assist in properly locating the piston ring seals. • Support the assembly turbine wheel (6) and bearing housing in a suitable fixture.
• Install the thrust bearing spacer (44) if fitted. Install the thrust collar (36). Caution : Align the balance mark on the thrust collar with that on the shaft. EA7M4045 • Using clean engine oil, lubricate the thrust bearing (12). Install the thrust bearing. Install the 3 flat hear screws (58). Using torque wrench, tighten to required torque. Nm in-lbs 4.5 40 Torque value EA7M4046 • Fit the new piston ring seal (16) to the oil slinger (31).
• Apply a small amount of oil to the O ring seal, install O ring seal (32). EA7M4049 • Insert the oil slinger (31) into the oil seal plate (43). EA7M4050 • Install the oil seal plate (43) into the bearing housing (4). Caution : Align the balance marks on the oil slinger (31) with that on the shaft end. EA7M4051 • Gently tap the oil seal plate (43) with a soft hammer to seat in position.
• Install the retaining ring (66). Check correct location using a screwdriver. EA7M4053 • Align the balance marks and install the compressor wheel (7). EA7M4054 • Install the compressor wheel lock nut (61) and tighten to the torque value. Note : Left hand thread. Nm in-lbs 17 150 Torque value Caution : Ensure that the balance marks are aligned on the compressor wheel and the shaft.
• Locate the CHRA into the turbine housing (5). Install the 3 clamp plates (88) and tighten the 6 bolts (57) to the torque value. Torque value Bolts (57) Nm in-lbs 20 180 EA7M4056 Caution : Make sure the scribe marks are aligned. • Secure the turbine housing and check the trust clearance using a dial gauge. Trust clearance mm in Minimum 0.038 0.0015 Maximum 0.093 0.0037 EA7M4057 • Check the radial clearance using a dial gauge. Radial clearance (H2D) mm in Minimum 0.364 0.
• Install the 2 clamp plates (51), eight lock washers (54) and tighten the 8 bolts (59) to the torque value. Install the V-band clamp (29) and tighten the lock nut (62) to the torque value. Trust value Nm in-lbs Lock nut (62) 8.5 75 Bolts (57) 8.5 75 EA7M4060 Caution : Make sure the scribe marks are aligned.
8. Troubleshooting The following description summarizes the probable cause of and remedy for general failure by item. Immediate countermeasures should be taken before a failure is inflamed if any symptom is detected. Hard to start the engine Fuel system admits air Bleed air (check feed pump) Clogged fuel supply piping or clogged air vent pipe in tank. Detect the cause and remove clogs or obstacles. Clogged fuel filter Replace filter element with a new one. Fuel feed pump failure Check for function.
Insufficient output Driven machine normal? Hydraulic pressure source Excess intake air resistance Change or reduce the propeller pitch Clogged air cleaner Clogged intake air pipe Clean Clean Excess exhaust resistance Clogged muffler Clean or replace Fuel system failure Air intrusion into fuel system Air bleeding Clogged exhaust pipe Clogged cylinder head exhaust outlet Clean Clogged fuel filter Clogged fuel pipe Clean Clean or replace Clogged air vent in fuel tank Insufficient fuel volume f
Overheating Driven unit normal? Cooling system Hydraulic pressure source Insufficient cooling water Sagged V-belt Add water Adjust Pressure cap clogging and malfunction Broken or worn V-belt Clogged heat exchanger Replace Clean Clogged heatexchanger tubes Thermostat malfunction Clean or replace Set relief pressure of control valve Replace Incresed exhaust pressure Clean Reduction in cooling water pump performance Clean Replace Heat exchanger malfunction Clean Excess intake air resistan
Black smoke is produced. Driven machine normal? Insufficient output Fuel Hydraulic pressure source Set relief pressure of control valve Refer to “Insufficient output.” Improper fuel Replace Fuel pump Too early injection timing Adjust or replace Governor Improper adjustment Adjust Excess injection volume Uneven injection volume Adjust Adjust or replace Malfunction of lever and linkage Repair or replace White smoke is produced.
engine seizure and [ Except trouble of driven machine ] Starter motor will not turn or output less power.
Battery is dead or not chargeable.
9. Special Tool List No. Tool Names Tool No. 1 Front Oil Seal Assembly Jig EF.123-173(NOK) Descriptions Applications EAMD086I 2 Front Oil Seal Puller Jig EF.123-052 EAMD025I 3 Rear Oil Seal Assembly Jig EF.123-184(NOK) EA8M3003 4 Rear Oil Seal Puller Jig EF.123-048 EAMD042I 5 Valve Spring Press EF.123-065 EA8 6 Crank Shaft Gear Punch EU.2-0647 7 Valve Stem Seal Punch EF.122-089 EA0M4007 EAMD096I 8 Adapter for Cylinder Pressure Test EU.2-0530 EB4O403L No. 3 : CR (U.S.
No. Tool Names Tool No. 9 Injection Pump Alignment Jig EF123-015 (Only L086TI) Descriptions Applications EAMD107I 10 Piston Sleeve EF.123-064 11 Cylinder Liner Puller EF.123-086 12 Filler Gauge 60.99901-0027 EF.120-208 (For all engines) EAOO4014 13 Filter Wrench 65.
10. Tightening Torque • Tightening torque for major parts Screw Strength (diameter x pitch) (grade) Cylinder head bolt M14 x 1.5 10.9T 6.0 kg.m + 180 + 150 (Angle) Connecting rod bearing cap bolt M14 x 1.5 12.9T 18.0 kg.m Crankshaft main bearing cap bolt M16 x 1.5 12.9T 30.0 kg.m Balance weight fixing bolt M12 x 1.5 10.9T 10.0 kg.m Flywheel fixing bolt M14 x 1.5 10.9T 21.5 kg.m Crankshaft gear fixing bolt M12 x 1.5 10.9T 13.0 kg.
• Tightening torque table for standard bolt Refer to the following table for bolts other than described above. Degree of strength Diameter x 3.6 4.6 4.8 5.6 5.8 6.6 6.8 6.9 8.8 10.9 12.9 (4A) (4D) (4S) (5D) (5S) (6D) (6S) (6G) (8G) (10K) (12K) 54 64 90 108 pitch (mm) Limit value for elasticity (kg/mm2) 20 24 32 30 40 36 48 Tightening torque (kg•m) M5 0.15 0.16 0.25 0.22 0.31 0.28 0.43 0.48 0.50 0.75 0.90 M6 0.28 0.30 0.45 0.40 0.55 0.47 0.77 0.85 0.
11. Maintenance Specification Table for Major Parts Group Part Inspection Item Inside diameter of cylinder liner for wear Cylinder block & liner Engine body Amount of liner projection The flatness of upper surface of cylinder block Hydraulic test for 1 minute (kg/cm2) Cylinder head & valve Valve seat depression Piston ring parts gap Piston ring Piston ring side clearance 4 Correct with a Referenced length : surface grinder 200mm Replace if leaky 0~0.3 - seat 109.9 ~110.1 108.4 4 110.
Group Part Inspection Item Radial run-out of journal and pin Outside diameter of journal Outside diameter of pin Crank shaft Ellipticity of journal and pin Concentricity of journal and pin Taper of journal and pin Clearance between crankshaft and bearing Stand value Limit for assembly for use 0.01 83.966~ 83.988 70.971~ 70.990 0.025 0.01 0.03 0.01 0.03 0.052~0.122 0.25 End play of crankshaft 0.15~0.325 0.5 Run-out of crankshaft 0.
Group Part Inspection Item Stand value Limit for assembly for use Diameter of intake valve stem 8.950~ 8.970 0.02 Diameter of exhaust valve stem 8.935~ 8.955 0.02 Clearance Intake between valve stem and Exhaust valve guide 0.030~0.065 0.15 0.045~0.080 0.15 Intake Thickness of valve head Exhaust 2.2 Clearance Intake between valve guide and valve Exhaust spring seat 2.
Group Part Inspection Item Clearance between tappet & cyl. block Valve Tappet system Diameter of tappet Stand value Limit for assembly for use 0.035 ~ 0.077 0.1 19.944 ~ 19.965 19.89 Replace tappet Replace tappet - Replace if severely worn or deformed 4.8 or less 3.5 Check oil leakage and clearance between each part 0.8~1.4 0.6 Use recommended oil - 105 - 120 Axial play of oil pump gear 0.055 ~ 0.105 - Clearance between drive gear shaft & oil pump cover hole 0.032 ~ 0.077 - 0.
Group Part Inspection Item Limit Stand value for assembly for use Heat exchanger & water pump for corrosion, damage & improper connecting Heat Exchang Test for leakage (air pressure) (kg/cm2) er Pressure valve for opening pressure (kg/cm2) Cooling system Water pump Delivery volume l/min - Engine speed 2,300rpm - Water temp.85 ˚C - Back pressure : 0.5 kg/cm2 Correction Correct or replace Submerge in water and replace if air bubbles found 3.0 0.
