TO THE CUSTOMERS

This maintenance manual is designed to serve as a reference for DOOSAN Heavy Industries &
Machinery LTD. (here after DOOSAN) customers and distributors who wish to gain basic product
knowledge on DOOSAN DB58 and PU066 engine.
To maintain the engine in optimum condition and retain maximum performance for a long time,
CORRECT OPERATION and PROPER MAINTENANCE are essential.
In this manual, the following symbols are used to indicate the type of service operations to be
performed.

Removal Adjustment

Installation Cleaning

Disassembly Pay close attention-Important

Reassembly Tighten to specified torque

Align the marks Use special tools of manufatur’s

Directional Indication Lubricate with oil

Inspection Lubricate with grease

Measurement

During engine maintenance, please observe following instructions to prevent environmental damage;

• Take old oil to an old oil disposal point only.

• Ensure without fail that oil and diesel fuel will not get into the sea or rivers and canals or the ground.
• Treat undiluted anti-corrosion agents, antifreeze agents, filter element and cartridges as
special waste.
• regulations of the relevant local authorities are to be observed for the disposal of spent
The
coolants and special waste.

If you have any question or recommendation in connection with this manual, please do not hesitate
to contact our head office, dealers or authorized service shops.
For the last, the content of this maintenance instruction may be changed without notice for some
quality improvement. Thank you.

DOOSAN Infracore Co., Ltd.

Oct. 2000
 CONTENTS

1. General Informations ..................................................................................................... 1

1.1. General Repair Instructions 1.4. Engine Assembly (DB58)
1.2. Engine Specification 1.5. Engine Assembly (PU066)
1.3. Performance Curve (PU066)

2. Major Maintenance .......................................................................................................... 6

2.1. Preventive Maintenance 2.3. Engine Inspection
2.2. Diagnosis and Remedy

3. Disassembly and Reassembly of Major Components ................................... 31

3.1. Major part fixing nuts and bolts 3.3. Inspection
3.2. Major components disassembly 3.4. Engine reassembly

4. Maintenance of Major Components ...................................................................... 96

4.1. Lubricating System 4.3. Fuel System
4.2. Cooling System

5. Engine Electrical .......................................................................................................... 117

5.1. Starting motor 5.2. Alternator

6. Special Tool List ........................................................................................................... 119

• Appendix
• WORLDWIDE NETWORK
1. General Information

1.1. General repair instructions

1. Before performing service operation, disconnect the grounding cable from the battery for
reducing the chance of cable damage and burning due to short-circuiting.
2. Use covers for preventing the components from damage or pollution.
3. Engine oil and anti-freeze solution must be handled with reasonable care as they cause paint
damage.
4. The use of proper tools and special tools where specified is important to efficient and reliable
service operation.
5. Use genuine DOOSAN parts necessarily.
6. Used cotter pins, gaskets, O-rings, oil seals, lock washer and self-lock nuts should be
discarded and new ones should be prepared for installation as normal function of the parts
can not be maintained if these parts are reused.
7. To facilitate proper and smooth reassemble operation, keep disassembled parts neatly in
groups. Keeping fixing bolts and nut separately is very important as they vary in hardness and
design depending on position of installation.
8. Clean the parts before inspection or reassembly. Also clean oil ports, etc. using compressed
air to make certain they are free from restrictions.
9. Lubricate rotating and sliding faces of parts with oil or grease before installation.
10. When necessary, use sealer on gaskets to prevent leakage.
11. Carefully observe all torque specifications for bolts and nuts.
12. When service operation is completed, make a final check to be sure service has been done
properly.

-1-
1.2. Engine specification

Engine Model DB58 PU066

Items ( Generator ) ( Power unit )
Water- cooled, 4 cycle in -line
Engine type
Naturally aspirated
Combustion chamber type Direct injection type
Cylinder liner type Dry liner
Timing gear system Gear driven type
No. of piston ring Compression ring 2, oil ring 1
No. of cylinder-bore x stroke (mm) 6 - 102 x 118
Total piston displacement (cc) 5,785
Compression ratio 17.5 : 1
Engine dimension (length x width x height) (mm) 1,155 x 705 x 854
Engine weight (kg) 450
Rotating direction (from flywheel) Counter clockwise
Fuel injection order 1-5-3-6-2-4
Fuel injection timing (B.T.D.C static) 20 °
Injection pump type Zexel in - line A type
Governor type Mechanical governor RSV type
Injection nozzle type Multi-hole type (5 hole)
Fuel injection pressure (kg/cm )
2
220
Compression pressure (kg/cm2) 28 (at 200 rpm)
60 Hz 50 Hz DIN6270B
( 1,800 rpm ) ( 1,500 rpm ) ( ISO 3046 )
87 PS 73 PS Power
Power ( ISO 3046 ) Prime ( 64 kW ) ( 54 kW ) 116 PS/ 2,800 rpm
95 PS 80 PS Torque
Stand by ( 70 kW ) ( 59 kW ) 36kg .m / 1,600 rpm
Intake and exhaust valve clearance (at cold) (mm) 0.4
Open at 28 ° (B.T.D.C)
Intake valve
Close at 62 ° (A.B.D.C)
Open at 70 ° (B.B.D.C)
Exhaust valve
Close at 28 ° (A.T.D.C)
Lubrication method Pressurized circulation
Oil pump type Gear type
Oil filter type Full - flow, Cartridge type
Lubricating oil capacity (max./min.) (lit) 13 / 10
Oil cooler type Water cooled
Water pump Belt driven impeller type
Cooling Method Pressurized circulation
Cooling water capacity (engine only) (lit) 12
Wax pallet type Wax pallet type
Thermostat type ( 82 ~ 95 °C ) ( 71 ~ 90 °C )
Alternator voltage - capacity (V - A) 24 - 45
Starting Motor voltage - output (V - kW) 24 - 4.5
Battery - capacity (V - AH ) 24 - 120

-2-
1.3. Performance Curve ( PU066 )

kW PS kg . m N . m
36 360

32
300
28
100
120

90

100
80

70 80

60

60
50

g/PS . h g/kW . h
40 40

180 250
220
140

1000 1600 2200 2800

REVOLUTION (rpm)

EDM1012I

DESCRIPTION DIN6270B ( ISO- 3046 )

POWER OUTPUT ( Rated ) 85 kW ( 116PS ) / 2,800 rpm

TORQUE ( Max.) 353 N .m ( 36 kg .m ) / 1,600 rpm

FUEL CONSUMPTION ( Rated ) 245 g / kW .h (180 g / PS . h)

-3-
1.4. Engine assembly ( DB58 )

3 4 5 6 29 7
11 12
2 10
1 9

14 16 15 17 18
26 27
13
28

19 20 21 22 23 24 25

EDM1001I

1. Oil filter 11. Water outlet 21. Drain valve

2. Lifting hook 12. Oil filler cap 22. Oil pan
3. Injection nozzle 13. Cooling fan 23. Starter
4. Oil cooler 14. Alternator 24. Flywheel
5. Intake stake 15. Oil level gauge 25. Flywheel housing
6. Intake manifold 16. Cylinder head cover 26. Exhaust manifold
7. Fuel filter 17. Guide tube 27. Breather hose
8. Injection pump 18. Push rod chamber cover 28. Fuel pipe
9. Cooling water pump 19. Crank shaft pulley 29. Fuel Injection pipe
10. Thermostat 20. Mounting bracket

-4-
1.5. Engine assembly ( PU066 )

3 4 5 6 29 7
11 12
2 10
1 9

87

14 16 15 17 18 26 27
13
28

19 20 21 24 25
22 23

EDM1013I

1. Oil filter 11. Water outlet 21. Drain plug

2. Lifting hook 12. Oil filler cap 22. Oil pan
3. Injection nozzle 13. Cooling fan 23. Starter
4. Oil cooler 14. Alternator 24. Flywheel
5. Intake stake 15. Oil level gauge 25. Flywheel housing
6. Intake manifold 16. Cylinder head cover 26. Exhaust manifold
7. Fuel filter 17. Guide tube 27. Breather hose
8. Injection pump 18. Push rod chamber cover 28. Fuel pipe
9. Cooling water pump 19. Crank shaft pulley 29. Fuel Injection pipe
10. Thermostat 20. Mounting bracket

-5-
2. Major Maintenance

2.1. Preventive maintenance

The preventive maintenance means that the operator performs the servicing of engine to obtain
long life and best performance from DOOSAN diesel engine.

2.1.1. Cooling water

• Regarding the engine cooling water, the hard water must be used (Do not use the soft water).
• The engine cooling water can be used diluting it with antifreezing solution 40 % and the
additive for rust prevention (DCA4) 3 ~ 5 %.

• The density of above solution and additive must be inspected every 500 hours to maintain it
properly.

NOTE
The proper density control of antifreezing solution and rust preventing additive will be
able to prevent the rusting effectively and maintain the stable quality of engine.
For the improper control might give the fatal damage to the cooling water pump and
cylinder liners, detail care is needed.

• Since DB58 and PU066 cylinder liner is dry type, particularly the cooling water control should
be applied thoroughly.

• The density of antifreezing solution and additive for rust prevention is able to be confirmed
by the cooling water test kit. ( Fleetguard CC2602M )

• How to use the cooling water test kit

(1) When the cooling water temp. of engine is in the range of 10 ~ 55 °C, loosen the plug for
cooling water discharge and fill the plastic cup about a half.

NOTE
In taking the cooling water sample, if the water in auxiliary tank were taken, it is hard to
measure the accurate density. Take the cooling water sample necessarily loosening the
cooling water discharge plug.

(2) At the state of a test paper soaked in the sampled water, after taking the paper out
through water agitation, shake off the water.
(3) Wait for about 45 sec. till the color change of test paper.

NOTE
However, it should not elapse longer than 75 sec, and if it did, the hue would change.

(4) Make the numerical value by comparing the test paper which hue has changed with the
color list of label on storage bottle.
(5) By comparing the hue changed into yellowish green or so with the green color indication
of test paper storage bottle, confirm the density.
( Then, the density indication must be in the hue range of 33 % to 50 % ).

-6-
 (6) The brown at the middle of test paper and the lower pink color indication represent the
additive state for rust prevention, and the proper range is that the meeting numerical
value of brown ( vertical) and pink color ( horizontal) locates in the range of 0.3 to 0.8 at
the color list of label on the test paper storage bottle.
(7) In case of less than 0.3, replenish the additive for rust prevention (DCA4), and in case of
more than 0.8, pour out the cooling water about 50 % and then readjust the density after
refilling with clean fresh water.

• Amount of Anti- freeze in winter

Ambient
Cooling water (%) Anti-freeze (%)
Temperature (˚C)
Over -10 85 15
-10 80 20
-15 73 27
-20 67 33
-25 60 40
-30 56 44
-40 50 50

2.1.2. Fan belt

• Use a fan belt of specified dimensions,

and replace if damaged, frayed, or
Depress here
deteriorated. Fan pulley
(Water pump pulley)
• Check the fan belt for belt tension. 10 mm
If belt tension is lower than the
specified limit, adjust the tension by Alternator pulley
relocating the alternator. ( specified
deflection: 10 ~ 15 mm when pressed
down with thumb ) Crank pulley
EDO6001I

-7-
2.1.3. Engine oil

• Check oil level with the oil level gauge and replenish if necessary.
• Check the oil level with the engine cooled. If the engine is warm, allow time for 5 ~ 10 minutes
for oil drain into the crankcase before checking oil level.
The oil level must be between Max and Min. lines on the gauge.

• Engine oil should be changed at the specified intervals. (200 hr)

Oil in the oil filter should be changed simultaneously.
- First oil change : 50 hr operating

• The oil viscosity grade should be selected SAE NO.15W40 and the oil grade be selected API
CH-4 or above.

Designation SAE No. Content

ACEA-E2 or ACEA-E3
15W40 bellow 0.5% sulfur
(LUBIA 6000 or CH-4)

or above CD 15W40 -

* If long oil change intervals are to be used, ACEA-E3 oil must be used.

2.1.4. Oil filter

• Check for oil pressure and oil leaks,

and repair or replace the oil filter if
necessary.

• Change the oil filter cartridge

simultaneously at every replacement
of engine oil. Oil filter
(Cartridge)

Head, oil filter

Drain plug

EDO3001I

-8-
2.1.5. Fuel filter

• The fuel filter should be replaced at

DB58
every 400 hours.

Element,
Fuel filter

Housing,
Fuel filter

EDM3002I

PU066

Head, filter

Cartridge,
Fuel filter

EDM3003I
2.1.6. Air cleaner.

• In case that elements are deformed,

damaged or if the air cleaner has a
crack, replace it.

• By the definite interval, the elements

must be cleaned and replaced.

EFM1002I
2.1.7. Radiator

• The radiator is air cooling type and has

a large cooling fan capacity. Radiator Cap

- Cleaning of radiator fins: Every 600 Radiator

hours.

EA5O3002

-9-
2.1.8. Valve clearance and adjustment

Caution
The cylinder head bolts were previously
tightened with the torque wrench.
Therefore it is not necessary to
retighten the cylinder head bolts before
adjusting the valve clearance.

EA0O4014

• Bring the piston in either the No.1

cylinder or the No.6 cylinder to TDC
(top dead center) on the compression
stroke by turning the crankshaft until
the TDC notched line on the crankshaft
pulley is aligned with the timing pointer.

Check to see if there is play in the No.1

intake and exhausts valve rocker
EJM1035S
arms.
If No.1 cylinder intake and exhaust
valve rocker arms are shifted, the No.6
piston is at TDC on the compression
stroke.
If the No.1 cylinder intake and exhaust
valve rocker arms are fixed, the No.1
piston is at TDC on the compression
stroke.

• Adjust valve clearances when No.1 or

No.6 piston is TDC on the
Front side Rear side
compression stroke

Intake and exhaust valve

0.40 mm
Clearance (at cold)

When No.1 piston at TDC

in compression stroke
• Loosen each valve clearance adjusting EJM1036S
screw as shown in the figure.

- 10 -
 • Insert the feeler gauge ( 0.4 mm )
between rocker arm and valve stem
end.

• Turn the valve clearance adjusting

screw until slight drag can be felt on
the feeler gauge.

• Tighten the lock nut securely.

• Rotate the crankshaft 360 °.

Realign the crankshaft pulley TDC
Front side Rear side
notched line with the timing pointer.

• Adjust the valve clearances for

remaining valves as shown in the
Exhaust
figure.
Intake When No.6 piston at TDC
in compression stroke
Rocker arm screw
2.6 ± 0.5 kg.m
lock nut torque EJM1037S

2.1.9. Injection Timing

Caution
Take care to avoid entry of dust or
foreign particles into the pump interior
when the timing adjustment is made.

< Check procedure >

• Align the crankshaft pulley TDC mark

with the pointer.
Remove the inspection hole cover at
the front of the injection pump on the
timing gear case cover.

EJM1035S

- 11 -
 Check the alignment between the
pointer 4 on the injection pump gear
nut lock plate and the projection area
mark 3 on the injection pump gear
case.
If it is in misalignment, recheck with
turning the crankshaft pulley one more
turn to repeat the foregoing procedure
to mark sure that it is in alignment. EJM1038S
Check the alignment of the notched
lines 1 and 2 . (These notched lines
were aligned at
3
the factory to set the injection pump
body and the mounting flange.)
Next, inspect the crank angle position
of the injection timing.

4
• Turn the crankshaft pulley EJM1039I
counterclockwise about 30° crank
angle.

• Disconnect the injection pipe from the

No.1 plunger.
This will allow you to visually check the
full injection starting flow at No.1
plunger.

EDM1009I

• Remove the delivery valve holder 1 ,

the valve seat 2 , valve spring 3 , and
the delivery valve 4 from the No.1
plunger.

• Assemble the delivery holder 1 and

tighten it to the specified torque.
Do not reassemble the delivery valve,
the delivery valve spring and the valve
seat. EJM1041S
These parts will be reassembled later.

- 12 -
• Hold the fuel control lever at the fully
open position.

EJM1042S

• Slowly turn the crankshaft pully

clockwise, at the same time, continue
to feed the fuel with pumping the
priming pump.
When the fuel stop to flow out from the
No.1 delivery valve holder, stop the
pump instantaneously.
This crank angle position is the
injection starting of the engine.

• Observe and make sure that mark

TDC
(injection starting angle line a °) on the
crankshaft pulley is aligning with the Crankshaft pulley

pointer.
Blow out the remaining fuel from the
a°
delivery valve holder.
Make sure that there is no fuel being
delivered from the priming pump.

EJM1044I
Fuel injection timing (BTDC) 20 °

• Remove the delivery valve holder from

the No.1 plunger.
Holder
• Reassemble the delivery valve internal
parts to the delivery valve holder.
Seat
• Reassemble the delivery valve holder
assembly to the No.1 plunger and
Spring
tighten it to the specified toque.

Delivery Valve
Delivery valve EJM1041S
4.25 ± 0.25 kg.m
holder torque

- 13 -
• Assemble the No.1 cylinder injection
pipe and tighten it to the specified
torque.

Injection pipe
3.1 ± 0.2 kg.m
nut torque

Caution
Do not overtighten the injection pump
body.
The injection pump body is made of
aluminum.
Overtighten will distort the injection
pump body shape and adversely affect
control rack operation.

< Adjusting procedure >

• Align the pointer and the specified

timing mark on the crank pulley.

• Perform the steps of “Check

Procedure” of Injection Timing. (2.1.9)

• Loosen the 4 injection pump fixing

nuts.

• Timing adjustment
To advance the timing
Pivot the injection pump at the pump
drive shaft toward out.
4 fixed nuts
To retard the timing
Pivot the injection pump at the pump
drive shaft toward in. (toward the EJM1045S
cylinder block)

Caution
The 1 mm misalignment between the
two setting mark lines corresponds to
about 2 ° in crank angle.

• Do a fine injection pump position

adjustment, while continue the
pumping operation to feed the fuel,
and stop to pivot the injection pump
when the fuel stop to flow out from the
No. 1 delivery valve holder.

- 14 -
 • Tighten the four injection pump fixing
nuts.

• Once remove the No. 1 delivery valve

holder, and reassemble the delivery
valve, spring and the valve holder with
the specified torque.

• Install the No.1 injection pipe and

tighten it to the specified torque.

2.1.10. Cylinder compression pressure

• Stop the engine after warming up, and

take out preheating plug and injection
pipe.

• Install the special tool (compression

gauge adapter) at the preheating plug
hole, and connect the compression
pressure gauge there.

EJM1046S
Standard value 28 kg / cm2 over
Limit value 24 kg / cm2
Difference between
Within ± 10 %
each cylinder

- Condition : Water temperature 75 °C.

- Engine rotation 200 rpm (10 rotation )

EJM1047S

- 15 -
2.1.11. Injection nozzle

Normal Abnormal Abnormal EFM1006I

• Install a nozzle on the nozzle tester.

• If the inspected injection pressure is less than the specified value, adjust using the adjusting
shims.

Engine Model DB 58 PU066

Injection nozzle pressure 220 kg / cm 2 220 kg / cm 2

• Check the atomizing state and replace it if abnormal.

2.1.12. Fuel injection pump

• Check the housing crack, damage etc. and replace it if abnormal.

• Check if the idle operation and speed regulating lever’s sealing is removed.
• The adjustment and testing of fuel injection pump should necessarily be done at the test
bench.

2.1.13. Feed pump strainer

• Release joint bolt A.

• Remove the strainer with a screwdriver
and wash the strainer with clean diesel
fuel.

A
EJM1029S
EJM1029S

Strainer

EJM1030S

- 16 -
2.1.14. Separator (Add if necessary )

• Check water level of the separator.

• Release the plug at the bottom to
eliminate water when water level
( floating ) reaches the warning point.
Warning
Elimination plug surface
1.2 ± 0.3 kg.m
torque
Floating

Elimination plug

EJM1031S

2.1.15. Air bleeding

• Loosen the priming pump cap 1 on the

Injection pump. 2
• Loosen the hollow screw for air
bleed 2 .

• Operate the priming pump until there

are no more bubbles visible in the fuel
being discharged from the fuel filter fuel 1
return eye bolt.

• Retighten the hollow screw. EJM1032S

• Operate the priming pump several
times and check for fuel leakage
around the injection pump and the fuel
filter.

2.1.16. Battery

• Inspect for any leakage of electrolytic solution owing to battery crack, and replace the battery
in case of poor condition.

• Inspect for amount of electrolytic solution, and replenish if insufficient.

• Measure the gravity of electrolytic solution, if less than specified value (1.12 ~ 1.28),
replenish.

Viewing Liquid level upper limit Isolator

the gravity Liquid level Liquid level lower limit
meler indicating line
1,100
1,200
1,300 UPPER LEVEL
LOWER LEVEL

EFM1007I

- 17 -
2.1.17. Starting motor

• In case of engine maintenance, clean pinion and ring gear thoroughly putting in the fuel, and
coat them with grease.
Also, in case of washing engine room and so forth, inspect the wiring state being careful for
water not to get in.

- 18 -
2.2. Diagnosis and remedy

1. Engine Starting Impossible

Starting motor operation poor Starting motor revolution

Inspection of battery electorlytic Engine Fuel

Iiquid amount & gravity
Inspect air cleaner Inspect amount of fuel
Normal Too low

Ajustment・ Normal Polluted Normal None

Recharging
Replace or Replenish
Inspection of loose electric clean element Inspect fuel
wiring & short injection No injection
Check compression
pressure Normal
Retigten・
Normal
Replace Too low
Continuous
Normal operation after
Inspection of starting switch Repair・
air removal
Replace
Inspect
Repair・ Inspect of
Normal injection
Replace other parts
timing
Inspection of starting relay Check valve Adjust
clearance Normal
Normal Replace
Inspect injection
Normal Adjust
nozzle (injection
Inspection of magentic switch
Check cylinder pressure, injection
Replace state, etc.)
Repair head gasket
Normal
Replace Repair・
Normal Normal
Replace
Starting motor
disassembly Engine disassembly Injection pump
(valve assembly, piston disassembly
cylinder liner, etc.)

Inspect supply pump operation

Inspect supply pump valve・strainer Air mixture in fuel

Normal

Injection pump Retighten connection

Clean・ Normal
disassembly parts・Replace gasket
replace
Inspect fuel filter Air removal

Element polluted・ Continuous air mixing

Overflow valve poor
Supply pump
Replace disassembly

- 19 -
 2. Engine Overheated

Operating state
1. Overload
2. Radiator core clogged
3. Continuous over-run
Cooling unit Fuel unit

Check coolant
Inspect fuel quality Fuel excessive supply

Normal Too low Poor

Check fan belt Clean and replace Check injection nozzle

Repair with specified fuel
tension wear
Replace
or damage etc.

Replenish Inspect cooling

Normal water leakage Normal Abnormal

Check fresh
Replace
water tank cap Exteranl Internal Adjust
repair Repair
injection Replace
Normal Retighten Engine
disassembly pump
Replace

Check thermostat Replace

Normal

Inspect Repair
Damage
Radiator Replace

Check cooling Repair

Normal
water pump Replace

Clean cooling
Normal
water passage

Engine
disassembly

- 20 -
 3. Output Insufficient

Engine Installation improper

Check for coupling

Fuel unit Others
alignemnt

Check for air mixing Inspect air cleaner Adjust or replace

in fuel coupling
Normal Clean Relpace
Inspect fuel supply pump
Inspect engine control
Normal Clean Replace rod, link, cable, etc. Inspect air leakage
of air piping line

Inspect fuel filter over flow valve Normal Adjust

Retighten
Normal
Normal Replace Replace
Check valve clearance

Inspect injection pipe Normal Adjust

Normal Repair Replace Inspect cylinder head

gasket for damage
Inspect injection nozzle,
injection pressure, Normal Replace
atomizing state
Engine disassembly
Normal Adjust Replace (valve assembly)

Check injection timing

Normal Adjustment

Disassemble engine or
injection pump

- 21 -
 4. Oil pressure lowered

Check if oil pressure

gauge indicates wrongly

Check oil amount

Normal Too low

Check cooling Use recommended oil

temperature (replenish)

Too high
Normal

Refer to engine overhea

Inspect oil quality

Normal

Check oil relief Water & fuel mixed Improper

valve in oil

Replace with
Disassemble engine
Normal recommended oil
Retighten or injection pump
Replace

Disassemble
engine

- 22 -
 5. Fuel Consumption Excessive

Causes according to Use Conditions

1. Overload
2. Govemor's Arbitrary Adjustment
3. Full Speed Operation for Long time
4. Sudden Speed Change from Low to
Inspect fuel leakage High Speed

Normal

Oil leakage
Inspect injection nozzle
(injection pressure Adjust Replace
atomizing state, etc.) Retighten Replace

Normal

Check injection timing Adjust

Normal

Repair Replace
Inspect compressed Check valve
Cylinder liner,
pressure clearance
Piston ring, Piston

Normal

Disassemble
Adjust
injection pump

Normal

Inspect head gasket Replace

Normal

Disassemble engine
(valve assembly, piston,
cylinder liner, etc.)

- 23 -
 6. Oil Consumption Excessive

Cause according to use conditions

1. Excessive oil infusing
2. Continuous operation in low or
extremely cold state

Inspect oil leakage

Inspect air cleaner

Normal Oil leakage Clean Replace

Check oil quality External Internal

Replace with Retighten Check compressed

specified oil Replace pressure

Engine disassembly Normal

(piston, cylinder liner)
Disassemble
cylinder head
(valve stem seal)

7. Engine Knocking

Inspect combustion of fuel & oil

(carbon residue of exhaust gas)

Unconfirmed Confirm

Inspect compressed Disassemble

pressure engine
Too low
Normal
Check valve clearance and
Inspect injection cylinderhead gasket for damage
pump

Normal Adjust Normal Replace

Adjust

Check fuel quality Disassemble

engine
Use specified fuel

- 24 -
 8. Battery Discharge

Battery Wiring, Switch Generator

Check electrolytic Inspect cut wire Check fan belt

liquid amount shorts and loose tension & damage
connections

Repair Replace

Normal

Electrolytic Battery room Battery self Battery over

liquid's damage discharge charging
standard
Inspect Generator
Replenish Replace Charging Voltage regulator

Normal Abnormal

Check charged stated Adjust

Replace

Discharging

Disassemble
Generator Voltage
regulator

- 25 -
 Condition Causes Remedies

1) Starting difficult • Valve’s poor shut, stem distortion Repair or replace

(1) Compression pressure • Valve spring damage Replace valve spring

• Cylinder head gasket’s leak Replace gasket

• Wear of piston, piston ring or liner Adjust

2) Idle operation abnormal • Injection timing incorrect Adjust

• Air mixing at injection pump Remove air

3) Engine output insufficient

(1) Continuous output • Valve clearance incorrect Adjust
insufficient • Valve tightness poor Repair

• Cylinder head gasket’s leak Replace gasket

• Wear, stick, damage of piston ring Replace piston ring

• Injection timing incorrect Adjust

• Fuel injection amount insufficient Adjust injection pump

• Nozzle injection pressure Adjust or replace

improper or stuck

• Supply pump’s function lowered Repair or replace

• Fuel pipe system clogged Repair

• Air suction amount insufficient Clean or replace air

cleaner

(2) Output insufficient • Compression pressure Disassemble engine

when in acceleration insufficient
• Injection timing incorrect Adjust
• Fuel injection amount insufficient Adjust injection pump
• Injection pump timer’s function Repair or replace
insufficient
• Nozzle injection pressure, injection Repair, replace
angle improper
• Supply pump’s function lowered Repair or replace
• Air intake amount insufficient Clean or replace air
cleaner

4) Overheating • Engine oil insufficient or poor Replenish or replace

• Cooling water insufficient Replenish or replace

• Fan belt loosened, worn, damaged Adjust or replace

• Cooling water pump’s function lowered Repair or replace

• Water temp. regulator’s operation poor Replace

• Valve clearance incorrect Adjust

• Exhaust system’s resistance increased Clean or replace

- 26 -
 Condition Cause Remedies

5) Engine noisy For noises arise compositely such as

rotating parts, lapping parts, etc., there is
necessity to search the cause of noises
accurately.
(1) Crankshaft • As the wear of bearing or crankshaft Replace bearing &
progress, the oil clearances increase. grind crankshaft

• Lopsided wear of crankshaft Grind or replace

• Oil supply insufficient due to oil Clean oil passage

passage clogging

• Stuck bearing Replace bearing &

Grind

(2) Con rod and • Lopsided wear of con rod bearing Replace bearing
Con rod bearing • Lopsided wear of crank pin Grind crankshaft

• Connecting rod distortion Repair or replace

• Stuck bearing Replace &

grind crankshaft

• Oil supply insufficiency as clogging Clean oil passage

at oil passage progresses

(3) Piston, piston pin & • Piston clearance increase as the wear Replace piston &
piston ring of piston and piston ring progresses piston ring

• Wear of piston or piston pin Replace

• Piston stuck Replace piston

• Piston insertion poor Replace piston

• Piston ring damaged Replace piston

(4) Others • Wear of crankshaft, thrust bearing Replace thrust

bearing

• Camshaft end play increased Replace thrust plate

• Idle gear end play increased Replace thrust

washer

• Timing gear backlash excessive Repair or replace

• Valve clearance excessive Adjust valve

clearance

• Abnormal wear of tappet, cam Replace tappet, cam

6) Fuel Consumption • Injection timing incorrect Adjust

Exttive • Fuel injection amount excessive Adjust injection
pump

- 27 -
 Condition Cause Remedies

7) Oil Consumption
Excessive
(1) Oil level elevated • Clearance between cylinder iiner & Replace
piston

• Wear of piston ring, ring groove Replace piston,

piston ring
• Piston ring’s damage, stick, wear Replace piston ring
• Piston ring opening’s disposition Correct position
improper
• Piston skirt part damaged or Replace piston
abnormal wear
• Oil ring’s oil return hole clogged Replace piston ring

• Oil ring’s contact poor Replace piston ring

(2) Oil level lowered • Looseness of valve stem & guide Replace in set

• Wear of valve stem seal Replace seal

• Cylinder head gasket’s leak Replace gasket

(3) Oil leak • Looseness of connection parts Replace gasket,

repair
• Various parts’ packing poor Replace packing
• Oil seal poor Replace oil seal

- 28 -
2.3. Engine inspection

2.3.1. Stopping engine

Cut off the main circuit breaker of the generator control panel. After checking the engine for
any unusual condition at the idling speed, then press the stop button to stop the engine.

2.3.2. General engine inspection cycle

In order to insure maximum, trouble-free engine performance at all times, regular inspection,
adjustment and maintenance are vital.

• Daily inspections in below figure should be checked every day.

• The following maintenance details should be executed thoroughly at regular internals.
: Check & adjust : Replace

Every Every Every Every Every

Inspection Daily Remark
50hrs 200hrs 400hrs 600hrs 1200hrs
Check for leakage(hoses, clamp)
Check the water level
Cooling Change the coolant water
System Every
Adjust the V-belt tension 2,000hrs
Clean the radiator
Check for leakage
Check the oil level gauge
Lubrication
Change the lubricating oil 1st
System

Replace the oil filter cartridge

1st
Check the leakage for intake
Intake & manifold
Exhaust
System Clean and change
the air cleaner element clean
Check the leakage fuel line
Clean the fuel strainer
of fuel feed pump
Remove sediment from fuel tank
Fuel Drain the water in separator
System Replace the fuel filter element
When
Check fuel Injection timing
necessary
When
Check the injection nozzles necessary
Check the state of exhaust gas
Check the battery charging
Engine When
Check the compression pressure
Adjust necessary

Adjust Intake/Exhaust When

valve clearance 1st necessary

- 29 -
2.3.3. Use of original parts for repair and replacement

For engine is being mechanically harmonized with many parts, only when the original parts that
the manufacture recommends to use is used, the engine trouble would be preventively
maintained and capable to keep up the maximum performances.
For the analogous parts not the original parts are poor in qualities and gives ill performance,
it may rather bring early engine failure.

- 30 -
3. Disassembly and Reassembly of Major Components

3.1. Major Part Fixing Nuts and Bolts

3.1.1. Cylinder head cover

( Unit : kg . m )

3.0 ± 0.5

Cylinder Head Bolt Torque

- Type A) Hexagon bolt : 11.5 ± 0.5 5.3 ± 1
- Type B) Dodecagonal bolt
1st : 4 kg.m
2nd : 90 °
3rd : 90 °-10 ° (Angle method)

2.7 ± 0.25
(19.5 ± 1.8)

Preheating plug

5.3 ± 1

EJM1001S

- 31 -
3.1.2. Cylinder block

( Unit : kg . m )

5.3 ± 1

2.6 ± 0.5

2.6 ± 0.5

2.6 ± 0.5

24.1 ± 1 2.1 ± 0.5

EJM1002S

- 32 -
3.1.3. Oil pan and level gauge

( Unit : kg . m )

2.9 ± 0.3

2.6 ± 0.5

8.0 ± 1

EJM1003S

- 33 -
3.1.4. Camshaft and rocker arm

( Unit : kg . m )

2.2 ± 0.5

2.2 ± 0.5

2.2 ± 0.5

2.6 ± 0.5

16 ± 1.5

Lubricate engine oil

5.5 ± 1

EJM1004S

- 34 -
3.1.5. Crankshaft, piston and flywheel

( Unit : kg . m )

A Type : 12 ± 0.25
B Type : 9.25 ± 0.25

Mark : on bolt head

B Type 12

A Type 11

60 ± 5
22.3 ± 2.2

EJM1005S

- 35 -
3.1.6. Thermostat and housing

( Unit : kg . m )

2.6 ± 0.5

5.3 ± 1

5.3 ± 1

EJM1006S

- 36 -
3.1.7. Intake and exhaust manifold

( Unit : kg . m )

2.6 +
_ 0.5
2.9 +
_ 0.5

2.6 +
_ 0.3

EJM1009S

- 37 -
3.1.8. Timing gear case and flywheel housing

( Unit : kg . m )

2.2 _
+ 0.5

16.0 _
+ 1.0
2.2 _
+ 0.5

16.0 _
+ 1.0

EJM1010S

- 38 -
3.1.9. Oil cooler, oil filter and oil pump

( Unit : kg . m )

_ 1.0
5.3 +

_ 1.0
5.3 +

_ 1.0
5.3 +

_ 0.5
2.6 +

_ 0.5
2.6 +

EJM1011S

- 39 -
3.1.10. Fuel system

( Unit : kg . m )

1.9 ± 0.2

1.3 ± 0.2

1.7 ± 0.1
3.1 ± 0.2

4.2 ± 0.8

4.2 ± 0.8

EJM1012S

- 40 -
Engine repair parts
1. Cylinder head gasket
2. Cylinder head cover gasket
3. Intake manifold gasket
4. Exhaust manifold gasket
5. Thermostat housing gasket
6. Thermostat gasket
7. Tappet chamber cover gasket
8. Tappet cover fixing bolt gasket
9. Crank shaft rear oil seal
10. Timing gear case oil seal
11. Valve guide oil seal
12. Oil pan gasket
13. Drain plug gasket
14. Oil filter cover gasket
15. Oil filter fixing bolt gasket
16. Oil cooler gasket
- 41 -
EJM1053S
17. Gear case to cylinder block gasket
18. Cover to timing gear case gasket
19. Relief valve O-ring
20. Cylinder block side plug gasket
21. Water drain valve gasket
22. Oil pump hole cover gasket
23. Water pump gasket
24. Oil pipe gasket
25. Oil pipe gasket
26. Fuel pipe joint bolt gasket
27. Leak off pipe joint bolt gasket
28. Injection nozzle gasket
29. Injection pump gasket
30. Injection pump oil pipe gasket
31. Cylinder head cover nut gasket
3.2. Major components disassembly

3.2.1. Main structure parts (1)

Repair kit EJM2010S

1.Rubber hose (Coolant by-pass) 9. Oil pump driving pinion

2. Rocker arm shaft assembly 10. Nut
3. Push rod 11. Crankshaft pulley and dust cover
4. Cylinder head bolt 12. Taper bushing
5. Cylinder head assembly 13. Timing gear cover
6. Cylinder head gasket 14. Oil thrower
7. Coolant pump assembly 15. Fly wheel
8. Tappet chamber cover

- 42 -
 Importance

2) Rocker arm shaft

Loosen the rocker arm shaft fixing
bolts a little in numerical sequence as
specified.

EJM2013S

5) Cylinder head
Loosen the cylinder head bolts a little
in the numerical order shown in the
figure.

Front

EJM2014S

11) Crankshaft pulley

Use an appropriate wrench (54 mm) Crankshaft pulley
to remove the crankshaft pulley nut.

Wrench

EJM2015S

12) Taper bushing

Use the taper bushing remover to
remove the crankshaft end taper Remove tool Taper bush
bushing.
Crankshaft

Bolt (M14 X 1.50) Pulley

EDM1010I

15) Flywheel
Loosen the flywheel bolts a little in the
numerical order as specified.

3 1
5 6
2 4

EJM2017S

- 43 -
3.2.2. Main structure parts (2)

EJM2018S Repair kit

1. Oil cooler 9. Timing gear case

2. Oil pan 10. Idler gear shaft
3. Oil pump and coupling 11. Crank shaft bearing cap
4. Flywheel housing 12. Crank shaft bearing (lower part)
5. Piston and connecting rod 13. Thrust bearing
6. Idler gear 14. Crank shaft
7. Cam shaft 15. Crank shaft bearing (upper part)
8. Tappet 16. Oil spray nozzle (PU066 only)

- 44 -
 Importance

6) Idler gear
Measure the following points before
disassembly.

< Idler gear end play >

Standard Limit
0.058 ~ 0.115 mm 0.2 mm
Feeler gauge
EJM2019S

< Timing gear back lash >

Standard Limit
0.10 ~ 0.17 mm 0.3 mm

Includes the crankshaft gear, the

camshaft gear and the idler gear

Dial indicator EJM2020S

7) Camshaft
Measure the following points before
Camshaft gear
disassembly.

< Cam Gear End Play > Thrust plate

Standard Limit Camshaft

0.050 ~ 0.114 mm 0.2 mm Feeler gear

EJM2021S

11) Crankshaft bearing cap

Measure the crankshaft endplay at
Feeler gear
the thrust bearing (center main
bearing) before disassembly.

< Crankshaft End Play >

Standard Limit
0.15 ~ 0.33 mm 0.4 mm

Crankshaft EJM2022S

- 45 -
3.2.3. Rocker arm disassembly

EJM2023S

1. Bracket 3. Spring
2. Rocker arm 4. Rocker arm shaft

- 46 -
3.2.4. Cylinder head disassembly

EJM2024S

1. Exhaust manifold and gasket 7. Spring seat ( upper )

2. Intake manifold and gasket 8. Valve spring
3. Coolant outlet pipe 9. Spring seat ( lower )
4. Thmostat 10. Valve
5. Thermostat housing and gasket 11. Valve stem oil seal
6. Valve cotter

Importance

6) Valve cotter
Use the valve spring compressor to
remove the valve cotter.

Valve spring compressor EJM2027S

- 47 -
3.2.5. Piston and connecting rod disassembly

4 1
2
3

EJM2028I

1. Piston rings 4. Piston

2. Snap ring 5. Connecting rod bearing
3. Piston pin and connecting rod

- 48 -
Importance

Caution
Remove any carbon deposits from the Carbon deposit
upper part of the cylinder bore.
This will prevent damage to the piston
and the piston rings when they are
removed from the cylinder bore.

EDM1011I

1) Piston rings
Use a piston ring remover to remove
the piston rings.
Do not attempt to use other tools.
Stretching piston ring will result in Piston ring
remover
reduced piston ring tension.

EJM2030I

2) Snap ring
Use a pair of snap ring pliers to
remove the snap ring.

EJM2031S

3) Piston pin
Tap the piston pin out with a hammer
and brass bar. Piston pin

EJM2032S

- 49 -
3.3. Inspection

3.3.1. Cylinder block

• Clean the cylinder block thoroughly and make a visual inspection for cracks or damage.
• Replace if cracked or severely damaged, and correct if slightly damaged.
• Check oil and water flow lines for restriction or corrosion.
• Make a hydraulic test to check for any cracks or air leaks.
( Hydraulic test ) : Stop up each outlet port of water/oil passages in the cylinder block, apply
air pressure of about 5 kg / cm2 against the inlet ports, then immerse the
cylinder block in water for about 3 minute to check any leaks. ( Water
temperature : 70 °C )

3.3.2. Cylinder head

1) Inspection

• Carefully remove carbon from the lower lace of the cylinder head using nonmetallic material
to prevent scratching of the valve seat faces.

• Check the entire cylinder head for very fine cracks or damage invisible to ordinary sight
using a hydraulic tester or a magnetic flaw detector.

2) Distortion at the lower face

• Measure the amount of distortion

(t)
using a straight edge and a feeler
gauge at six positions ( A ~ F) as
B
shown in the right figure. A
• If the measured value exceeds the
D
C
standard value, retrace the head with
grinding paper of fine grain size to
correct such defect. E
F
• If the measured value exceeds the
EA3M2031
maximum allowable limit, replace the
cylinder head.

< Lower face warpage and height >

Standard Limit
Warpage 0.2 mm or less 0.3 mm
Thickness : t 89.95 ~ 90.05 mm 89.65 mm

EJM2034S

- 50 -
 3) flatness
Measure flatness of the intake/exhaust
manifolds fitting surfaces on the
cylinder head using a straight edge and
a feeler gauge.

Standard Limit
0.05 mm 0.2 mm

4) Hydraulic test
Hydraulic test method for the cylinder
head is same as that for cylinder block.

EJM2036S

3.3.3. Valve stem and valve guide clearance

1) Measuring method - I

• After install dial gauge needle on the

inserted valve stem, set up calibrator
to “0”. ( as shown in figure )

• Move valve head from side to side.

Record total dial indicator reading.
This valve is the clearance between
the valve stem and valve guide.

• Valve and guide set must be replaced

if measured value exceed the
EJM2037S
specified limit

< Valve stem clearance (T.I.R) >

Standard Limit
Intake side 0.039 ~ 0.071 mm 0.20 mm
Exhaust side 0.064 ~ 0.096 mm 0.25 mm

- 51 -
2) Measuring method - II

• Measure valve stem outside

diameter.

• Measure valve guide inside

diameter by using of caliper calibrator
of telescoping gauge.

• The difference between the valve

stem outside diameter and the valve
guide inside diameter is the valve
stem clearance. EJM2038S

3) Valve guide replacement

• Removal of valve guide

Pull out the valve guide, by using
hammer and valve guide remover, Remover
from bottom of cylinder head.

EJM2039S

• Install of valve guide

The height from the bottom of the
Installer
cylinder head to the edge of valve
guide top should be 14.1 mm.

EJM2040S

- 52 -
4) Valve depression

• Install the valve 1 to the cylinder

head 2 .
2
• Measure valve depression by using
the depth gauge or calibrator from the
bottom of cylinder head.

• Seat insert and valve must be

1
replaced if the measured value
exceed the specified limit.

• If the valve is replaced, the valve EJM2041I

guide must be also replaced.

Standard Limit
Intake and exhaust
1.0 mm 2.5 mm
valve depression

5) Valve contact width

• Inspect the valve contact faces for the

roughness and unevenness.
Make valve contact surfaces smooth.

• Measure the width of valve contact.

Standard
Valve contact width, Intake 2.4 mm
Valve contact width, Exhaust 1.6 mm
EJM2042I

6) Valve seat replacement

• Arc weld entire inside

circumference 1 of the valve seat 2 . Driver
( see figure )

• Cool valve seat for a few minutes.

Cylinder
This will make removal of the valve
head
seat easier.

• Pull out the valve seat by using the

inner extractor.

• Carefully remove the carbon and EJM2043S

other foreign material from the
cylinder head insert bore.

- 53 -
7) Valve seat installation

• Carefully place Jig 1 .

Presser
3
Caution
The smooth face of jig must contact the 1
valve seat.
Valve
2 seat

• Assemble valve insert by slowly

pressing it against the jig with the Cylinder
bench press. head
EJM2044I
( The amount of needed pressure is
more than 2,500 kg. )

Caution
Do not press the valve seat excessively
with the bench press.
It may damage the valve seat.

8) Valve seat correction

• Remove the carbon deposits from the

valve seat surface. 150
A
• Remove the rough areas by using
30
valve cutter. ( 30°, 90° or 150° )
Do not cut the valve seat too much.

Angle Location Standard

Valve seat
Intake valve seat 90 ° Valve guide
Exhaust valve seat 90 °
EJM2045I

Caution
Use an adjustable valve cutter pilot.
Do not allow the cutter pilot to wobble
inside the valve guide.

EJM2046S

- 54 -
 • Spread compound on the surface of
valve seat.

• Insert valve into valve guide.

• Lap the valve and valve seat with the
lapping tool.

• Check that valve contact width is

correct.
45°
B

EJM2047I

• Check that the entire surface of valve

seat is in contact with the valve.

EJM2048S
3.3.4. Valve spring

1) Valve spring free length

• Measure the valve spring with the

vernier caliper.

• Replace the spring if the measured

value is less than the specified limit.

EJM2049I

Model Standard Limit

DB58 Exhaust and intake - 53.65 mm 52 mm
Valve spring Outer 53.65 mm 52 mm
PU066 free length inner 52.4 mm 51 mm

- 55 -
 2) Valve spring inclination

• Measure the valve spring inclination

by the using of square. Inclination
• Replace the valve spring if the
measured value exceed the specified
limit.
Free
spring
Standard Limit
Valve spring
2.5 mm 3.5 mm
Inclination
EJM2050I

3) Valve spring tension

• Measure the valve tension by using

spring tester.

• Replace the valve spring if the

measured value exceed the specified
limit.

Spring tester

EJM2051S

Model Standard Limit

DB58 Valve spring tension - 22.5 kg 20.0 kg
At 41.5 mm Outer 22.5 kg 20.0 kg
PU066 set length inner 10.9 kg 9.9 kg

3.3.5. Tappet

• Check the valve tappets for excessive

wear, damage or abnormalities.

Pitting Clack normal contact

Abnromal contact
EA0M4070

- 56 -
 • Measure the outside diameter of
tappet with the micrometer.

Standard Limit
Tappet outside
ø27.96 ~ ø27.98 mm ø27.92 mm
diameter

EJM2052S

• Measure the clearance between

tappets and cylinder motion parts by Dial indicator

the using dial indicator.

Standard Limit
Tappet and tappet
0.020 ~ 0.054 mm 0.1 mm
bore clearance

EJM2053S

3.3.6. Push rod

• Measure the run out of push rod with

the feeler gauge.

• Roll the push rod along a smooth flat

surface as shown in the figure.

Limit
Push rod of run-out 0.2 mm

feeler gauge
EA0M4073

3.3.7. Rocker arm correction

• Check the valve stem contact part of

rocker arm.

• Grind contact surface with an oil stone

if it is irregularly contacted.

• Replace the rocker arm if it is

extremely damaged.

EJM2055S

- 57 -
1) Rocker arm and shaft

• Check the disassembled parts for

wear, damage and abnormalities.

EJM2056S

2) Rocker arm shaft outside diameter

• Measure the outside diameter of

rocker arm with the micrometer.

• Replace shaft if measured value

exceed the specified limit.

Standard Limit
Diameter of rocker
ø18.98 ~ ø19.00 mm ø18.85 mm
arm shaft

EJM2057S

3) Rocker arm and shaft clearance

• Measure the inside diameter of rocker

arm bushing with the vernier caliper.

• Measure the out side diameter of

rocker arm shaft.
Replace the rocker arm or rocker arm
shaft if measured value exceed the
specified limit.

Standard Limit
EJM2058S
Diameter of rocker
ø19.02 ~ ø19.05 mm ø19.07 mm
arm bushing

Standard Limit
Rocker arm bushing
and rocker 0.02 ~ 0.07 mm 0.2 mm
arm shaft clearance

• Check the rocker arm oil port whether

alien substance is in it or not.
Clean the rocker arm oil port with
compressed air if necessary. EJM2059I

- 58 -
3.3.8. Idler gear and shaft

• Replace the idler gear shaft if the

measured value exceeds the specified
limit.

Standard Limit
Diameter of idler
ø44.945 ~ ø44.975 mm ø44.9 mm
gear shaft

• Measure the inside diameter of idler

EJM2060S
gear with the dial indicator,

Standard Limit
Clearance of idle
0.045 ~ 0.105 mm 0.2 mm
gear and shaft

EJM2061I

- 59 -
3.3.9. Camshaft

• Use the jig to install or overhaul

camshaft bearing in cylinder block.

• Measure the clearance between the

cam journal and the camshaft bearing.

Standard Limit
Clearance of cam Jig
journal and 0.03 ~ 0.09 mm 0.15 mm
cam bearing
EJM2062S

Cam bearing

EJM2061I

• Align the camshaft bearing oil port with

the mating oil port ( machined on the
cylinder block ).

Align oil pots

EJM2061I

• Measure the cam lobe with the

micrometer.
Replace the camshaft if the measured
values exceed the specified limit.

Standard Limit
Cam lobe height(C-D),In 7.44 mm 6.94 mm
Cam lobe height(C-D),Ex 7.71 mm 7.21 mm
Cam journal diameter ø56.0 mm ø55.6 mm
I II I II
A
C B B

D A
EJM2065I

- 60 -
 • Set up the camshaft on a measuring
stand.

• Measure the run out of camshaft with

the dial indicator.
Record the measured value (T.I.R)
Replace the camshaft if the measured
value exceeds the specified limit.

Limit EJM2066I
Camshaft run-out 0.12 mm

3.3.10. Cylinder liner

1) Cylinder liner bore measurement

• Measure the bore at measuring

position 1 in line with the
crankshaft 3 and across the 3
crankshaft 2 .
1

EJM2067I

• Measured position : 20 mm from the

top of liner. (max. wear portion)

• Replace the cylinder liner if the

2
measured value exceeds specified
limit.

Standard Limit
Diameter of cylinder
ø102.017 ~ ø102.046 mm ø102.20 mm
liner bore
EJM2068I

Caution
The casting liner is specially honed
without the chrome plating inside, so
that chrome plated ring ( top ring and oil
ring ) must be used.

- 61 -
 2) Cylinder liner inspection

• Set up the straight square along the Liner

Linerprojection
projection
top edge of cylinder liner.

• Measure liner projection with the Square

Square
feeler gauge.

Standard
Cylinder liner Cast liner 0.02 ~ 0.07 mm
Projection Steel liner 0.015 ~ 0.115 mm Feeler gauge

EJM2069S
The difference in the liner projection
height between any two adjacent
cylinders must NOT exceed 0.3 mm.

3) Cylinder liner replacement

• Set the cylinder liner remover to the

cylinder liner.

• Check that cylinder liner remover

shaft ankle is firmly gripping the
cylinder liner bottom edge.

• Slowly turn the remover shaft handle

counter-clockwise to pull the cylinder
liner free.

EDM3004S
Caution
Take care not to damage the cylinder
body upper face when remove the
cylinder liner.

3.3.11. Cylinder block

1) Grade selection of cylinder liner

• Select a grade from the outside

diameter of the cylinder liner and
inside diameter of block combination.

• Determine a grade of the cylinder

20mm
liner after measuring the inside
diameter of the cylinder block.

• Loose fitting cylinder liners (the liner

is too small for the cylinder bore) will
adversely affect engine cooling
EA3M2043
efficiency and may lead to serious
engine damage. Cylinder liners which
are too large for the cylinder bore will
be difficult to install.

- 62 -
2) Cylinder block bore measurement

• Measure at measuring point 1

across the positions W- W, X-X, Y-Y
and Z-Z.
1
Measuring point 1 diameter : 115 mm

• Calculate average value of four

measurements to determine the
correct cylinder liner grade.

EJM2072I

Grade marking Cylinder block bore diameter

1 ø 105.090 ~ ø 106.000 mm
2 ø 106.000 ~ ø 106.010 mm

EJM2073S

3) Cylinder liner outside diameter

• Measure the liner outside diameter at

1 , 2 and 3 measuring point
across X-X, Y-Y.
Measuring Points :
1 20.0 mm
2 105.0 mm
3 185.0 mm

• Calculate the average value of 6

EJM2074S
measurements to determine the
correct cylinder liner grade.

• Combination of the cylinder bore and

the cylinder liner outside diameter.

Steel liner Cast iron liner

( tightness ) ( clearance )

Cylinder liner 0.001 0.005

fitting clearance ~ 0.019 mm ~ 0.026 mm

- 63 -
 < Cylinder bore and liner outside diameter >

(A) Steel cylinder liner

Grade Cylinder bore Cylinder liner outside diameter

1 ø105.001 ~ ø105.010 mm ø105.011 ~ ø105.020 mm
2 ø105.011 ~ ø105.020 mm ø105.021 ~ ø105.030 mm
3 ø105.021 ~ ø105.030 mm ø105.031 ~ ø105.040 mm

(B) Cast iron cylinder liner

Cylinder liner diameter

Grade marking
2 position 1 , 3 position
øD ø102.020 ~ ø102.031 mm ø102.017 ~ ø102.035 mm 1
(Inner diameter) ø102.031 ~ ø102.042 mm ø102.028 ~ ø102.046 mm 2
øE ø105.973 ~ ø105.984 mm ø105.970 ~ ø105.988 mm A
(Outer diameter) ø105.984 ~ ø105.995 mm ø105.981 ~ ø105.999 mm B

Part no of Cylinder liner diameter

marking
cylinder liner grade Outer Inner
65.01201 - 0068 1 A 1A
65.01201 - 0069 1 A 1B
65.01201 - 0070 2 B 2A
65.01201 - 0071 2 B 2B

Marking
EJM2172I

4) Cylinder liner assembly

• Carefully wipe away any foreign

material from the cylinder liner inside
and outside surfaces and the cylinder
bore. Cylinder liner
Cylinder block
• Cleanly wash cylinder liner and bore
surfaces with new kerosene or diesel
oil.

• Use a clean rag to remove all traces

of kerosene or diesel oil from cylinder
EJM2075S
liner and bore surfaces.

• Insert the cylinder liner into cylinder

block from the top of the cylinder
block.

- 64 -
 • Set the cylinder liner installer to the
top of the cylinder liner. Bench press
Installer shaft center
• Position the cylinder body so
that the installer center is directly
beneath the bench press shaft center.

• Check that the cylinder liner is set

perpendicular to the cylinder.

• Use the bench press to apply an initial

seating force of 500kg to the cylinder EJM2076S

liner.

• Use the bench press to apply a final

seating force of 2,500kg to fully seat
the cylinder liner.

• After installing the cylinder liner,

measure the cylinder liner projection.

5) Piston grade selection

• ”Piston grade” refers to the piston

diameter and the cylinder liner bore
combination.

• Selection of the proper piston grade

will ensure efficient engine operation,
free from cylinder liner and piston 2 1

problems.

• Measure the cylinder liner bore after

installing the cylinder liner. EJM2077I

• Determine the appropriate piston

grade after measuring cylinder liner
bore.

6) Cylinder liner bore measurement

• Loacte the two measuring points.

Cylinder liner measuring point 1
: 20 mm
Cylinder liner measuring point 2
: 105 mm

• Measure cylinder liner bore at

measuring points 1 and 2 in four
different directions ( X-X, Y-Y, W-W
and Z-Z ). EJM2073S

• Calculate the average value of the 8

measurements.

Standard
Cylinder liner bore ø102.020 ~ ø102.042 mm

- 65 -
 Caution
It is most important to use correct
piston-liner combination. Incorrect
combination will result in piston seizure.
Always measure the cylinder bore and
select the appropriate piston grade.

3.3.12. Piston

1) Piston outside diameter

• Piston outside diameter vary

depending on the piston type to be
used.

• Measure the piston outside diameter

2 (see figure).

Steel
< Piston grade > Strut

Grade Limit
A ø101.953 ~ ø101.967 mm EJM2078I

B ø101.963 ~ ø101.977 mm

< Cylinder liner bore and piston >

Clearance 0.053 ~ 0.077 mm

Caution
The cylinder liner-piston kit clearances
are preset.
However, the cylinder liner installation
procedure may result in slight decreases EJM2079S

in the cylinder liner bore clearances.

Always measure the cylinder liner bore
clearance after installation to be sure
that it is correct.

- 66 -
2) Piston ring and piston groove
clearance

• Measure the piston ring and the

piston ring groove clearance with a
feeler gauge.

• Measure it at several points around

the piston.

• Replace the piston ring If the

measured value exceeds the
specified limit.

EJM2080S
< Piston ring and piston groove clearance >

Standard Limit
Top ring 0.070 ~ 0.120 mm 0.20 mm
2nd ring 0.050 ~ 0.085 mm 0.15 mm
Oil ring 0.030 ~ 0.070 mm 0.15 mm

3) Piston ring gap

• Insert the piston ring horizontally (in

the position it will assume if it were
installed to the piston) into the
cylinder liner.

• Push the piston ring with an inverted

piston into the cylinder liner until it
reaches measuring point 1 or 2 .
The cylinder liner diameter is the
smallest at these two points.
EJM2082S
Do not allow the piston ring to slant to
one side or the other. It must be
perfectly horizontal.
Cylinder liner measuring point 1
: 10 mm
Cylinder liner measuring point 2
:130 mm

• Measure piston ring gap with a feeler

gauge.
The piston ring must be replaced if
the measured value exceeds the
specified limit.

Standard Limit
Top ring gap 0.25 ~ 0.45 mm 1.50 mm
2nd ring gap 0.40 ~ 0.60 mm 1.50 mm
Oil ring gap 0.20 ~ 0.40 mm 1.50 mm

- 67 -
4) Piston pin

• Measure piston pin outside diameter

with micrometer at several points.

• Replace the piston pin if the

measured value exceeds the
specified limit.

Standard Limit
Piston pin ø 35.000
ø 34.95 mm
outside diameter ~ ø 35.005 mm
EJM2083S

5) Piston pin hole

• Measure diameter of the piston pin

hole with inside dial gauge.

Standard
Piston pin and ø 35.010
piston clearance ~ 35.018 mm

EJM2084S

6) Piston pin and piston pin hole clearance

• Determine the clearance between the

piston pin and the piston pin hole by
calculating the difference between the
piston pin hole diameter and the
piston pin outside diameter.

Standard
Piston pin and 0.005
piston pin hole clearance ~ 0.018 mm
EJM2085S

• If an inside dial indicator is not

available, use the following procedure
to check the piston pin fit.
(1) Heat piston to approximately 60°C
with the piston heater.
(2) Push strongly against the piston
pin with your thumb. The piston
pin fitting should feel tight.

EJM2086S

- 68 -
3.3.13. Maintenance of cylinder block, cylinder liner and piston

To maintain the engine in optimum condition and retain maximum performance for a long
time, the cylinder block, cylinder liner and piston which have the same grade marking number
( the same size tolerance ) should be assembled. The marking number ( the part’s grade ) and
marking position is as follows.

• Cylinder block
a) Marking number ; 1 or 2
( Size grade for of cylinder bore
Marking
diameter )
b) Marking position ; Top of the
cylinder block side surface

EJM2174I

• Cylinder liner
a) Marking number ; 1A, 1B, 2A or 2B
1A

Can used the piston A grade

Can used the cylinder block 1 grade

b) Marking position ; Cylinder liner

lower surface

Marking
EJM2173I

• Piston
a) Marking number ; A or B
( Size grade for piston outer diameter )
b) Marking position ; Center of the piston upper surface

Assembly process of cylinder block, cylinder liner and piston

(1) Check the marking number (1 or 2) of cylinder block. (Top of side surface)
(2) Then assemble the liner whose first digit of the marking (1A, 1B, 2A, 2B) is just the same
with it on the cylinder block.
(3) Assemble the piston whose marking is just same with the second digit (A or B) of the
assembled cylinder liner’s marking.

- 69 -
3.3.14. Connecting rod

1) Connecting rod alignment

• Measure the parallelism between the

connecting rod big end hole and small
end hole with a connecting rod
aligner.

• Replace the connecting rod if the

measured value exceeds the
specified limit.

Standard Limit
EJM2087S
Balance 0.05 mm or less 0.20 mm

2) Piston pin and bush clearance

• Measure an inside of connecting rod

bushing and outside of piston pin with
the caliper gauge and micrometer.

• Replace a connecting rod bush or

piston pin if the measured value
exceeds the specified.

Standard Limit
Piston pin and 0.012
0.05 mm EJM2088S
bushing clearance ~ 0.030 mm

3) Connecting Rod Bush Replacement

• Connecting Rod Bush Removal

(1) Clamp the connecting rod in a vise.
(2) Pull out connecting rod bush by
using a brass bar with a bench
press or a hammer.

• Connecting rod bush assembly

(1) Use special jig to assemble the
connecting rod bush.

Caution
Align the connecting rod bush oil hole EJM2089S
with the connecting rod oil hole.

- 70 -
 (2) Use a piston pin hole grinder 1
fitted with a reamer 2 or an
adjustable pilot reamer to ream
the piston pin hole.

Standard
Connecting rod ø 35.017
bush inside diameter ~ ø 35.030 mm

EJM2090S

4) Connecting rod bearing Inspection

• Fit the connecting bearing lower half

into the connecting rod bearing cap.

• Check the tension of the connecting

rod bearing lower half.
If the tension is insufficient, the
bearing must be replaced.

• Tighten the connecting rod and the

bearing cap to the specified torque.
EJM2091S
A type B type
Connecting rod 12.0 9.75
bolt torque ± 0.25 kg.m ± 0.25 kg.m

A type : 11 Marked on bolt head

TY TY
B type : 11
or
12

• Measure the inside diameter of the

connecting rod bearing with an inside
dial gauge.

Standard
Connecting rod ø 63.974
bearing diameter ~ ø 64.005 mm

EDM2044I

- 71 -
3.3.15. Crankshaft

1) Crankshaft and bearing inspection

• Check the crankshaft journal surfaces and pin surfaces for excessive wear and damage.
• Check oil seal fitting surfaces of the crankshaft front and rear ends for excessive wear and
damage.

• Replace or repair the crankshaft if any excessive wear or damage is discovered.

• Check the crankshaft oil ports for obstructions.
• Clean oil port with high pressure air if necessary.

2) Crankshaft journal and pin diameter

• Measure the crankshaft journal

outside diameter with the micrometer
across 1 - 1 and 2 - 2 .

• Measure crankshaft journal outside

diameter at two points 3 and 4 by
using the micrometer.

• Repeat step 1 and 2 to measure the

crankshaft outside diameter.
The crankshaft must be reground if EJM2093S

the measured value of the crank pin

outside diameter and/or crankshaft
journal diameter exceeds the
specified limit.

Standard
Crankshaft journal ø 79.905
outside diameter ~ ø 79.925 mm

Standard
Crankshaft pin ø 63.924
outside diameter ~ ø 63.944 mm

• Measure the crankshaft journal

outside diameter (and/or crankshaft
pin outside diameter) and bearing
inside diameter to determine the
bearing clearance.

- 72 -
3) Crankshaft journal and bearing clearance

• If the bearing clearance exceeds the

specified limit, the crankshaft must be
reground and/or the bearing must be
replaced.

Standard Limit
Main bearing 0.025
0.11 mm
clearance ~ 0.090 mm

Standard Limit
Rod bearing 0.03
0.10 mm
clearance ~ 0.073 mm

4) Crankshaft bearing diameter

• Install the main bearing cap with

bearings to the cylinder block with the
specified torque and facing the arrow
mark on the bearing cap toward front.
Place them in order of punched
cylinder numbers.

• Measure the main bearing diameter

with an inside dial gauge.

EJM2094S
Main bearing cap torque 24.1 ± 1 kg.m

Main bearing diameter ø 80 mm

5) Crankshaft run-out

• Mount the crankshaft on a set of V-

blocks.

• Set the dial gauge to the center

of the crankshaft journal.

• Gently rotate the crankshaft in the

normal direction of engine rotation.
Read the dial indicator (TIR) as you
turn the crankshaft.
The crankshaft must be replaced if EJM2095S
the measured value exceeds the
specified limit.

Standard Limit
Crankshaft run-out 0.05 mm 0.40 mm

If the repaired crankshaft generated a

crack, replace it.

- 73 -
6) Main bearing and con-rod bearing tension

• Check to see if the bearing has

enough tension, and set bearing into
its regular position with the finger
pressure.

EJM2091S

7) Crankshaft regrinding

• Pay close attention to the following

steps in order to ensure the reground-
crankshaft reliability.

Undersize bearing
0.25 mm 0.50 mm
Availability

< Crankshaft regrinding procedure >

(1) Grind the crankshaft journal part and
pin part.

Less them 3.8

(2) Fillet the crankshaft journal and
crank pin radius to a minimum of
R 3.5 ± 0.2.
There must be no stepping around
the fillet area.
(3) Finish the crankshaft journal, crank
R Part
pin and oil hole corners to a smooth EJM2096S
surface having a chamfer radius of
1 mm.

Crankshaft journal
0.4 μor less
and crank pin roughness

(4) Measure the clearance between

crankshaft journal and crank pin.
(5) Measure the crankshaft run-out.

- 74 -
8) Crankshaft grinding limit

Classification Limit
Crank journal outside
ø 79.419 mm
Diameter

Crank pin outside

ø 63.424 mm
Diameter

Undersize bearings ( 0.25 and 0.5 mm )

are available to compensate for
excessive clearance between the
crankshaft journal bearing and the
crankshaft. Regrinding of the crankshaft
to fit the undersize bearings is required.

Standard Limit
Main bearing 0.039
0.11 mm
clearance ~ 0.098 mm

Standard Limit
Connecting rod 0.03
0.10 mm
bearing ~ 0.073 mm

9) Crankshaft gear replacement

• Visually inspect the crankshaft gear.

Remover
• Replace the crankshaft gear as
following steps if excessive wear or
damage is discovered.

(1) Disassemble the crankshaft gear by

using the crankshaft remover.

EJM2097S

(2) Replace new part.

(3) Use the crankshaft gear installer to
install the crankshaft gear.

Installer
EJM2098S

- 75 -
3.3.16. Flywheel and flywheel housing

1) Ring gear inspection

• Inspect the ring gear.

• If the ring gear teeth are broken or
excessively worn the ring gear must
be replaced.

2) Ring gear replacement

• Strike around the edges of the ring

gear with a hammer and chisel to
remove it. EJM2099S

3) Ring gear installation

• Heat the ring gear evenly with a gas

burner to invite thermal expansion.
Pay attention that temperature of ring
gear is not exceeded 200 °C.

• Use a hammer to install the ring gear

when it is sufficiently heated.

EJM2100S

4) Oil seal replacement ( rear )

• Use a pry bar to remove the flywheel

housing oil seal.
Installer

• Assemble the oil seal to flywheel

housing by using the oil seal
assemble jig.

EJM2101S

5) Oil seal replacement ( front )

• Use an adapter and a hammer to

remove the crankshaft front end oil
Installer
seal.

• Assemble the oil seal to flywheel

housing by using the oil seal
assemble jig.

EJM2102S

- 76 -
3.4. Engine Reassembly

3.4.1. Piston and connecting rod assembly

1 4
3
2B

2A

EJM2103I

1. Piston 4. Piston ring

2. Piston Pin and connecting rod 5. Connecting rod bearing
3. Snap ring 6. Connecting rod bolt

- 77 -
1) Piston

• Use a piston heater to heat piston to

approximately 60 °C.
Heater of piston

EJM2104S

2A) Connecting rod

• Install the piston and connecting rod

with setting the marks as illustrated. Piston
• Assemble the piston pin into the
Front mark
piston and connecting rod bushing.

Put cylinder number

marked side in this
piston

EJM2105S

3) Snap ring

• Assemble the snap rings by using

snap ring flyer.

• Check that the piston moves

smoothly on the piston pin.

EJM2031S

4) Piston ring

• Assemble the piston ring by using

piston ring assembly jig.
Top Ring
• Systematically assemble piston rings
as follows: 2st Ring

(1) Oil ring

(2) 2nd compression ring
Oil Ring
(3) 1st compression ring

EJM2106I

- 78 -
 Rightly assemble the 1st and 2nd
compression rings that the marked
side must be facing “up”.
Oil ring may be assembled any way
because it is not indicated.

• Lubricate the surface of piston ring

with engine oil.

• Check it whether piston rings are

smoothly rotating in the piston ring
grooves.

5) Connecting rod bearing

• Assemble the connecting rod bearing

to the big end and the cap.

• Lubricate the bearing with engine oil.

• Assemble the connecting rod and

connecting rod bearing, and tighten
cap bolt as the specified torque.

- 79 -
3.4.2. Cylinder head assembly parts

Repair kit
EJM2107S

1. Valve stem oil seal 7. Thermostat housing and gasket

2. Intake and exhaust valve 8. Thermostat
3. Spring seat (lower) 9. Cooling water outlet
4. Intake and exhaust valve spring 10. Intake manifold and gasket
5. Spring seat (upper) 11. Exhaust manifold and gasket
6. Valve cotter

1) Valve stem oil seal

• Lubricate the oil seals and valve stem Installer

sealing area with engine oil.

• Assemble the valve stem oil seal by

using oil seal installer.

EJM2109S

- 80 -
2) Intake arid exhaust valves

• Place the cylinder head on a flat

wooden surface.
Valve stem
• Lubricate valve stem with the engine
oil.

• Assemble the valves to the intake or

exhaust valve guides.
Assemble the valves to their original
lapped valve seats.

EJM2110S

4) Intake and exhaust valve springs

• Assemble the valve spring with their

painted end facing top. Painted part

EJM2111I
5) Spring seat
6) Valve cotter

• Use a spring compressor to push the

valve spring into position.

• Install the spring seat split collar.

Compressed spring
EJM2112S

• Set the spring seat split collar by

tapping lightly around the head of the
collar with a rubber hammer.

EJM2113S

- 81 -
10) Intake manifold and gasket

• Assembly the intake manifold gasket. Rear of unchamfered corner

The intake manifold gasket must be
installed with its unchamfered corner
facing “up” and to the front of the
engine.

Rear

EJM2114S

• Assemble the intake manifold.

• Tighten the intake manifold bolts to
the specified torque a little at a time in
the numerical order. ( see figure )

Intake manifold bolt 2.6 ± 0.5 kg.m

torque

EJM2115S

11) Exhaust manifold and gasket

• Install the exhaust manifold gasket.

• The “TOP” mark must be facing up.

TOP

EJM2116I

• Install the exhaust manifold

• Tighten the exhaust manifold bolts to
the specified torque a little at a time in
the numerical order. ( see figure )

Exhaust manifold bolt 2.9 ± 0.5 kg.m

torque

EJM2117S

- 82 -
3.4.3. Rocker arm and shaft assembly

EJM2119S

1. Rocker arm shaft 3. Rocker arm

2. Spring 4. Bracket

Import Operation

1) Rocker arm shaft

• The rocker arm shaft must be installed with the oil holes facing up.

- 83 -
3.4.4. Main components

EJM2120S Repair kit

1. Oil spray nozzle ( PU066 only ) 9. Idler gear shaft

2. Crankshaft bearing ( lower ) 10. Idler gear
3. Crank shaft 11. Piston and connection rod
4. Thrust washer 12. Oil pump and coupling
5. Crank shaft bearing ( upper ) and cap 13. Flywheel housing
6. Timing gear case 14. Oil pan
7. Tappet 15. Oil cooler
8. Camshaft

* The tappet must be installed before the camshaft installation.

- 84 -
2) Crankshaft bearing (lower)

• There is no oil hole and oil groove on

the lower bearing. But opposite upper Oil hole and groove
Rightly set up
bearing has oil hole and oil groove. (upper part)

No oil hole and groove

(Lower part)
EJM2122S

3) Crankshaft

• Assemble the crankshaft gear in front

side.

Caution
Make sure the part number of
crankshaft because its counterweight
size may be different depending upon
engines. Front

EJM2123S

4) Thrust washer

• Assemble thrust washer with the oil

groove side facing the crankshaft
sliding face.

Oil groove
EJM2124S

5) Crankshaft bearing cap

• Lubricate the bearing cap bolts with

engine oil.
Arrow
• Assemble the bearing caps to the
crankshaft.
The arrow mark must be pointing to
the front of the engine.
Front

EJM2125S

- 85 -
 • Tighten the bearing cap bolts to the
specified torque a little at a time in
the numerical order. ( see figure )

Crankshaft bearing
24.0 ± 1 kg.m
cap bolt torque

• Check that the crankshaft turns

Spread engine oil
smoothly by manually rotating it.
EJM2126S

6) Timing gear case

• Tighten timing gear case bolt to the

specified torque.

Timing gear case 2.6 ± 0.5 kg.m

bolt torque

• Apply silicon to the indicated area.

(see figure)

EJM2127S

8) Camshaft

• Tighten thrust plate bolt through the

camshaft gear hole.

Thrust plate 2.6 ± 0.5 kg.m

bolt torque

Camshaft gear 16 ± 1.5 kg.m

bolt torque
Camshaft gear
EJM2128S

9) Idler gear shaft

• Assemble an idler gear shaft by using

the thrust collar fixing bolt as a guide. Oil hole

• The oil hole must be facing the

camshaft.

• Lubricate the idle gear shaft with

engine oil.

EJM2129S

- 86 -
10) Idler gear

• Assemble the idle gear.

Set the timing marks “A”, “B”, and “C” Injection pump gear Mark "B"
Idle gear
as shown in the figure.

• Tighten the idle gear bolts seating the

thrust collar to the specified torque.
The thrust collar must be installed
with the chamfered side facing the Mark "C" Camshaft
front of the engine. Mark "A" gear
Camshaft gear
Idle gear bolt torque 5.5 ± 1 kg.m EJM2130S

11) Piston and connecting rod

• Set the piston ring gaps as shown in 2nd Ring compression ring
the figure.

• Lubricate the piston, the piston ring

and the connecting rod bearings with
engine oil. Oil ring Top ring

• Position the piston front mark towards 60° 60°

EJM2131S
the front of the engine.

• Use the piston ring compressor to

Piston ring compressor
compress the piston rings.
Hammer grip
• Push the piston in until it makes
contact with the crank pin by using a Front
mark
hammer grip.
At the same time, rotate the
crankshaft until the crank pin reaches EJM2132S
its highest point.

• Set the bearing cap cylinder number

marks and the connecting rod
cylinder number marks.

• Lubricate the connecting rod cap bolt Cylinder

threads and setting face with MoS2 number
grease.

• Tighten the connecting rod cap bolts EJM2133S

to the specified torque.
Refer to the following table.

Torque 12 ± 0.25 kg.m 9.75 ± 0.25 kg.m

Bolt head 11 12

EJM2134S

- 87 -
12) Oil pump assembled

• Lubricate the oil pump with the

specified engine oil.
Coupling
• Install the oil pump with the coupling.
• Tighten the oil pump bolts to the
specified torque.

Oil pump bolt torque 5.3 ± 1.0 kg.m

EJM2135S

13) Flywheel housing

• Apply silicon to the shaded area. (see

figure)

• Install the flywheel housing.

Tighten the flywheel housing bolts to
the specified torque.

Outer bolt 16.1 ± 1 kg.m

Silicon
Inner bolt 2.6 ± 0.5 kg.m (for face of cylinder
body only)
EJM2136S

14) Oil pan

• Apply liquid gasket to the area

indicated by the arrows in the figure.

• Install the gasket and oil pan.

• Tighten the oil pan bolts to the
specified torque.

Oil pan bolt torque 2.6 ± 0.5 kg.m

EJM2137S

15) Oil cooler

• Assemble the oil cooler with gasket

after applying sealant to the oil cooler
gasket.

• Tighten the oil cooler bolts to the

specified torque. in the numerical
order (see figure).

Oil cooler torque 2.6 ± 0.5 kg.m

EJM2138S

- 88 -
3.4.5. Major component assembly

EJM2139S Repair kit

1. Flywheel 9. Oil pump driving pinion

2. Crankshaft pulley nut 10. Push rod
3. Tappet chamber cover 11. Taper bushing
4. Water pump 12. Crankshaft pulley and dust cover
5. Cylinder head gasket 13. Timing gear cover
6. Cylinder head bolt 14. Oil thrower
7. Cylinder head 15. Rubber hose
8. Rocker arm shaft assembly

- 89 -
1) Flywheel

• Lubricate the flywheel bolt with

engine oil.

• Install the flywheel.

Tighten the flywheel bolts to the
specified torque in the numerical
order. (see figure)

Flywheel bolt torque 20 ± 1.5 kg.m Lubricate with engine oil

EJM2142S

Injection pump

• Align the injection pump gear “C”

timing mark with the idler gear “C” Injection pump gear Mark "B"
Idle gear
timing mark.

Mark "C" Camshaft

Mark "A" gear
Camshaft gear
EJM2130S

• Tighten the injection pump bolts to the

specified torque.

Injection pump bolt torque 2.6 ± 0.5 kg.m

EJM1029S

2) Crankshaft pulley nut

• Tighten the crankshaft pulley nut to

the specified torque by using a Crankshaft pulley
wrench.

Crankshaft pulley nut torque 60 ± 5 kg.m

Wrench

EJM2144S

- 90 -
3) Tappet chamber cover

• Apply silicon to the tappet chamber

cover gasket.

• Assemble the tappet chamber cover

and tighten the bolts to the specified
torque.

Tappet Chamber
2.6 ± 0.5 kg.m
Cover Bolt Torque

EJM2145S

4) Water pump

• Apply silicon to the pump gasket

before installing the water pump. Apply silicon

EJM2146S

5) Cylinder head gasket

• The gasket “TOP” mark should be

faced up and “FRONT” mark is Front, Mark TOP
towards the front of the engine.

Water Pump

Front

EJM2147S
6) Cylinder head bolts
7) Cylinder head

• Carefully place the cylinder head on

the cylinder block.

• Tighten the cylinder head bolts to the

specified steps and torque in the
numerical order as figure and Front
following table.

EJM2148S

- 91 -
 Bolt type Torque

hexagonal bolt 1st step : 7.0 kg.m

2nd step : 11.5 + 0.5 kg.m

1st step : 4.0 kg.m

dodecagonal bolt 2nd step : 90 °
3rd step : 90 ° (-10 °)

< 12-gonal bolt limited value >

Standard (mm) Limit (mm)

115 116.2
102 103.2

• Apply engine oil to the cylinder head

bolts threads and setting faces.

8) Rocker arm shaft assembly

• Tighten the rocker arm bolts to the

specified torque a little at a time in the
numerical order. (see figure)

Rocker arm shaft

3.1 ± 0.5 kg.m
bracker bolt torque

• Lubricate the rocker arm and the

rocker arm shaft with engine oil. EJM2149S

• Adjust valve clearance.

- 92 -
3.4.6. External parts

3 4 7 29 4 30
11 12
23 10
5 9

14 1 15 17 18
26 27
13

19 20 21 22 2 24 25

EDM1014I

1. Cylinder head cover 11. Water outlet 22. Oil pan

2. Starter 12. Oil filler cap 23. Lifting hook
3. Injection nozzle 13. Cooling fan 24. Fly wheel
4. Injection pipe 14. Alternator 25. Flywheel housing
5. Oil filter 15. Oil level gauge 26. Exhaust manifold
6. Fuel pipe 17. Guide tube 27. Breather hose
7. Intake pipe 18. Push rod chamber cover 28. Oil cooler
8. Injection pump 19. Crank shaft pulley 29. Intake manifold
9. Cooling water pump 20. Mounting bracket 30. Fuel filter
10. Thermostat 21. Drain valve

- 93 -
1) Cylinder head cover

• Tighten the cylinder head cover bolts

to the specified torque a little at a time 4
in the sequence. (see figure) 2
1
Cylinder head cover
3.0 ± 0.5 kg.m 3
bolt torque

Fan belt

• Adjust the fan belt tension. EJM2154S

2) Starter

• Tighten the starter bolts to the

specified torque after install the
starter to the flywheel housing.

Starter fixing
8.4 kg.m
bolt torque

EJM2155S

3) Injection nozzle

• Install the injection nozzle with the

injection nozzle gaskets.
o-ring

Injection nozzle
1.9 ± 0.2 kg.m
bolt torque

• Be careful not to damage the nozzle

tips. Seal ring
EJM2163S

4) Fuel injection pipe

• Install the fuel injection pipes 1 and

tighten the bolts to the specified
torque.

Injection pipe torque 3.0 ± 0.2 kg.m

EJM2164S

- 94 -
 • Carefully position and set the clips 2 .

It is very important that each clip be

positioned correctly.
An improperly positioned clip will
result in objectionable fuel pulsing
noise and injection pipe breakage.

• Install the fuel leak off pipes 3 .

5) Oil filter

• Install the oil filter assembly with

tightening the bolts securely.

Oil filter assembly

4.3 ~6.3 kg.m
mounting bolt torque

EJM2175I

6) Fuel pipe

• Install the fuel pipe and tighten the

fuel pipe joint bolts to the specified
torque.
Take care not to interchange the
check valves and joint bolts.

Fuel pipe joint

1.7 ± 0.1 kg.m
bolt torque

EJM2166S

7) Intake pipe

• Install the intake pipe and tighten the

intake pipe flange bolts to the
specified torque.

Intake pipe flange

2.6 ± 0.5 kg.m
bolt torque

EJM2167S

- 95 -
4. Maintenance of Major Components

4.1. Lubrication system

4.1.1. General information

OPENNING PRESSURE
4.0 - 4.8 kg/cm2

RELIEF VALVE CYLINDER BLOCK MAIN GALLERY

INJECTION PUMP

BY-PASS VALVE
OIL COOLER CAM SHAFT BEARING CRANK JOURNAL
2.0 kg/cm2

IDLE GEAR SHAFT ROCKER ARM SHAFT

BY-PASS VALVE
1.0 kg/cm2 OIL FILTER

VALVE ROCKER ARM CRANK PIN PISTON

RELIEF VALVE
7.0 kg/cm2
OIL PUMP
IDLE GEAR FACE TAPPET VALVE

OIL STRAINER

OIL PAN

EA4M3001

- 96 -
4.1.2. Oil pump

1) Disassembly

3
6

EA4M3002

< Disassembly Steps >

1. Strainer 4. Drive shaft and gear

2. Suction Pipe 5. Pinion Gear
3. Cover and dowel 6. Pinion gear shaft

- 97 -
2) Inspection

• Visually inspect the disassembled

parts for the excessive wear and
damage.

• Correct or replace the parts if the

wear or damage is discovered during
inspection.

EJM3003S

(1) Oil Pump Drive Gear

• Use a feeler gauge to measure the

clearance between the oil pump
cover (oil pump case) inside
surface and the drive gear.

• If the clearance exceeds the

specified limit, the drive gear and/or
the oil pump cover must be
replaced.

EJM3004S
Limit
0il pump cover and
0.12 mm
drive gear clearance

(2) Oil pump pinion gear

• Use a feeler gauge to measure the

clearance between the oil pump
case cover inside surface and the
pinion gear.

• If the clearance exceeds the

specified limit, the pinion gear
and/or the oil pump cover must be
replaced.

EJM3005S
Limit
0il pump cover and
0.12 mm
pinion gear clearance

3) Oil pump reassembly

• To assemble, follow the disassembly

procedures in reverse order.

- 98 -
4.1.3. Oil cooler

1) Disassembly

6
5
4

EJM3008S

< Disassembly Steps >

1. Oil cooler element 4. O - ring

2. Gasket 5. By - pass valve spring
3. By -pass plug 6. By - pass valve

2) Inspection

• Correct or replace the part if the wear or damage is discovered during inspection.

- 99 -
 (1) Oil cooler element

• Install the oil cooler element to the

oil cooler, then tighten the oil cooler
element fixing bolts to the specified
torque.

Oil cooler element

2.6 ± 0.5 kg.m
fixing bolts torque

EJM3010S
3) Oil cooler reassembly

• To assemble, follow the disassembly

procedures in reverse order.

4.2. Cooling system

4.2.1. General information

Water pipe
Thermostat

R
Cylinder head
a
d
i
a
t
Reserve tank o
r
Cylinder block

Water pump

EJM4001I

- 100 -
4.2.2. Water pump

1) Disassembly

3 2
6 4

8
7
1

EJM4003S

< Disassembly Steps >

1. Pulley 5. Unit bearing

2. Cover 6. Mechanical seal
3. Gasket 7. Hub
4. Impeller 8. Snap ring

Import Operation

(4) Impeller

• Remove the impeller by using the Remover

jig.

EJM4005S

- 101 -
(5) Unit bearing

• Remove the unit bearing by using a

bench press and a suitable
remover.

EJM4008I

(6) Mechanical seal

• Remove the mechanical seal by

using a suitable remover.

EJM4009S

(7) Hub

• Remove the hub by using a bench

press and a suitable rod.
Bench press

Hub

EJM4006S

(8) Snap ring

• Remove the snap ring by using a

pair of the snap ring plier.

EJM4007S

- 102 -
2) Inspection
(1) Unit bearing

• Correct or replace the part if the

wear, defect or other damage is
discovered during inspection.

3) Water pump reassembly

EJM4011I
Import Operation

(1) Unit bearing

• Lubricate the bearing with Spreading of multipurposable grease

multipurpose grease.

• Use a bench press to assemble the

unit bearing at the pump.

Outside from sealed surface

EJM4011S

(2) Snap Ring

• Use a pair of snap ring plier to

install the snap ring.

EJM4007S

(3) Hub

• Use a bench press and a bar to

install the hub.

EJM4015S

- 103 -
(4) Mechanical seal

• Apply sealant to the seal unit outer

periphery before installation.

Spreading of
sealant

EJM4016S

• Use a bench press and a bar to

install the seal unit into the pump
body.

EJM4017S

(5) Impeller

• Use a bench press to install the

impeller to the shaft.
Bench press
• Use a feeler gauge to measure the
clearance between the impeller and
the pump body.

Clearance between
0.3 ~ 0.8 kg.m
impeller and pump body
Feeler gauge
EJM4018S

(6) Pulley

• Install the pulley and tighten the

pulley bolts to the specified torque.

Pulley fixing Fan flange

2.6 ± 0.5 kg.m
bolts torque

Pulley

Cooling fan

EDM4001I

- 104 -
4.2.3. Thermostat

• Correct or replace thermostat if the

Thermometer
wear, defect or other damage is
discovered during inspection. Ruler

Model DB58 PU066

Valve Temperature Lift Temperature Lift

Wood piece
Close 82 °C opening 71 °C opening
Standard 95 °C 10 mm 90 °C 10 mm EFM2055I

Maximum 110°C less 16 mm 90 °C less 10 mm

4.3. Fuel system

4.3.1. General information

Injection Nozzle

Fuel filter

Feed pump

Water sedimentor Injection pump

Fuel tank

EJM5001S

• The fuel system consists of the fuel tank, water sedimentor, the fuel filter, the injection pump
and the injection nozzle.

• The fuel from the fuel tank passes through the water sedimentor, and the fuel filter, where
particles and other foreign material are removed from the fuel.

• Fuel, fed by the injection pump plunger, is delivered to the injection nozzle in the measured
volume at the optimum timing for efficient engine operation.

- 105 -
4.3.2. Fuel filter

1) Disassembly ( DB58 )

3 4

7 6
7

Element kit EJM5003S

< Disassembly Steps >

1. Drain plug 5. Fuel filter element

2. Center bolt 6. Spring seat
3. Fuel filter body 7. Spring
4. Body cover gasket

2) Inspection

• Make the necessary adjustments, repairs and part replacements if excessive wear or
damage is discovered during inspection.

3) Fuel filter reassembly

•To reassemble the fuel filter, follow the disassembly procedure in the reverse order.

- 106 -
4.3.3. Injection Nozzle

1) Disassembly

1 11

10

9
2
3 4 8

EJM5008S

< Disassembly Steps >

1. Nozzle holder body 7. Push rod spring

2. Seal ring 8. Spring seat
3. Injection pipe connector 9. Nozzle adjusting screw
4. Injection nozzle 10. Cap nut gasket
5. Retaining nut 11. Nozzle holder cap nut
6. Nozzle holder push rod

Import Operation

4) Injection Nozzle
Remove the nozzle assembly from the nozzle body. Keep the parts separately to maintain
the proper needle valve to body combination.

2) Inspection
Make the necessary adjustments, repairs and parts replacements if excessive wear or
damage is discovered during inspection.

- 107 -
(1) Push rod spring

• Check the push rod spring for wear,

weakness and corrosion.

EJM5005S

(2) Nozzle holder push rod

• Check the nozzle holder push rod

curvature.

• Check the nozzle holder push rod

and needle valve contact surface
for excessive wear and poor
contact.

EJM5006S

(3) Injection nozzle

• Check the injection nozzle needle

valve, the valve seat, and the
injection nozzle hole for carbon
deposits.
If carbon deposits are present, the
injection nozzle and the needle
valve must be replaced.

• Hold the nozzle body vertically.

Pull the needle valve about one-
EJM5007S
third of the way out of the nozzle
body.
Release the needle valve.
Check that the needle valve falls
back into the nozzle body as far as
the valve seat.
If the needle does not fall back into
the nozzle body as far as the valve
seat, the injection nozzle and the
needle valve must be replaced.

- 108 -
3) Reassembly
(1) Injection pipe connector

Injection pipe
5.5 ± 0.5 kg.m
connector torque

EJM5009S

(2) Injection nozzle

• There must be no oil on the contact

surface of the injection nozzle and
the injection nozzle holder.
Clean these contact surface with
diesel fuel before installation.

• The nozzle dowel pin must be

aligned with the dowel hole in the
nozzle holder body.

EJM5010S

(3) Retaining nut

• Clamp the injection nozzle in a vise.

• Tighten the retaining nut to the
specified torque by using a wrench.

Nozzle retaining
7 ± 1 kg.m
nut torque

EJM5011S

(4) Nozzle holder cap nut

• Clamp the injection nozzle in a vise.

• Tighten the nozzle holder cap nut to
the specified torque by using a
wrench.

Nozzle holder cap

4.5 ± 0.5 kg.m
nut torque

EJM5013S

- 109 -
(5) Nozzle adjusting screw
( injection starting pressure check )

• Attach the injection nozzle holder to

the injection nozzle tester.

EA0M3003

• Loosen the adjustment screw 1 .

• Check the injection nozzle starting

pressure and the spray condition by
operating the injection tester.
EJM5024S
< spray condition check >
Operate the injection nozzle tester
hand lever 4 to 6 times while
looking for abnormal injection
nozzle spray conditions. Correct Incorrect Incorrect

( See figure )
(1) Correct (Good)
(2) Incorrect (Bad - orifice)
(3) Incorrect (Bad - dripping)

• Adjust the injection nozzle starting

pressure.
Turn the adjusting screw clockwise
while operating the injection nozzle
tester handle.

DB58 PU066
Adjusting pressure ( setting ) 225 ~ 230 kg/cm2 225 ~ 230 kg/cm2
Injection nozzle starting pressure 220 kg/cm2 220 kg/cm2

Caution
Keep away your skin from the tester
because pressure of nozzle tester is
very high when inject.

- 110 -
4.3.4. Injection pump calibration

1) DB58 engine
(1) Injection pump assembly : 65.11101 - 7266A ( 101605 - 9950 ZEXEL )
- Injection pump : NP- PES6A95C410RS2000 ( 101061 - 8410 )
- Governor : NP-EP/ RSV200-1200AQ36A311 (105419 - 3720 )
- Plunger and barrel : 131153 - 3220
- Delivery valve : 131110 - 6220
- Feed pump : KP-FP/ KS-A (105220 - 4561 )
- Prestroke : 3.6 ± 0.05 mm
(2) Nozzle holder assembly : 65.10101 - 7295 ( 105160 - 465A DPICO )
(3) Nozzle : 65.10102 - 6044 ( 105025 -138A DPICO )
(4) Injection pipe : 65.10301 - 6144
(5) Injection order :1-5-3-6-2-4
(6) Injection timing : BTDC 20˚ ± 1˚

Nozzle & Holder Ass’y 105760-6140 Opening pressure : 175 kg/cm2

(A) Test condition
Injection pipe( IDxODxL ) - ø 2.0 x ø 6.0 - 650 mm
for injection pump
Test oil ISO4113 Temperature :40 ± 5˚C
65.10102-6044 Nozzle (5 x ø 0.27)
Nozzle & holder Ass’y
(B) Engine standard parts 65.10101-7295 220 kg/cm2
Injection pipe ( IDxODxL ) 65.10301-6144 ø 1.6 x ø 6.0 x 580 mm
Rack diagram and setting valve at each point
Pump Injection Q`ty on RIG(mm / 1,000st)
3
Rack
Check position Speed Press.
Standby power (A) Test condition
Point (mm) (rpm) Remarks (mmHg)
for inj. Pump
A 8.8 900 57.3 52.1 ± 2 -
B 9.2 875 59.5 (59.9) -
C 7.3 350 11.5 7.3 -
D 5.6 950 - 8.3 -
E 14.0 100 100 - -
Boost pressure : zero boost
Governor weight Weight = 740 g Lever ratio(min/max) 1 : 1.2
Governor spring k = 6.08 kg/mm Plunger ø 9.5 left hand 20 lead
Idle spring k = 2.2 kg/mm Delivery valve retraction volume 35 mm3/st, t=0.1
Start spring k = 0.014 kg/mm Delivery valve opening pressure 24.5 kg/cm2
Feed pump 105210-4561 Delivery valve spring k = 1.63 kg/mm

- 111 -
(7) Rack diagram

E
14

9.2 B A
Rock Position (mm)

8.8

7.3 C

5.6 D

100 350 875 900 950

Injection pump speed (rpm)

EJM5022I

- 112 -
 2) PU066 engine
(1) Injection pump assembly : 65.11101 - 7321 ( 101605 - 9630 ZEXEL )
- Injection pump : NP- PES6A95C410RS2000 ( 101062 - 8120 )
- Governor : NP-EP/ RSV200-1450AQ43A311 (105419 - 1340 )
- Plunger and barrel : 131153 - 3220
- Delivery valve : 131110 - 6220
- Feed pump : KP-FP/ KS-A (105220 - 4561 )
- Prestroke : 3.6 ± 0.05 mm
(2) Nozzle holder assembly : 65.10101 - 7295 ( 105160 - 465A DPICO )
(3) Nozzle : 65.10102 - 6044 ( 105025 -138A DPICO )
(4) Injection pipe : 65.10301 - 6144
(5) Injection order :1-5-3-6-2-4
(6) Injection timing : BTDC 20˚ ± 1˚

Nozzle & Holder Ass’y 105760-6140 Opening pressure : 175 kg/cm2

(A) Test condition
Injection pipe( IDxODxL ) - ø 2.0 x ø 6.0 - 650 mm
for injection pump
Test oil ISO4113 Temperature :40 ± 5˚C
65.10102-6044 Nozzle (5 x ø 0.27)
Nozzle & holder Ass’y
(B) Engine standard parts 65.10101-7295 220 kg/cm2
Injection pipe ( IDxODxL ) 65.10301-6144 ø 1.6 x ø 6.0 x 580 mm
Rack diagram and setting valve at each point
Pump Injection Q`ty on RIG(mm / 1,000st)
3
Rack
Check position Speed Press.
(A) Test condition
Point (mm) (rpm) Remarks (mmHg)
for inj. Pump
A 8.67 1400 54 ± 4 - -
B 6.5 400 6.9 ± 14 - -
C 8.84 900 55.3 ± 2 - -
D 9 500 41.6 - -
E - 100 104 - -
F 5.5 1540 10
Boost pressure : zero boost
Governor weight Weight = 740 g Lever ratio(min/max) 1 : 1.2, 1 : 1.2
Governor spring k = 12 kg/mm Plunger ø 9.5 left hand 20 lead
Idle spring k = 1.9 kg/mm Delivery valve retraction volume 43 mm3/st, t=0.09 mm
Start spring k = 0.0051 kg/mm Delivery valve opening pressure 25.9 kg/cm2
Adapter spring k = 11 kg/mm
Feed pump 105210-4561

- 113 -
(7) Rack diagram

14

12

10
D C A
Rock Position (mm)

8
B
6
F

0
0 100 400 500 900 1400 1540

Injection pump speed (rpm)

EDM5001I

- 114 -
3) Injection pump

EJM5018S

1. Pump housing 56. Shim 117a. Connection bolt

2. Cover assembly 61. Plunger spring 118a. Gasket
3. Bolt, cover 62. Seat, spring(upper) 121. Plug screw
4. O-ring 63. Seat, spring(lower) 122. Gasket
5. Gasket 67. Control rack 130. Connect
16. Screw, plug 68. Stop bolt 130a. Adapter
18. Bolt, stud 76. Pinion 131a. Bolt
20. Spring washer 77. Sleeve 132a. Gasket
21. Nut 78. Bolt 133a. Gasket
23. O-ring 90. Camshaft 145. Plug screw
30. Plunger 91.91a. Taper roller bearing 146. Gasket
36. Delivery valve 92.92a Camshaft ring 152. Connection bolt
37. Delivery valve spring 93.93a. Shim 154. Packing
40. Delivery valve holder 95. Center bearing 191. Bracket
45. Lock plate assembly 101a. Bearing cover 192. O-ring
49. O-ring 104a. Bolt 194. Washer
55. Tappet 112a. Woodruf key 195. Spring washer
115a. Adapter 196. Nut

- 115 -
4) Governor

EJM5018S

1. Governor housing 80. Cover 182. Lever shaft

4. Plate 82. Bolt 183. Collar
6. Adapter 83. Bolt 190. Control lever
7. Bolt 100.Fly wheel 192. Nut
9. Spring 101. Woodruf key 195. Return spring
10. Bolt 102. Spring washer 198. Spring washer
13. Nut 103. Nut 201. O-ring
19. Adapter 117. Sleeve 202. Bush
20. Bolt 118. Shim 203. Shim
21. Gasket 130. Governor spring 205. Shaft lever
35. Governor cover 132. Starting spring 207. Support lever
38. Tension lever bolt 136. Nut 211. Snap ring
39. Nut 137. Gasket 220. Damper spring
44. Stop bolt 138. Cap 236. Gasket
46. Cap 140. Idle spring 239. Gasket
47. Plug 141. Nut 240. Lead seal
48. Adjusting bolt 150. Speed setting lever 241. Wire, lead seal
49. Nut 170. Guide lever 255. Bracket
50. Stop bolt 173. Split pin 331. Angleich spring
51. Bolt 174. Floating lever link 332. Connection nut
52. Bolt 181. Tension lever

- 116 -
5. Engine electrical

5.1. Starting motor

5.1.1. Main data and specification

Part name Specification

Rated voltage 24 V
Rated output 4.5 kW
Rating 30 sec
Direction of rotation Clockwise (viewed from the pinion side)
Operation speed More than 3,500 rpm (No load)
More than 1,080 rpm (Load)

5.1.2. Construction

1 5 3
6
7 21 23
8 4
9 24
17 16 14 15
2

22

18 19 20 26

25 13 12 11 10
EDM5002I

1. Yoke assembly 10. Coil spring 19. Snap retainer

2. Bush holder assembly 11. Steel ball 20. Coil spring
3. End frame 12. Clutch assembly 21. Housing
4. Through bolt 13. Clutch shaft 22. Terminal cap
5. Armature assembly 14. Coil spring 23. Screw
6. snap retainer 15. Pinion starter 24. Cover
7. Idle gear 16.Pinion stop nut 25. Through bolt
8. Clutch roller 17. Snap ring 26. Magnet switch assembly
9. Retainer 18. Snap ring

- 117 -
5.2. Alternator

5.2.1. Main data and specification

Part name Specification

Type 3 Phase AC alternator (Built in regulator)

Rated voltage 24 V
Rated output 45 A
Max. allowable speed 5000 rpm
Polarity Negative (-)
Direction of rotation Clockwise (viewed from the pulley side)
Weight 6 kg

5.1.2. Construction

5
4
1

6 2
Wiring Diagram
3
7

TO BATTERY +
24

17 REGULATOR
16
P
RL = 150~250 OHM
13
8 15

19
12
20
21
22
11
10
9 23
18
14
12 EA8O3007

1. Hex nut 9. Pin 17. Screw

2. Pulley 10. Stud bolt 18. Regurator
3. Fan 11. Insulator 19. Brush set ass’y
4. Collar 12. Bolt 20. Brush holder
5. Bearing ass’y 13. Frame 21. Spring
6. Rotor ass’y 14. Bushing 22. Brush
7. Stator ass’y 15. Neddle bearing 23. Brush
8. Cover 16. Rectipier 24. Baffle

- 118 -
6. Special Tool List

No. Description Part No. Illustration

1 Compression gauge adapter EU.2-0529

2 Valve spring compressor EF.122-249

3 Crankshaft gear punch EF.122-265

4 Crankshaft pilot bearing remover EF.122-253

5 Pilot bearing punch EF.122-251

6 Crankshaft rear oil seal installer EF.122-262

7 Crankshaft front oil seal installer EF.122-255

8 Valve stem oil seal installer EF.122-289

- 119 -
No. Description Part No. Illustration

9 Piston sleeve E1.03901-0124

10 Cylinder liner remover EF.122-281

11 Cylinder liner installer EF.122-261

12 Pulley bush puncher EU.1-0022

13 Pulley bush puller EU.2-0328

14 Feeler gauge 60.99901-0027

15 Snap ring plier T7610001E

16 Piston ring plier T7621010E

- 120 -
Appendix

• Torque Specifications ( Standards Bolts )

The torque values given in the following table should be applied where a particular torque is not
specified.
( Unit : kg.m )

Bolt
identification

4 7 9
Bolt
4T 7T 9T
diameter x pitch
Low carbon steel High carbon steel Alloy steel

M6 x 1.0 0.6 ± 0.2 0.75 ± 0.2 -

M8 x 1.25 1.3 ± 0.5 1.75 ± 0.5 2.0 ± 0.7
M10 x 1.25 2.8 ± 0.7 3.75 ± 0.9 5.0 ± 1.3
M10 x 1.5 2.7 ± 0.7 3.7 ± 0.9 4.9 ± 1.2
M12 x 1.25 6.25 ± 1.2 7.75 ± 1.5 9.65 ± 1.9
M12 x 1.5 5.8 ± 1.2 7.2 ± 1.4 9.1 ± 1.8
M14 x 1.5 8.75 ± 1.9 11.85 ± 2.3 14.50 ± 2.9
M14 x 2.0 9.1 ± 1.8 11.2 ± 2.2 13.6 ± 2.2
M16 x 1.5 13.3 ± 2.7 17.30 ± 3.5 20.40 ± 4.1
M16 x 2.0 12.7 ± 2.5 16.5 ± 3.3 19.5 ± 3.9
M18 x 1.5 19.2 ± 3.8 24.9 ± 5.0 29.30 ± 5.9
M20 x 1.5 26.3 ± 5.3 34.40 ± 6.9 40.40 ± 8.1
M22 x 1.5 33.0 ± 8.3 46.25 ± 9.2 54.10 ± 10.8
M24 x 2.0 45.8 ± 9.2 58.20 ± 14.0 70.60 ± 14.1

The mark indicates that the bolts are used for female-threaded parts that are made of soft
materials such as casting, etc.

- 121 -