DX12 Tappet replacement

. Instruction

2019. 5
Engine BG.
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✓

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01. Oil drain & Remove cylinder head cover
02. Removal of Rocker arm, Caliper & Pushrod
03. Removal of Engine front items
04. Set cylinder #1 OT
05. Turn the engine to stand up
06. Removal of oil pan & gasket
07. Removal of TGCC (Timing Gear Case Cover)
08. Removal of idle gear
09. Removal of camshaft gear
10. Removal of camshaft & Tappet

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5
6
 2

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1

(1) Fan Flange ; bolt (1ea) -

(2) Alternator Machine side
(3) Idle pulley bracket + belt ; bolt (3ea) -
(4) Vibration Damper + plate ; bolt (12ea) -
(5) Fan Mounting ; bolt (4ea) -
(6) Alternator lower bracket bolt Machine side

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# 6 IN. DOWN # 6 EX. UP

‘OT’

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9
10
Crank gear

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Marking

Marking

[Removed idle gear]

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 Tappets

Tappets

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01. Assembly of new tappet
02. Assembly of camshaft, flange & camshaft gear
03. Assembly of idle gear
04. Assembly of TGCC
05. Assembly of Oil pan
06. Turn the engine on the pallet
07. Assembly of Front oil seal
08. Assembly of Vibration damper
09. Assembly of Engine front items
10. Assembly of pushrods and rocker arm
11. Set cylinder #1 OT
12. Valve clearance adjustment
13. Assemble Cylinder head cover & packing

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 Tappets

PART NUMBER DESCRIPTION QT'Y

150125-00056 TAPPET,VALVE 12

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 Camshaft gear
FLANGE

FLANGE bolt (2ea) 0.9 kg.m Camshaft gear bolt (4ea) 3.1 kg.m
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(C)

(B)

(A)

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 TGCC mounting bolt 11.2 kg.m
PART NUMBER DESCRIPTION QT'Y
400628-00038 GASKET, TGCC 1

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 Oil pan gasket

DESCRIPTON BRAND PART NUMBER DESCRIPTION QT'Y

Liquid gasket DOWCORNING DC-780 400604-00037 GASKET,OIL PAN 1

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OIL PAN BOLT 3.1 kg.m

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 HOLDER GUIDE

PART NUMBER DESCRIPTION

860104-06261 JIG;DX12 FRONT OIL SEAL JIG SET

PART NUMBER DESCRIPTION QT'Y

65.01510-0041 SEAL, OIL (FRONT) 1

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 Front Oil Seal

GUIDE

Front Oil Seal

HOLDER

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25
Plate

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 2

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1

(1) Fan Flange ; bolt (1ea) 20kg.m

(2) Alternator Machine side
(3) Idle pulley bracket + belt ; bolt (3ea) 6.2kg.m
(4) Vibration Damper + plate ; bolt (12ea) 22kg.m
(5) Fan Mounting ; bolt (4ea) 11.2kg.m
(6) Alternator lower bracket bolt Machine side

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Rocker Arm bolt (12ea) 6.2 kg.m

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# 6 IN. DOWN # 6 EX. UP

‘OT’

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 6 5 4 3 2 1
Valve Cylinder #
adjustment IN EX IN EX IN EX IN EX IN EX IN EX

Torque driver #1 TDC ● ● ● ● ● ●

360 o rotation ● ● ● ● ● ●

Valve Intake 0.4 mm

Clearance Exhaust 0.5 mm
Combination
wrench Adjust nut torque 4.4 kg.m

PART NUMBER DESCRIPTION

860104-02469 JIG;TORQUE DRIVER(WERA)

Feeler gage

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 31

Hose clamp, breather hose 0.6 kg.m

PART NUMBER DESCRIPTION QT'Y
PACKING, CYLINDER
400606-01394 1
HEAD COVER

Cylinder head cover bolt (20ea) 2.2 kg.m

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01. TEST BENCH & PROCEDURE

02. TEST RUN CHECK SHEET

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Air cleaner Battery set Muffler Fuel in/out Oil pressure gage IC direct to Intake Coolant tank

Blow-by

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■ General Information
Country Location Work Center

Machine Model DX520LCA Machine Serial CECEH- Test Date

Engine Suffix DX12-MBE07 Engine Serial Inspector

■ Test run result

CATEGORY ITEMS RESULT REFERENCE Remark
IDLE ______________ rpm 975 ~ 1025 rpm
Engine Speed HIGH ______________ rpm 2000 ~ 2100 rpm
SPEED STABILITY □ OK □ NG
AT IDLE ______________ bar > 1 bar
Oil Pressure
AT HIGH ______________ bar > 3 bar
From Valve Train □ Normal □ Harsh
Noise
From Other side □ Normal □ Harsh
SMOKE □ Normal □ Excessive
Emission
BLOW-BY □ Normal □ Excessive
FRONT OIL SEAL □ OK □ NG
OIL PAN □ OK □ NG
Leakage
HEAD COVER □ OK □ NG
Other side □ OK □ NG

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