M-52 Emergency Generator Set (Incl. Instruction Book)

FINISHED
PLAN
BOX NO : 11
M- 52
VENUS SKY
D KINGJIM
1. No.976GS ·
G FILE GS A4-S 6cm
Spec. No. : 61K DWT MBC
Date : 2015-08-13
SPECIFICATION
for Diesel Emergency Generator
ORA WING TYPE FOR FINAL

OUTPUT I 00 kW x 1800rpm
ENGINE MODEL DOOSAN IN FRA CORE AD I 36TI
ALTERN A TOR MODEL LEROY SOM ER M46.2 M3 C6/4
APPLICATION SHIP EMERG E CY GEN-SET
STARTING PRIMARY ELECTRIC BAITER Y
SECONDARY SPRING STARTER
CLASS NK
SHIPYARD NANTONG COSCO
KHI SHIP ENGINEERING CO., LTD
HULL NO. NE236
5 2017-05-17 Final Drawing ;u- ~

4 2016-03-30 Working Drawing ;u- -\~
3 2015-10-28 I nd Approval Comment ~ ~
2 2015-08-24 Same as NE I73 ' s Approval Drawing ~
-\~
l 2015-08-13 Approva l Drawing ~
~'"""'
REV. DATE DESCRIPTION CHECKED APPROVED
APPROVED BY S.K. Woo ~ GPC Co.,Ltd.

CHECKED BY S.H. Cheon .:n GPC Tel: +82 (0)55 343 9870
WRITTEN BY I.H. Yun ~ E-mail : gpc@korea.com
PC
Grmhae Korea
TEL 82-55-343-9870
E-MAIL gpc@korea.com
CONTE s
Title Code·/ DWG No.
1.General Specification GOO

1.1 General Terms GOO 01 A
1.2 Recommended Fuel Oil Specification GOO 06 0
1.3 Recommended Lube Oil Specification GOO 10 D
1.4 Recommended Coolant Specification GOO 20 D
2.Gen-Set Specification G10

2.1 Principal Particular G1001 D
2.2 Installation Diagram G10 13 12
2.3 Overhaul Height G10 15 D
2.4 Scope of Supply G10 25 D
3.Engine Specification & Drawings D10

3.1 Engine Main Specification AD136TI
3.2 Cooling Water System Diagram 010 10 D
3.3 Coolant Heater System Diagram 010 20 D
3.4 Fuel Oil System Diagram D10 30 D
3.5 Lube Oil System Diagram 010 40 D
3.6 Fuel & L.O Hoses, Adapter Diagram 010 50 D
3.7 Spring Starter D10 65 D
3.8 Expansion Joint D10 86 D
3.9 Spark Arrester Type Silencer D10 90 D
3.10 Radiator Duct D20 40 D
4.Aiternator Specification & Drawings. A10

4 .1 Principal Particular A10 01 L
4 .2 Alternator Constants A10 11 L
4 .3 Out-Line LSA 461 8 002
4.4 Terminals Connections 2679.AB0297D
4 .5 Wiring And A.V.R Connections 3188 .AC0710A
4.6 Space Heater 2455 .0994A
4 .7 Rheostat, Voltage A 10 52 L
4.8 Cable Connection Diagram A 10 60 A
5.Eiectric System Drawings. E10

5.1 Auto Control Panel E02 63 D
5.2 Alarm & Trip Table E03 10 OS
5.3 Battery Charger E20 40 D
5.4 Battery Switch Box E20 50 D
5.5 Battery Box E10 10 A
5.6 Battery E10 20 A
5.7 Junction Box & Connection E10 80 D
6.Tool & Spare part

,. P10
6 .1 Standard Service Tool P10 01 D
6.2 Spare parts
Diesel Engine P10 10 D
Alternator 'i P10 20 L
Auto Control Panel & Battery.Chargr&ll P10 31 D
1/1
c
Gimhae Korea
1. General Specifica ion
1/1
PC
Gimhae Korea
General Terms
t. Rules and Regulatf
·The Diesel Gen set shaH rompl~ with the requirements of the following rules & regulations of the
ratest issue.
· lihe other items whi:cll am not. oovered in this specimatfen·s are to be manutacttJredi in accor-dafilce
with the maker's option.
2:. nstallation
·B'ulth Diesel Engine al'ild AC Alte;,nafor shall be cou pled direcUy wtth dry disc couplin9 and are flexibly
il'tstalled on a com mon bed whi<l.il is. m ade of prefabricate€! I welded steel structure.
·lihe diesel Gen set is to ~ r-ig,i.dfy. in-stalled on the vesseVs structure of floor fo undation.
3L language and Utrtlt.

·Nam e plates, gauges, documents. alild drawings are to be written in English.
·.A/IIll)nits are to be in S1 unit system as far as practicabfe.
4, Painting
·1' , diesel Generator set siitallt!le~ pa!nte d with th e color of-followings
at"M!UN SELL No. : 7 .5 li3G 11fl!
o ertler
1/1
GPC
Gimhae Korea
CODE
GOO 06 0
Recommended Fuel Oil Specification

1. ISO 8217
Designation ISO-F
Test
Characteristic Limit DMX DMA DMZ
method
1)
• • 0
Density at 15°C kg /m' ISO 3675 max. 2) 890.0 890
3) min. 1.40 2.00 3.00

Kinematic viscosity at 40°C eSt ISO 3104
max. 5.50 6.00 6.00
Flash point, oc ISO 2719 min. 43 60 60
Pour point (upper), oc d)
Winter quality ISO 3016 max. - -6 -6

Summer quality max. - 0 0
Cloud point, oc ISO 3015 max. -1 6

5)
- -
Carbon residue , [Micro method , 10%
max. 0.30 0.30 0.30
(VN) distillation bottoms]. % (m/m)
ISO 10370
Carbon residue, [Micro method] ,
max. - - -
%(m/m)
Ash , %(m/m) ISO 6245 max. 0.01 0.01 0.01
Sediment, %(m/m) ISO 3735 max. - - 0.07
Total Existent Sediment, %(m/m) ISO 10307-1 max. - - -

Water, %(VN) ISO 3733 max. - - -
Cetane number ISO 5165 min. 45 40 40
Sulfur, %(m/m) ISO 8754 max. 1.0 1.5 1.5
Vanadium , mg/ kg ISO 14597 max. - - -

Aluminum plus silicon , mg/kg ISO 10478 max. - -
Visual Inspection clear clear clear
1) Density in kilograms per liter at 15°C should be multiplied by 1000 before comparison with these
values.
2) In some countries there will be a maximum limit.
3) 1 eSt =1 mm'/s
4) Purchasers should ensure that this pour point is suitable for the equipment in board, especially if
the vessel is operating in both the northern and southern hemispheres.
1/L.
CODE
GPC
Gimhae Korea GOO 10 D
Recommended Lub. Oil Specification
1. Performance
Maker recommended to use of oil designed to meet categories or API service classification.
- CH-4 : For turbocharged engine
2. Viscosity
Maker recommended to use of multi-viscosity lub oil , and recommended alternative SAE
viscosity grades according to the ambient temperature are as below.
SAE Grade Ambient Temperature
10W-30 -30oc to 30°C

Recommended 15W-40 -1 ooc and above
20WAO 1ooc and above
10W -30°C to ooc

20W-20 -15oC to 15oC
Alternative
30 ooc to 30°C
40 25°C and above
3. Lube Oil Chart

• Replace oil before it is reached every 6 month or every 250 hours operation whichever~.
earlier.
• Replace governor oil if it is contaminated , or if the governor instability is suspected from oil•
contamination .
!'
-
Engine L.O System
AP Equip type I Model -
MAX MIN
• AD136TI 15 . 5~ 12~
1/fJ.
GPC
Gimhae Korea $0010 0
4. Recommended Lu~· O"I for Manufactures & Brand

Lube Oil Bran d SAE
Manuf;a res
Name ' Grade
Mutti Viscosity RPM DELO V1 15iW-40

CALTEX
smgte Viscosity RPM DELO 300 OIL 30
SUPPER DUTY
,· Viscosity 1'r5W-40
GULF MOTOR OIL
S'ing e Viscosity
EXXON Mi.ttti Viscosity DELVAC MX 15\N-40

MOBIL
~e Viscosity DELVAC 1230 30
RIMULA X OIL 1l5W-40
Multi Viscosity RIMULA 0 1:alW-40
SHELL RIMULA ULTRA 5W-30
Single Viscosity RIMULA OIL 30
VANELLUS C6 GLOBAL [ 15\111-40

BP 1\U!Wli Viscosity
VAN ELLUS CF-4 HJW-40
I
ESSOLUBE 0 -3 tGW-40
ESSO M'>l i Viscosity
ESSOLUBE XD-3 1·5W-40
CASTRO L Multi Viscosity TECTION GLOVAL 15W-40

URSA SUPPER LA
M-ulti Viscosity ' 1t5W-40
URSA MARINE
FAMM '
Single Viscosity TARO 16 XD 30 30
SO 5000 GOLD or 10W-40

SK ' ti Viscosity
ZIC 5000 POWER 1QW-40
ulti Viscosity RUBIA 6800 15W40 1'5-W-40
TOTAL
Single Vi scosity RUBIA 30 30
GENERAL GENERAL
utti Viscosity 1HWJ-40
SEKIYU K.K WUPP ER CO SAVE r
i
212
GPC
Gimhae Korea
CODE
GOO 20 D
Recommended Cpolant Specification
Doosan Diesel engine require a" Heavy Duty Coolant" which is defined as a correct
mixture of good quality water. antifreeze and supplemental coolant additives(SCA's)
1. Water
Good quality water is important for cooling system performance. Excessive levels of calci um
and magnesium contribute to scaling problems, and excessive levels of chloride and sulfates
cause cooling system corrosion .
Calcium and Magnesium(Hardness) Maximum 170 ppm as (CaC03 +MgC03)

Chloride 40 ppm as (CI)
Sulfur 100 ppm as (804)
-
2. Anti-freezer
Fully formulated antifreeze must be mixed with quaHty- water -at· a· 50:·50 ratio . this mixture of
antifreeze and water gives a -36 ·c freezing point and 108 ·c boiling point, Using higher
concentrations of antifreeze will raise the freezing point of the solution and increase the
possibility of a silicate gel problem
Water : Antifreeze Freezing Point( "C) Boiling Point("C)

'
3:1 -12 103
2:1 -18 105
3:2 -25 106
1:1 -36 108
3. Replacement Interval
Coolant drain and flush the coolant system after 1 year of service.
Refill with new Heavy Duty Coolant.
1I 1
GPC
Gimhae Korea
c oo~
G1~
1J1
G C
Gimhae Korea
CODE
G10 01 D
Principal Particular
Diesel Generator Set
1. Diesel Engine Model
- Maker Doosan lnfracore
- Model AD136TI
- Type 4-stroke, In-line, Rad iator: cooling type
- Rated Out-put 188 PS (138kW)

- Revolution 1,800 rpm
- Fuel Oil Light Diesel Oil (DMA or DMZ /IS08217)
- Ambient Condition 45 ·c, 101 .3kPa , 60% .
2. Alternator Model
- Maker Leroy Somer
- Model M 46 .2 M3 C6/4
- Type Self-exc[!ed , Brushless
- Rated Out-put 100 kW (160 kVA) at 45'C
- Frequency 60Hz
- Voltage AC 450V
- Phase 3 Phase
- Power factor 0.625 lagging .
-Enclosure IP 23 (Drip-proof)
- Enclosure connection box IP44
- lnsulation(Stator/Rotor) Class H witt] Temp rise F
- Cooling system Air cooled
- Space heater 220V x 1, Ph x 60Hz X 250W
3. Dimension & Weight

- Length 3,000 mm
- Width 930 mm
- Height 1,430 mm
- Weight 1,900 kg
1/1
A
1591
GENERATOR
DESCRIPTION WEIGHT(kg) ENGINE (OPTION) GEN. OUTPUT
MODEL L WEIGHT( kg:
ENGINE 773 • 100 kW M46.2 M3 920 585
RADIATOR 150
COMMON BED 170 • AD136TI
BATIERY WITH BOX 150 138kW X 18DORPM
B GENERATOR 585 B
OTHERS 72
TOTAL 1.900
AUTO CONTROL PANEL
4 ~1J!lD eoo 15
$1\ 321 _!S

I
BATTERY W1~
BATIERY BOX \
\¥ ~
~
t--
t--
!
I
------j----- --
=:!.
AR FLO W
M I
L
J I
0
"'
jil
710
790 lj
TG.) 870
G G
S.T~~lliQQ
~!iiM!<I Y . (( CTR!\0 :HA!tT~R

- !::F.Cbt-.JOAfl:t : SPt<i~G H~~rr;r;
H
GP
Gimhae Korea
CODE
G10 15 D
SUBJECT : OVERHAULING PROCEDURE FOR PISTON
1. RE MOVING ROCKER LEVER HOUSING .

TURBOCHARGER AIR CLEANER IN THE TOP OF ENGINE.
2. REMOVING CYLINDER COVER
3. REMOVING OIL PAN FROM ENGINE.
4. REMOVE BOLTS OF CONNECTING ROD.
5. PUSH UP A PISTON & CON-ROD ASS'Y IN THE BELOW ENGINE

BLOCK
I"'S"TON COr<NECflNC ~. (4 .::ht9)

AlR JNTAKE MANJF<>LD {6.9 .. \'1) 8<~ ll5T MA t..nrol!> (27kg)
& IN"TER COOJ.£.R: (8,8l\·'l)
CYUI'IOER HU.O C()I.Vl (2,:5kQ)
1/1
PC
Gwnhae Korea
CODE
G10 25 D
Scope of Supply
Description Q'ty/Eng Remark

'
'f. p rive Arrangement
t
~. 1 SAE #14 Flywheel & Ring Gear 1
I
l1 ~. 2 SAE #1 Flywheel Housing 1

Type : Dual Port Flywheel Housing
~
['• 2. t: ront End
j
2.1 Viscous Type Vibration Damper with Pulley 1
~I
~ .2 2
' Front Engine Bracket
j, 3. ~ ngine Mounting
~. 1 Common Bed & Mounting for Engine, 1

Radiator, AC Generator
\
p. 2 Vibration Isolator and Mounting Hard-wares 4

I 4\. [Exhaust System
~. 1 Turbocharger 1
4.2 Wet Type Exhaust Manifold 1
J
4.3 90° Exhaust Outlet Elbow with Insulation 1
4.4 Expansion Joint & Mounting Parts 1
\
4.5 Spark Arrester Type Silencer 1
'
'· 5. ntake Air System
I
I
5.1 Intake Air Manifold 1
l 5.2 Normal Duty Dry Type Air Cleaner with 1

f Plumbing & Mounting Parts
!
5.3 Air Restriction Indicator 1
I
~ .4 Inter Cooler 1
'
-Type : Jacket Water To Air
I
G'· ~ ooling System
~.1 Water Pump 1

Type : Centrifugal
~
~.2 Thermostat & Thermostat Housing 1
~.3 Water Manifold 1
6.4 Radiator including Mounting Hard-wares & Plumbing 1
I
6.5 Cooling Fan & Fan Drive Arrangement 1

6.6 Coolant Heater with Thermostat 1
I.
1/4
GPC
Gimhae Korea
CODE
G10 25 [}
·-
Desaiption• Q'ty/Eng Rernari<
7. Lube Oil System
~.1 Lube Oil Pump 1
-Type : Engine Driven Gear Pump
~.2 Lube Oil Cooler 1

-Type : Multi-plate type
~.3 Lube Oil Filter 1

-Type : Spin-on Ca~
'
'
~.4 Oil Pan 1
-Capacity : 15.5/12 t.N..'er
\7 .5 Breather 1
'
7.6 Manually Operated Rot'at"l)'.tS:W'Np POmp. 1
Drain Oil Pump
I
~.7 L.O Drain Flex. Hose 1
8. Fuel & Governing System

8.1 Fuel Injection Pump 1
' Mechanical Go ve~
i
Type : RSV Type
8.2 Fuel Lift Pump 1

Including Fuel Feellt lflttmpt
I Manual Type
8.3 Fuel Filter 1
Type : Duplex, Spilll-oo I
8.4 Fuel Supply & Retum & t..e:aR~ TanRl' 1

Line Flexible Hose & .A-etapf£»1'
8.5 Double Wall Fuel Pirnes;with Drain.Tank' 1
'
2!4.
CODE
Gimtlae Korea G1 0 25 D
Description Q'ty/Eng Rem ark

9. ~tartin g System
~.1 Electric Battery Starter for Primary

- Electric Starting Motor 1
- Battery Charger 1
- Battery with Box 1
'
Type : Maintenance free sealed
'
Capacity : 150AH(24V)
- Battery Switch 1
~.2 Manual Starter for Secondary
I
- Spring Starter
Spring Starter 1
Cranking Handle 1
'
.
1!1/J. ~~egrated Control Panel for Emergency DIG
11D.1 Engine Instruments 1
- Hour-meter
- Tachometer
'
' - Voltmeter
- C.W Temp. Sensing PT-1000hm
- Lube Oil Temp. Sensing PT-1000hm
- Lube Oil Press. Sensing Transmitter '
'
I
~0.2 For Automatic/Manual Starting 1
- Power Change Over Switch
I - Auto Start Standby Lamp

- Running Lamp
'
I - Manual Push Button '
- Automatic Push Button
' - Start Push Button
- Stop Push Button
'.
- Reset Push Button
- Emergency Stop
- Manual Mode Lamp
3/4
GPC
Gimhae Korea
CODE
G10 25 D
Description Q'ty/Eng Remark

10. 10.3 Safety Device 1
- Overspeed Switch Set at 2050 r/min for
Engine Shutdown
-High C.W Temp. Switch Set at 102 ·c for Alarm
-Low L.O Press . Switch Set at 120kPa for Alarm
-High L.O Temp. Switch Set at 12o ·c for Alarm
- F.O Leakage Alarm
- Starting Failure Alarm
- Battery Charger Failure Alarm
-Pick Up Sensor Fail Alarm
-Spring Starter Engaged Alarm .
11. A.C Generator

-Auto voltage Regulator 1
- Hand Voltage Regulator 1
- Space Heater
12. Spare Parts

12.1 Maker Standard Spare Parts for Engine 1
' 12.2 Spare Parts for Auto Control Panel & Battery Charger 1
I
12.3 Alternator 1
13. Standard Service Tools
Standard Service Tools as per TL-3013-00 1
14. Literature
Engine Parts Catalogue 1
Engine Operation & Maintenance Manual 1
Engine Test Sheets 1
Marine Agency Certificate 1
4/4
GPC
Gimhae Korea
CCQE
I!JtO
3~. , ig ine Specificat·on

' . i·
& Drawings
1/1
Engine main specification MODEL : AD136TI
1- . 6eneral
1 . 1 Mod el AD136TI
1 .2 Type 4stroke , in-line , water cooled
direct injection, diesel engine
1 .3 Rotation Counter clockwise(viewed from flywheel side)
1 .4 Turbo charger Turbo charger and inter cooler
1 .5 Cylinder No . 6
1 .6 Bore 111 mm
1 . 7 Stroke 139 mm
1 .8 Total volume 8 ,071 cc
1 .9 Weight (dry)
-Engine Approx . 773 kg
2 _ fi:ngine efficiency
2.1 Continuous rated power 188 PS
2. 2 Rated speed 1 ,800 RPM
2.3 Low idring rpm 725±25 RPM
2. 4 Piston ve locity 7 .96 m/s
2 .5 Mean effective pressure 11 .42 bar
3t Installation
3 .1 Damper down (10.) , Damper up (1 0.), Side to side (22.5.)
3. 2 Axial clearance of crankshaft 0 .15-0.325 mm
41-. e=..xhaust system

4.1 Exhaust gas flow 503 1/sec
4 . 2 Exhaust gas temperature 450 ·c
5. 6n take system
5 .1 Max.permissible back pressure
- When filter is new 220 mmH 2 0
- When filter is contaminated 635 mmH 2 0
5 . 2 Intake manifold pressure 860 mm-Hg
5.3 Am ount of combustion air inlet 850 m•/h
6 . Cooling system
6 .1 Cool ant capacity approx. 26 ~
6.2 Thermostat open&close 71 - 85 "C

6.3 Cooling water max . temperatu re . 103 ·c
6.4 Max.raw water pump pressure 1 bar
6.5 Resistence of raw water pump inlet ± 0.3 bar
6 .6 Head of raw water pump 5 m
6.7 Fresh water pump capacity 150 .ll/min
7 . Lubricating system
7 .1 Capacity
- Oil pan 15 .5 PI
- Oil filter 3 _g.
7 .2 Oil pressure
- Under low id le rpm 1. 2 kg/ em 2
- Under rated rpm 3.5 kg/cm 2
7.3 Max permissi ble temp . 120 ·c
7 .4 Oi l pump capac ity 63 .t/min
8 . Fuel system
8.1 Max.permissible back pressure
- Wh en filter is new 63 mm- Hg
- When filter is con tam ina ted 100 mm -Hg
8 .2 Resistence of fuel line 510 mm-Hg
8 .3 Fuel consumptio n (at full load) 34±5% 1/'m
8 .4 Max flow rate 58 i'Jhr
9 . Electric syste m
9.1 Vol tage 24 v,olts
9.2 Battery 2-150 AH
9 .3 Max permissi ble resistance 0 .002 ~
2
2 3 4 6 7
Check ed
A A
GEl(}LII!JG WATE:~ !'ILLER & PRESSUilE (,}A~

POSITIVE PRESSURE : 0.5 ±0,2 kg/em 2
NEGATIVE PRESSURE : 0.08 ±0.02 kg/ern2
\
B B
EXHAUST MANIFOLD
AIR FLO\rl
c CYLINDER BLOCK c
TURBOCHARGER
& CYLINDER HEAD
0
D D
INJ(R COOLER
NOTE
SAFETY DEVICE_/ DRAIN
SEE NOTE No .3 1. COOLING SYSTEM DATA PT 3/8" COCK
MODEL .AD136TI 4. WATER FLOW AT THERMOSTAT OUTLET
COOLANT CAPACITY {TOTAL) 50 LITER
E FAN AIR FLOW 5000 L/ sec TEMPERATURE FLOW E
MAX. AIR RESTRICTION BELOW 71·c " B"
DISCHARGE SIDE OF 12.7 mmH20 71·c - ss·c .,A" , " 8 '
RADIATOR & FAN
ABOVE ss·c "A"
2. THE INLET AIR DUCT SHOULD BE AT LEAST 1.5 TIMES
THE SIZE OF THE RADIATOR AIR DUCTING OR OPENING.
3. SAFETY DEVICE
• HIGH WATER TEMP. SWITCH SET AT 102"C FOR ALARM . DESIGNED BY APPROVED BY SCALE
F C. K. PARK S. K. WOO N/S
TITLE c 0 0 LING wATER sysTEM

GPC DWG NO.
010 10 D
SHEET
111
2 3 6 7
2 3
PO\JER SOURCE
1------- - - - - - - - ·- r
B 0 ACllOV, 1(1), 60Hz, 750\J
• AC220V, 1(1), 60Hz, 1000\J, 4.~ CABLE GLAND
20c X 1 EA
JUNCTION BOX FOR

I I COOLANT HEATER
JJ 6
THERMOSTAT
OPEN 1 49•c
D CLOSE 1 3s·c
LED
COOLANT HEA TER
: BY YARD \JIRYIG
E ---- I BY GPC \JIRI ~
DESIGNED BY CHECKED B)' 1.\PIJIRO'WED BY FILE NAME DATE

B.D.MOON C.K.PARK .. S.K W:O,O, DOOSAN 31 AUG 2015
TITLE
COOLANT HEAT ER
GPC I
SHEET.
lfiJ
2 3 4 6 7
Checked
A FUEL RETURN CONNECTOR

A
(P/N I 3466)\
r------------------------,
AIR VENT
I
i I FUEL RETURN HOSE
(P/N I 4401-6S-2200U
65A 1 DOUBLE WALL INJECTION PIPE
B FU EL RETURN B
FUEL LEAKAGE TANK & SWITCH
INJECTION NOZZLE
c c
F.O TANK DUPLEX FUEL FILTER
THROTTLE
FUEL SHUT-DDW'N VALVE\

\__ FUEL INJECTION PUMP
D ROBERT BOSCH RSV D
MECHANICAL GOVERNOR
ENGINE CRANKSHAFT
CENTER LINE
FUEL FEED PUM

FUEL INLET CONNECTOR
(P/N I 3466)
E E
FUEL SUPPLY
\ _ _ FUEL INLET HOSE
(P/N I 4401-6S- 2000U
L------------------------~
F ------------ I BY YARD DESIGNE D BY

B.H.LEE
APPROVED BY
S.K.WOO
SCALE
1,2 F
TITLE
FUEL OIL SYSTEM DIAGRAM
GPC DWG NO.
010 30 0
SHEET
1/1
2 3 6 7
2 3 4 6 7
MAIN OIL RIFLE

~---------.--------,--------.---------.---------,,---------.--------.----------~ SEE NOTE No. 4
B B
REGULATING
VALVE
c OIL COOLER OIL SPRAY NOZZLE c

BY-PASS VALVE SEE NOTE No. 3
SEE NOTE No. 2
NOTE
FLEXIBLE HOSE I. PRESS REGULA liNG VALVE OPEN PRESSURE

p /N I 4401-10S-760L 1 142 PSI (10 kg/cM2)
SEE NOTE No. 5 2. COOLER BY-PASS VALVE OPEN PRESSURE

1 71 PSI (5 kg/cM2)
E E
L.O DRAIN VALVE_/ 3. OIL SPRAY NOZZLE OPEN PRESSURE
\.__L.O DRAIN PUMP 1 28 PSI <2.0 kglcM2)
MANUAL ROTARY TYPE 4. LOIJ OIL PRESS SIJITCH SET AT 120kPCl
FOR ALARM
5. L.O HIGH TEMP. SIJITCH SET AT 120•c
FOR ALARM
DESIGNED BY APPROVED BY
F B.H.LEE S.K.WOO
TITLE LUBE OIL SYSTEM DIAGRAM

GPC DWG NO.
010 40 0
SHEET
111
2 6 7
1 2 3
r--tR~ Re visio n note
\
t
j
A: A
{I) HOSES
SAE lOORS HOSE ( 1503)

) PART NO. A B D E
I.D 0.!) l:llllli. llPGI' MIN. BURST MIN. IIEIIII) :VAO'JIJM~~VICE
9!1S3l!l. CJISD PRESS <PSil RADrus
I
·H01-6S- 2200L(9l14) 5/8-18UNF 60 6 45 7 .8 fi'.2' &.""50' 9000 101 29
; FUE'L 0\t..
-4401--6S-200Q(Mt4) 5/8-18UNF 60 6 45 7.8 l11'.2' : ite50; 9000 10 ~ 28 ,[
FaiL~ 14401-4S-760L 7/16-20UNF 50 3.3 45 4.8 1:!2 300.\l 12000 762. 28
@ ADAPTER
\
1
o l.'t
0
D:ES!GNED BY CHECKED BY APPRO VED BY FlliL NAME DATE SCALE

F 1. ) S...H.CMEON B.H.LEE S.K.WOO · All 22-Jun-0:8 N/S F
TITU!
Fuet & L.O Hoses, Adapter
GPC DWG i'ID. SHEET
1/1
'f
z 3 4 7
Checked
A A
l
B
n TRIP LEVER
1. OPEN THE FUEL VALVE .
FUEL VALVE IS NORMAL OPEN TYPE .

[ 'w'INDING ADAPTER KN OB [
2 . PULL THE KNOB.

<TRIP LEVER AUTOMATICALL Y RETURNS TO RESET POSITIO N)
3 . 'w'IND CLOCK'w'ISE TO LOAD UNTIL RED SPRINGS ARE VISIBLE.
D 4, PUL L THE TRIP LEVER DO'w'N TO START ENGINE . D

F/ H
E E
VISIBLE POINT OF
SPRING COLOR
DESIGNED BY APPROVED BY DATE SCALE

F S. H. CHEON S. K. WOO 22 Jun 08 N/S F
TITLE
SPRING STARTER
GPC DWG NO.
010 65 D SHEET
111
2 3 6 7
z 3 4 6 7
200±5
8-¢19 Holes 4-¢12 Holes
r--- B
F
,-,.,
,--- - !'"'
IL -L.I
-
., -
0 :;<
...
-+i
-
;;;
8
OUTLE T • .."'"'
-+i
0
I~ -
(")
-+i
If)
[
-
N
(l)
'9
-
,.,
lr
- f- '-' '--'
'-- .,... ..__,
H=
H
=
li-i-11
_[l
<JIS 1OOA-5K FLANGE>
/L 1 (6)JJ:.BX9J
3 4 5
D
9 NUT, HEXAGON 8 SS41 1.410

8 WASHER, SPRING 8 SWRH62 1.410
7 WASHER, PLAIN 8 SS41 1.410
6 BOLT, HEXAGON 8 SS41 t.410x1 .5Px40L
E E
5 CASKET 7300W
FlANGE SS400 MAKER STANDARD
3 BELLOWS SUS304 CORR.N0.1 5, 0.51
DESIGN TEt.lPERAlURE 600'
CASKET 7300W
DESIGN PRESSURE 5kg/cm2
FlANGE SS400 JIS 100A-5K
liST PRESSURE 4.5kg/cm'
AXIAl t.lOVD.tENT ±20mm DESIGNED BY APPROVED BY DATE SCALE
F B.H.LEE S.K.WOO 21 JUN 08 1,2 F
FLUID EXHAUST CAS
TITLE
JOINT . EXPANSION
GPC DWG NO.
010 86 0
SHEET
1/1
z 3 6 7
2 3 4 6 7
AP PART No. A B c D E i&F ¢G ¢H J - i&K WEIGHT BOTH FLANGE SIZE

A 0 93310810 120 800 1040 250 308 114.3 165 200 8-¢19 30 kg JIS 5K-100A A
•
0
93310811
93310812
125
145
1000
1075
1250
1365
320
350
360
400
139.8
165.2
200
230
235
265
8- ¢19
8-¢19
37 kg
60 kg
JIS 5K-125A
JIS 5K-150A
0 93310813 150 1520 1820 510 460 2 16.3 280 320 8-¢23 88 kg JIS 5K-200A
0 93310814 142.5 1715 2000 550 560 267.4 345 385 8-¢23 JIS 5K-250A
0 93310815 142.5 2100 2385 790 650 318.5 390 430 8 - ¢23 JIS 5K-300A
B B
c
PIPE 0. D
(YARD SU PPLY)
R· B
c INLET
__.. __u_ _____ _
J----·--·-E$>---------·---- ------I- c
D
1........- _.;;..
D_ ____,:....-..~ ...........
JIS 5K- 1sA DR,...IN Fl.A~lt:lE
PIPE 0. 0
(YARD !!;UPPLY)
~ arE ..
1. 'P!'I'lf: : e N'TRI~UGM. rl.OW SE!h.~~ ~RE;STI:'R lYflt;:
RESIDENTIAL SIL.ENG!;;R.
2. PRESSURE DROP. : SEE TAP
E 3. NOISE DROP : 18 - 25 dB(A) REDUCTION. E
4. MAKER/MODEL : NELSON MUFFLER/ 494 60- U
<JIS 15A- 5K DRAIN FLANGE>
5. TOTAL PRESSU RE DROP FOR YARD' S EXHAUST SYSTEM
EXH.GAS FLOW PRESS. SHOU LD BE RESTRICTE D Max. 1032 m mH20 INCLUDING SILENCER.
ENG INE ENGINE SILENCER
MODEL ( HP ) AT( _18r~O ~fM DROP
MODEL 6. MATER IAL : - BODY : ALCOSTA,
l1ter sec (mmH,O)
138 - FLANGE : SS41
AD 136 Tl 503 290
(188) DESIGNED BY APPROVED BY SCALE
F 93310811 S.H.CHEON S.K.WOO NIS F
186
AD 086 Tl 578 333 TITLE
(253) SILENCER
GPC DWG NO.
DlO 90 D
SHEET
111
2 6 7
A
0
\{) 45
·-+--+
l I
0 -+- B
B
I I I I
- ~ ~
0
0
~1 I
I
(")
(
I
I
- ~ ~
D
0
(\j
0
......
0
(]\
(]\
0
0
(")
1-
I
- ------, I
I
- - - - - r--r--
D
"r~.
0
0
-~
'
I
I
I
•
(")
~, I
- ~ I ~
·-t---+ +I -+- F
f
0
\{) 119 I. 321 .I. 321 ..I )19..
880
G G
910
6
. ator Specification
Drawings
PC
GB"nhae Korea
CODE
A10 01 L
Principal Particular
~A lternator
- Maker : Leroy Somer

- Model : M46 .2 M3 C6/4
- Type : Horizontal, Self-excited , Brushless
- Rated Out-put : 100 kW (160 kVA) at 45 "C
- Rated Speed : 1800 RPM

-Frequency : 60Hz
- Voltage : AC 450V
- Phase : 3 Phase
- Current : 205.3 Amp
- Power factor : 0.625 lagging
- Weight : 585 kg
-Enclosure : IP 23 (Drip-proof)
- Enclosure connection box : IP 44
- Insulation (Stator/Rotor) : Class H with Temp rise F
- Cooling system : Air cooled
- Overload Capacity : 110%
- Space heater : AC 220V x 1 Ph X 60Hz X 250W
- Class : NK
1/1
GPC
Gimhae Korea
CODE
A 10 11 L
Alternator Constants
(AC450V, 30, 60Hz, 1800RPM)
Alternator
•
Output 100 kW
Model M46.2 M3
Constants
~tatorArmature
0.015
Resistance(Ra)
Synchronous
255
Reactance(Xd)
Transient
12.9
Reactance(X'd)
Subtransient
7 .8
Reactance(X"d)
Negative
Sequence 8.7
Reactance(X2)
~ero Sequence
5.5
Reactance(XO)
f.rmature Time
0.016
Constant(Ta)
rrransient Time
0 .1
~onstant(Td)
Subtransient Time
0.01
Constant(T'd )
(Insulation Class H, Temp. Rise F)
Reactance in %
Resistance in n
Time Constant in sec
111
6PT10N: R11gulotour 2 et l fonoti Pni
~ ACCESS TO REGULATOR OPTION: A. V.R 2 end 3 functions
~ 920 76.3
PMG)
~
566
6 Xg
'- -- 24
~ -
.ret (
U'
i
!l
s:;
01 ;1
0
m z X
m
;[ ~
- 1-
ltl ______!! r-
I()
"'ISl i
u
f-- N
~
-
ISl ISl ISl
I
I
504 "'
;;; "
150 ISl
l
~ f-
I AIR
ln.
I\_ 2 trous 021

' I
\
AIR\
~
ACCES AUX DIODES

ACCESS TO RECTIFIERS
t
1
I
457
6 185 1 0 197 ~ i
429
527 1
L__ _ _ _ X TROUS "-'Y EQUIDISTANTS SUR 0U
Y DIA, X EQ SP HOUES ON U P.C.D !
j
BRIDE FLANGE ADAPTATORS DISQUE DISC COUPUNG PASSAOE Dl AIJTOCAD
IllS[ 01 CONf"OIIY'1E [lJ 1RAa:
..
02- lG-411 IIIIOlJSSAAD
D0-1~- IIDITHAUD
_,...,
......._r
......._r ......
.P(; I
I
A..DliT[ ~ P.M.C (OPlKH) IIDITHAUD
SAE BD N M XBG s SAE BX u X y AH A.ICIJ1[ 1"'K L.SA 412 DA.NS CNIIlQIJCH[
.t.JCUTE: ~TATION P'NKNJ ACCES 01-<>7-422 ODTHAUD I10UOD SITJA
IIIECII.I..AlD.It POUR 2 tT l ftlHC1'IOHS
1 575 511,175 530,225 12 12,5 14 466,72 438,15 8 14 25,4 1R<IJS s (SAt1) .,2 ~ .,2.-S 114-M-128 ........._r DDIS IIOUCHAUD 1
2 575 447,675 466,725 12 11 1 1/2 352,42 333,38 8 11 39,6
J 575 409,575 428,625 12 11
Disc 11
Disc 14
1/2
MASSE Kg
TYPE Xg J Kgm2 J Kgm2
Weight
~~!!g M•~ 460 585 1,91 1,78
f-~!!~~ ~~ 470 625 2,077 1,948

Ce dessln ne dolt etre modltle que sur DAD ou B.E. Slli.AC
L
Alternateur SHUNT - PMG - AREP Alternator
12 Fils I 8 Barnes - 12 Leads I 8 Terminals
Code connexions - Connection code Tensions- Voltage L-L Couplage usine- Factory connection
~
Bobinage 50 Hz 60Hz AV/DE
3PH Winding
L1 (U) 6 190-208 190- 240
Etoile parallele
Parallel Star T1 r7 7 220-230 -
T4
1 ~10 8 - 190-208
~"''2- N 7-s R 230: 0-110 V --> T8-T11
~0 .,.,,
R 438 - R448:
L3(W) L2 (V) 0 --> T3 I 220 --> T2
® 3PH
L1 (U)
Bobinage
Windino
6
50 Hz
380-415
60Hz
380- 480
~toile Serie T11 r1o--+-r n ..-..,
Series Star
7 440-460 - T11 -~/'---"'---"----"'
T41 T12-
8 - 380-416 ~-~..... W(3)-L3
T101
T71
T61 T9~ ......_IT3 .,...
....
R 230:0-110 V --> T8-T11 ......._..._, .,... V(2)-L2
T
T1 T11
T8 T51 T8 r IT2 ....
T6 T5 ...._ .,.. U(1)-L1
T3 T2 R 438 - R 448:
0 --> T3 I 380 --> T2
T41 T7r T1
L3(W) L2 (V)
AR/NDE
Bobinage 50 Hz 60Hz
1 PH Winding
AV/DE
6 220 - 240 220 - 240 T4 T3
7
\'
....
.... M
,~,T1~g
250-260 "'\
nln1f
8 200 220-240
....
.... L
no T9 I r __,r--
"'\
()::: ~T6
I T1 T4 _( T7 T10 I R 230: 0-110 V --> T1-T4
TBI v---- ~~~T2 ....
f'-.-'
L M L
.... L
Tension LM = 1/2 Tension LL R438 -R448:
T12r-
~~T1
Voltage LM = 1/2 Voltage LL 0 --> T10 1220 --> T1 T5
AR/NDE
0 1 PH ou/or 3 PH
Bobinage
Winding
6
50 Hz
220-240
60Hz
220- 240
AV/DE
Triangle serie L1 (U)

Series Delta T1 J1 7 250-260 -
W(3)-L3
T9 T4 8 200 220 - 240
T6 T7 V(2)-L2
R 230:0-110 V --> T8 -T11
T3 T10
T11 T8 T5 .l2 U(1 )-L 1
L3(W) T - L2(V)
L 'M L R 438 - R 448:
0 --> T3 I 220 --> T2
Tension LM = 1/2 Tension LL
AR/NDE
Voltage LM = 1/2 Voltage LL
Page 112
~~-~
C T - ~D~e~s:_s.:_: I I
: R_::R.:.__.....LV:..::e~ri::_:f:~E:..:V_ _j~D~a~te::._::_:0~6~10::;5~/9~7 IPLfRO'r Usine de Sillac, bd Marcellin Leroy
_ oo_o_ s_ r_ o5_3_ _ _ _ _ _~-"tE::...:t9:..:..7.:..::
t-s_c.,-H .o.: .;5·. .:. 45=.. :. . t1 YSOMER 1so1s ANGouLEME - cEoEx
d mise jour a 12/04/06 RR 06.168 COUPLAGE DES BORNES
C supprime B(M) 03/06/98 RR E/98.06.565 la
B R 230/R4 ..8 26/03/98 RR E/98.03.545 TERMINALS CONNECTIONS W: 2679. AB0297 ~~
A Shunt+ R 230A 18/03/98 RR E/98.03.542 w:e
E
(;---
'
Allimateur AREP
.... I AREP Alternator
,.----. ,.,.I...,._._Mlb\<W ... ..... "4.
MI'?M'Piltr
~., I II
12 FilS I WIRES- REGULATEUR I AVR- R450 M ou I or T
Bobs auxiliaires
Aux winding
ROUE POLAIRE I MAIN FIELD
EXCITATRICE
j -1
EXCITER .l -;-'
-1
....
-1
'P
~ c
"' ~ ~
.~.
•',! lnduit
pt <! ~
8
f( Armature l(
.
"i*
....
lnducteur
Exciter field
Ponf'S·teumants
Rctaq rti'Jdifiers
-y
>
~ u"":5 "'
..J
UJ !D
0
UJ
UJ
z
i±l
"'Cl
F:nn '~~ ,;, '~' 'i
s.
UJ < Cl
~
::>
..J
UJ
z "'
6
::>
0
1-
"'>
UJ
·r& "'::> ::J
~
z "'
~ w v---'
r
..J
ID
MARQUAGE / MARK :
10112111 19 T1a/toT12
OPTION - OPTIONAL
[ Tl 04 : T I I CT I sw I
~~I I ~~
3 ED ln/2/1 A - Y connection - D
ln12/1 A · couplage Y - D
I R 791 -·-1
T1 ~----.-------~
T2 - - -•
T3 R 791 T-
A N
Ph u 18
--> S1 Pour sens de rotation anti--l'it:naire blanc / white
.,...
T10 7 --> S2 For Anticlockwise rota.tioo
---> Tl - T2 - T3 : noir
---> N : bleu I blue
tJ ~ ou /or 470 n- 3W
Of.SEXCI TATION - DESENERGIZING
O~Nion/Opti on al:
~ta ge tension exte1r~ (enl'ever ST) Bobs auxiliaires - Auxiliary windings
Remote Voltage Trimme O;emove ST) ' '
9 12
~~~
R450 M
ouvrir E 01
ou/or
open E 01
R450 1'
<OONTACTS NON FOURNIS PAR LS

!tONTACTS NOT SUPPLIED BY LS
~·.i SCH ooo ST 197 ~ ~~t• de C.T lOess. OJ Jvenr· CR I Date: .c.;JJVN
1
u ~ IPLEROY" usine de Sillac. bd Marcellin Leroy
1~~ I = liJSOMfR 16015 ANGOULEME - CEDEX
SCHEMA DES CONNEXIONS E7
BRANCHEMENT DU REGULATE Ul~
INNERER KLEMMEN PLAN No: 3188 AC 0710
·::~ t Creation 10- 374 a
BOlTE A BORNES STATOR - STATOR TERMINAL BOX
KLEMM EN KASTEN
Resistance de rechauffage Resistances de rechauffage

Heater Heater
Stillstandsheizung Stillstandsheizung
101 102 101 102
1~ I~1
Serie 422 I 461 I 471 I 491 Serie 432 I 442
~C~.T~.-:;:;-:;-~D~e~ss:._::
1E/ _ _ _ _~l·v~e~rif. :. . --~ID;;_:a~te:...:_:..=,21.!..!_/1~0~/9~4 fPLfRO'r usine de 5 1·11 ac, bdMarce w1n Leroy
1--,----------t-=-::....;.:...:..::.:..::="--t
94 10 321 YSOMER 16015 ANGOULEME- CEDEX
D ALTERNATEURS-ALTERNATOR
c GENERATOREN
B PROTECTIONS - SCHUTZ
A ajoute types alt. 16/03/99 RR E/99.03.655
2 3
A
5,08 6,99
5,08
¢22.23
FMS c
-ct--~6--6--~
~ s.os 1 s.o8 1 6.99
D
t RESISTAN CE TOLERANCE : ±5%
2; rtfffECTI VE ELECTRICAL ANGLE : 3600° +10°, -0°
3 DIELECTRIC 'vv'ITHST ANDING VOLTAGE
~ MIL -STD- 202, METHOD 301CSEA LEVEL 2,000 VAC MIN)
4. INSULATI ON RESISTANCECSOOVDC) : 1,000 MEGA OHMS MIN

E
5. M-OUNTING HARD'vv' ARE INCLUDED
~. R 1EOSTAT VOLTAGE 'vv'ILL BE INSTALL IN ESB.
_j
~ 0€~161\lt:o~¥ CHECKED BY APPROVED BY DATE APPLICATION SCALE

JY.W'OO K.H.KIM S.K.WOO 1- MAY -2007 LEROY SOMER 1:1 F
TITLE
RHEOSTAT, VOLTAGE
GPC DWG NO. SHEET
1/1
1
t _l 2 I 3 I 4 I 5 I 6 l ~ I R
I I R..NoJ Rtmlon .... D•t• !S~g>ot ...~O>ttkod
A A
- t-
B B
,.
"
- ALTERNATOR ESBD -
( R (
MAIN PO\J ER t--
CABLE FOR MAIN PO\JER
TERMINAL BOARD
s MAIN PO\JER
I
t--
- T t-
D D
SPACE HEATER 101
r-----
h CABLE FOR SPACE HEATER , AC220V SPACE HEATER
TERMINAL 102 w PO\JER C220V>
I
-ft- - t-
E REMOTE VOLTAGE
TRIMMER TERMINAL
;a en
~w
CABLE FOR REMOTE VOLTAGE TRIMMER REMOTE VOLTAGE
TRIMMER
J
E
- r-
F F
CABLE & CABLE GLAND.

- t-
GLAN D SI ZE. QUANTITY. DETAILS.
G 20C 1 FOR REMOTE VOLTAGE TRIMMER G
20A 1 FOR SPACE HEATER
- 35 B 2 FOR MAIN POWER t-
H D£S6EDIY
T.liKtt
l CHECKED BY
I.H.LEE
l APPROVED 8'1'
S.k.WOO
I
FLEN»E.
AD136TI
I
DUE
2012-04-ZS
l SCALE
NIA
H
I TITLE CABLE CONNECTION DIAGRAM
rt,
GPC I
DWG NO. AlO 60 A 1 :DfTilH1~ET
1 I 2 I j I I 6 I I I 6
CODE
E10
•
5. Electric Sys ,' · raw1ngs
1/1
2 3 4 6 7 8
NO. SYI.IBOL. NAME PLATES. NOTE.
A A
380 200
B
•
0 0
I· EMERGENCY GENERATOR CONTROL PANEL.
ENGINE CONTROL & MONITORING SYSTEM

·I
I VI
MATERIALS.
1 ENCLOSURE. - STEEL • IP 44.

2.. ENGINE CONTROL & MONITOR IN G SYSTEM .
3. POWER SWITCH.
B
D~
~ 4
l o ~-n-o• l
5.. E-MERGENCY STOP BUTION.
~ 6. EARTH BOLT .
~
7. BELL.
c ~
8. SHOCK ABSORBER . c
C)
~
"
1(!)~~0CJ
Ll L:J [!) c:J E)
j
:::....
9. CONNECTOR.
1 0. CABLE GLAND.
0 0
0 ®
D
II~ Dl NOTE .
D
•
1. CASE : STEEL.
2. COLOR : 7.5BG 7/2.
3. ENCLOSUR E : IP44.
4. WEIGHT 20kg .
E E
CABLE GLAND.
G. SIZE. QUANTITY. DETAILS.
10 1 FOR CONNECTING BELL
20c -
F I.H.YUN
JOe 1 FOR CONNECTING YARD CABLE. TITLE
GPC DWG NO.

E02 63 D
SHEET
117
2 6 7
,.,.,.vp..;:.-
1
~-·
I ?
·-I 3 j I. I
T "• -
~ I
-~~~NOT Revision nOte
6.
~
I
NO. $Y~80L
1
~
I fl
~.;;-E PLAru~ ·"V- -~· _.. .._., ·;;mf~~~
A DETAILS OF ECM 850EH. A

LCD DETAILS.
STA. 1
ALARM / TRIP TABLE. ~APPLIED . STA 3-1
~
0 0 No. DESCRIPTION. SPECIFICATION. ALARMS & TRIP. SffiiNG TRIP. ALARM & COMMO~
ENGINE CONTROL & MONITCRING SYSTEM LCD DETAILS. ABNORMAL ALARM.
- I ( SYSTEM STATUS ] 1. OVER SPEED TRIP . I ACTION ON RUN . ~ CONNECTED. f---
(0 "'""'
D.C . VOLT. [ Jv 0 - 50 v 2050 RPM .
i O IM/Uli.IXIt. I
I O ~'~'·lWOCEUfl~Sl'-ii) ENGINE RPM. [ l RPM. 0 - 3000 RPM. 2. -
C.F.W. TEMP [ J ·c 0 - 200 ·c
1o- I LUB. OIL TEMP. [ J ·c 0 - 200 ·c 3. -
8 LUB. OIL PRESS. [ l BAR. 0 - 10 BAR.
8
(0 "-'"' I
(0 ""'"""' I 4. C.F.W. HIGH TEMP. ALARM. 102±2 ·c CONNECTED.
ENGINE USED TIME. [ l H. 0 - 9999 H
5. LUB. OIL HIGH TEMP. ALARM. 120±2 ·c CONNECTED.
ALARM LIST ====---
- f---
~ ~ ~ 0 EJ MAIN PROCEDURE. 5. LUB. OIL LOW PRESS. ALARM. I ACTION ON RUN .
120 ± 20 kPa.
CONNECTED.
LJ [!] [!) 0 ~ ""

£Q,t:,-bJ'If
STARTING.
CRANKING TIME. 5 SECONDS.
SE1TtNG.
7. PICK UP SENSOR FAIL. ALARM. SENSOR FAIL. CONNECTED.
c 0 0 DELAY TIME BETWEEN START ATTEMP 5 SECONDS.

NUMBER OF STARTS ATTEMPT. 3 TIMES .
SENSOR CIRCUIT FAI
c
'
. 8. START FAIL. CONNECTED.
~TA. 2 STA 3
-E 8- No DESCRIPTION. SPECIFICATION. No. DESCRIPTION. SPECIFICATION. 9. BATTERY CHARGER FAIL. ALARM . I'!ATTER'f CHARGER .CONNECTED. - 1-
AC POWER FAIL.
1
2
FRONT VIEW OF ECMS 85C.
LCD.
[~t]
TEST
LAMP &
BELL TEST. PUSH BUTTON. BATTERY LOW VOLT.
3. LFD lAMPS
0 POWER.
MANUAl MODE 1~1 RESET. PUSH BUTTON. 10. F.O. LEAKAGE ALARM. CONNECTED. D
AUTO MODE & START ST -B
- 0 UP KEY. PUSH BUTTON. 11. SPRING STARTER ENGAGE ALARM. CONNECTED.
4
&ARM.
TRIP.
BUTTONS.
0 DOWN KEY. PUSH B:.JTTON. 12
-
~~UALI MANUAL. PUSH BUTTON.

~ p
BELL STOP PUSH BUTTON. 13.
E [•u;oI AUTO PUSH BUTTON.

5.
E3 T
FITTING BOLT.
UNIT SELECT PUSH BUTTON.
MS-151
14.
15.
E
5. TFRMINAI BlOCK. 15P WW'. X 7.
IST~TI START PUSH BUTTON. 7. -
8.
15. -
- ~s~~ STOP PUSH BUTTON. 9.
10.
-
- 17 -
-
F
tlf!iiGNfD DY
I.H.YUN
1 Cti!CKEO SY
C.K.PARK
l APPROV!D 8Y
S.K.WOO
1 ~ILE ~Ap.4< -
DOOSAN
1oA ie
2010-JUN-22
StALl
N/5 F
TITLE OUT LINE OF ECMS BSOEH .
+,
GPC DWG NO.
E02 63 D I ~DITION SHEET
217
1 I 2 I 3 I I I 1 T 'f 1 T I I 6 I 7 I 8
1 I 2 I 3 I 4 I 5 I 6 I 7 I 8
I RevNol Revision note NO. SYMBOL NA.\1E PLATES. NOTE.
TERMINAL INFORMATION AND CONTROL DEVICE. I

A A
TERMINAL INFORMATION.
1 4
No. DESCRIPTION. No. DESCRIPTION. - CONTROL DEVICE.
- 801 REMOTE STOP 50,51,52 MPU+ , MPU- , SHIEL[. MAGNET PICK UP SENSOR. r-
802. REMOTE START. 53.54,55 AN1+ , AN1- • SHIELD ANALOG SENSOR 1.
R03. 11ElAY STOP. 56,57,58 AN2+ , AN2- , SHIELD ANALOG SENSOR 2.
804. START BLOCKING. 59,60,61 -
805 - 62,63,64 RTD 1A , 1B , 1B' PT 100 OHM 1.
B S!LC_QM SJGN,A,L COMMON B
65,66,67 RTD 2A , 2B , 2B' PT 100 OHM 2.
YO. ENGINE START RELAY.
68. F.G. (FRAME GROUND.)
Y1 FUFI VALVE RFI AY.
69,70,71 RTD 3A , 38 , 38' -
Y2. EMERGENCY STOP RELAY.
- Y3. BELL RELAY. r-
2 5
No. DESCRIPTION. No. DESCRIPTION. - CONTROL DEVICE.
c F.G. FRAME GROUND. 72. S.G. COM.(SIGNAL COMMON. SIGNAL COMMON. c
S.G. SIGNAL GROUND. 73. Dl 1. DIGITAL INPUT 1.
D.l. DIGITAL INPUT. 74. Dl 2. DIGITAL INPUT 2.
RS 485 +. RS 485 COMMUNICATION + 75. Dl 3. DIGITAL INPUT 3.
RS 485 -. RS 485 COMMUNICATION -. 76.
-<E
8- p D.C. +24 V INPUJ.
Dl 4. DIGITAL INPUT 4. - -
77. Dl 5. DIGITAL INPUT 5.
N D.C. -24 V INPUT.
78. Dl 6. DIGITAL INPUT 6.
-
- 79. 01 7. DIGITAL INPUT 7.
- 80. Dl 8. DIGITAL INPUT 8.
0 0
81. 01 9. DIGITAL INPUT 9.
3 82. Dl 10. DIGITAL INPUT 10.
No. DESCRIPTION. 83. S.G. CO~t(SIGNAL COMMON. SIGNAL COMMON.
RELAY NO. CONTROL DEVICE.
84. S.G. COM.(SIGNAL COMMON. SIGNAL COMMON.
- 01,02,03 N.C. - N.O. - COM. K1 CONTROL POWER.
85. SPARE. -
-
04,05,06 N.C. - N.O. - COM. K2 MANUAL MODE.
86. SPARE. -
07,08,09 N.C. - N.O. - COM. K3 AUTO MODE.
87. SPARE. -
10,11,12 N.C. - N.O. - COM. K4 AUTO MODE & START ST -BY.
88. Dl. START BLOCKING. START BLOCKING.
E 13,14,15 N.C. - N.O. - COM. K5 RUNNING.
89. S.G. COM.(SIGNAL COMMON. SIGNAL COMMON. E
16,17.18 N.C. - N.O. - COM. K6 PARALLELING.
90. EMERGENCY STOP. EMERGENCY STOP.
19,20.21 N.C. - N.O. - COM. K7 OVER SPEED TRIP.
22,23,24 N.C. - N.O. - COM. KB STOP.
- 25,26,27 N.C. - N.O. - COM. K9 START FAIL. r-
28,29,30 N.C. - N.O. - COM. K10 COMMON ABNORMAL ALARM.
31 ,32,33 COM . - N.O. - N.C. K11 CHARGER CUT OUT SIGNAL
34,35,36 COM. - N.O. - N.C. K12 BATIERY CHARGER FAIL.
F 37,38,39 COM. - N.O. - N.C. K13 SPARE 1. DESIGNED BY
I.H.YUN
I CHECKED
C.K.PARK
BY I APPROVED BY
S.K.WOO
IFILE NAME
DOOSAN
I DATE
2010- JUN-22
SCALE
N/S F
40,41,42 COM. - N.O. - N.C. K14 SPARE 2.
43,44,45 COM. - N.O. - N.C. K15 SPARE 3. TITLE TERMINAL INFORMA TION .
.rtz
GPC DWG NO.
E02 63 D I ~DillON SHEET
317
1 I 2 I 3 I I I I 'I' I I I I 6 I 7 I 8
I 2 I 3 I 4 I 5 I 6 I 7 I 8
I RevNo I Revision note NO. SYMBOL. NAME PLATES. NOTE.
INTERFACE BOARD.
A ECMS 850 EH. HARNESS INTERFACE BOARD. A
0 AMP 0. AMP 1 AMP 2. 0

- 00.
DO :;'
010203040506070809101112 131415 161718192021 DO::;
DO ""'
TB 3. DO
DO
B ~;;;;;;;;;;;;;;~ DO
DO
DO B
01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 DO
TB 1 DO
TB 4.
.QQ
~~;;~;;~;;~;;~;;;~;;~;~f;;;;;;;;;;;;;;; .:; 06 .
- C()ljiXIWCOWCOilllll! X1 X2 X3 X4 X5 X6 X7 X8 X9 X10 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
~~ 88 ~
00 <(
:!l DO
ill DO
TB 2 TB 5 '0 DO
; DO
~;;;;;;;;;;;;;;~~;;;;;;;;;;;;;;~
~DO
[ -:!DO [
:DO
61.111.2 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 *.QQ
0 0
ECMS 850 EH.

-r-
DETAILS OF AMP 0 , TB1- TB5.
1. AMF' 0.
0 0
-
2. AMP 0 - AMP 5 : AMP- 3A.
3. TB 1 - TB 5 · WEIDMULLER 3A.
4. RATING OF TERMINAL BLOCK(TB) DC 24V 3A.
E E
- -
F
DESIGNED BY
I.H.YUN I CHECKED BY
LK.PARK
I
APPROVED BY
S.K.WDD
I FILE NAME
DDDSAN
I DATE
2010-JUN-22
I SCALE
N/S F
r---------~~-------L----~------~--------~--------~------~
TITLE
INTERFACE BOARD .
GPC DWG NO.
E02 63 D
l EDITION
0
l SHEET
417
I 2 I 3 ~~~~--~~~~--~
~ ~r--~
1 ~1--~~l~l 6 I 7 I 8
2 3 4 7 8
NAME PLATES. NOTE.
A A
CONNECTION DIAG RAM.
FROr.l ~TTERY CtWiGER
DC 24V INPUT
~182
T.B2 TRJ 1 B< T.B.S
Lao'l_ao'i'"'lao']B05_Ico•£owjc<>p•jco•J IOI_l02_103jO<_105 "1 07 106 109 110 111 111 113 1"1 15 1 116 117 118 119 120 121 122 113 12' "I" "1"1" 30
I I" "1"1" I" I" 1"1"' I" I•• I" .nj•Jju •>I
II I I I I 1 I I I I
B 1
Pl
f-1-
Hl'
51
~I f1 i, cf•
ao1 ao2 eoJ B04 BOS~ow
~ il
l01 J 02 I03_la<_los 06
1°7 100 1"'1"1 11 11
{
1" 114 11' 1 1"1 11 1"1"1"1"1"1"1'' "I" "1"1"
~
30
f
I" " I" I,. I" 1"1" I"' I" I•• " 1•'1'' I" ,, I
B
e;
I;; ~ ~
illillillillill illillillillUd liitiJbJbjtiJ
~ OC24V•
DC 2•V -
E
~
"'"'
~ ~
~
' ~
-·
""""" """"' ""' ""'
'"'
WOO<.
RELAY RATING ; DC24V JA..

""'
SlAIU ST-BY
RUNNINC PA.RALlEUNG MR SP!EO SlOP
.- - .
l~P
.
SlART fNL ~t.(IN
"'AI.ARII.
"""""-
CJW!O[R
CVl OUT
SICIW.
SATIER'!'
CHARC£R
'"'
SP SP
~ ~ ~
SP
\!
~ - .... ..., . ~ ~
-~
( ~ ~
"' ~
"' (
e~~
+ ' + ' ,.t; ,J, .- N N N ~ ~ ~ 0
P2 N2 ~ ECMS 850EH . ~ ~ ~ l l :;1 i ~ :;i l ~ :;i " " li11i11H1 "..: Iii Iii Iii lii"
.... ID .... OC>"'
;; Iii Iii ' ' ' ~ ~ lii
" " " " e; e i!5 i!5
tm Y'l_Y2_L" "'1'1I" 1"1" I» "I" I"' I" I"' I" I" I" 1"1" I" 1671681"1" "I
r~
172173 "1"1" "I" I" I" I" I"' I" I" "'1,.1.,1 .. 1•• 1"' 1
I I
RElAY~. l T.B.~ I
I
p l T
YO Yl ~~
~
Ja><l" I" I" I" "I" I" I•• I" l"oJCOI!Icowcowlco•l
jcot-11:1 lC'2 Ill x• i 19
D
'E
ICR1DIJCR2DIIC1lCI
0 ...,.,.
'"
Sl
,--
CR2
51 51
""r.o
I
]' 151
k I m A
t B
N2
C 0 E r G H J
' l
W ~ P R S T U II W X ' l ~ : o d ' I : : D
s
51
ST
J J J
,._,. :;!__
ro.lB ' [
1 ., ". ~t•
~j" ~u~ 'l
EPB S1
"""'
00W)(1
" s
""'
I~. . AUXIUARY
i l"
WACN£1
SWITCH 1 :!:-~ I '= I=
uu
ro.Tl!.-
1 51 ~
~·-ffi
'"·" r-
E
~ EJ ...,...
[:....
~
JJ, AN
.-
1
[J .;?d BATT£RYCiil.RC£R E
-~
IMCN(TIC P1' 100 OH~ PT 100 OHU r.o. t.EAKAGE
PICK til'
St:NSOR
Ll/8 Ol PI!{SS.
IRANS IIm(R
"'crw rrwP. '"" AIJ,RW SW. '"'"'
S1ARTER
{AlAAt.!)
IALAR•)
LUB.OILTEt.tP
(AlAR• ) '"""'"""
sw.
ENGINE SIDE • MAKER.
DESIGNED BY APPROVED BY SCALE

F ~I_.H_.Y_UN______~----~---LS~.K~.W~O~O~-------L~~~--~~~-=~~~N~/S~--~ f
TITLE
CONNECTION DIAGRAM .
GPC DWG NO.
E02 63 D
SHEET
517
2 3 6 7
3
a
1 1 I
leo• lio2 fao>leoojBM "Jco•JiioMjcmijcDl>(cowj
I I IJ I tall I I I' I ·I
l" I02 foJ ro• los Iot1 101 I08 109 I•o I" 112 I'' I••I " I I" I" I•• I" lzo lz• lzz lzJ I" I'' I" I" I" I" IJO I IJ• IJz I" I'' I'' I,. I" IJ8 I" I" I" I" I•J I" l•sl
11~5 f" l
&TMI ~~~
STOP Sot~ [
.[ .- ::::J
:::':::J
JI I I I I I J II I I :I
B
;I~ i'i'
II Is
T~
il ~ [ ~ B
[ao1 Jooz[eru [ao•[OO>f:o•l [0>[02 oJjo•jD>jot~JD1]08]09]1Djnj_"J"_j"l''l l" l"l" l" l"l" l"l n lz• lzs i21127 1ZB I29 IJO I IJ>IJ2I JJ IJ<I Js iJOIJ71JSIJ91•ol"l •zi•JI.. I••I
~ ~
II ' ' '
~
~
illillillillill
=r =-
~~
ill illltJ l8lli WlUWWW
,... ;I('JT Sl .. sY lfUNJij~Ci f:'41W.L(LIWG. ~~ SP(EO STOP SlAin fAll ~~~~ ., cw.9CER
,...,_
C!JIOlll
~TI(R't
CWM!'
sP SP SP
""- _
c
6~!AY 9~\TI ·~
+
~ h~ i i t.i i ~ ~
I
: Gt:21W
... I
~
;/; .), ~ ~ ~ ~
•
...
a;a
-
~
-
4
f'l
Ill
""
'co
0
!'>I~ ~
Iii Iii IIi Iii ~ ~ M ~
§
- N ~ ~ ~ ~ ~ ~ ~
I~ c
1'1" )o J2 ~ow ••L QONThilL ~ANIL ll ; ::1U!E ~~~ ~
Iii fi ll Iii e e a H m s ; ~ ~ ~
~1 zl • ~ •I ~1 150 I" I" '' l''l " l"l " lsal " 1so 1•• 1"1 " 1'"'1"1" 1" 1.. 1"170 I'• 1"1"1" 1'' 1"1 " 1" 1"1 .. 1" 1"18.11"'1 " 1"1" 1.. 1., Joo J
[NGIN( SlOE CONN(CTION 1.8
~im~~t;j~j
~.
I
~
Q
g I!P~~~
lJ ~m!rf L,$.11 IIQll. [EJ - - ~- - ~ - -~·--
......... ~
·c, x.,
' P,~~- ~gil ~G- oQ ~·-
>~~ ·' C>h t:f
' ( •.N~tiQ~ lfq'a!!~-~
~
y --~ ·~ .
CQ!OI~ ~!!IO~~L
!. QVIiRSREEO TBIP
2. C.F.W. HIGH TEI,IP. Al}J!M.
3. LUB. OIL HIGH TEIJP. ALAR!-!.
4. LUB. OIL LOW PRESS. ALARM.
EMERCENCY SWITCH BOAAO.
5. PICK UP SENSOR FAIL ALARM.
6. START FAIL
SPYCY-50. 7. BATTERY CHARGER FAIL ALARM .
8. F.O. LEAKAGE ALARM.
CONNECnON BY MAKER
9. SPRING STARTER ENGAGE ALARM .
10. SE~SOR FAIL
BA.TIERY CAPACilY : 150AH DESIGNED BY APPROVED BY SCALE

F I.H.YUN S.K.WOO N/S F
nm y AR D CONNECTION DIAGRAM
GPC DWG NO.
E02 63 D
SHEET
617
2 3 6 7
1 I 2 I 3 I 4 I 5 l 6 I 7 I 8
I RevN ol Revision note NO. SYMBOL. NAME PlATES. NOT£.
A A
• MATERIAL LIST AND SPARE.
- r-
1. MATERIAL LIST.
NO. DESCRIPTION. MAKER. PART NO. ADDITIONAL DETAILS.

1. CASE. KMC STEEL. (380X500X200) -
B 2. ECMS 850 EH . KMC - - B
3. POWER SWITCH. FUJI. AR22F5L E4. -
4. - - - -
5. EMERGENCY STOP SWITCH. FUJI. AR22F5L E1. -
6. RELAY BOARD. KMC RB3. -
- 7. INTERFACE BOARD. KMC TBJ-2215 - r-
8. BELL. ILKWANG. BL-60DBMA. -
9. -
10. -
-
c 11.
12. - c
13. -
14. -
15. -
-<E
~ - -
0 2. SPARE PARTS. 0
NO. DESCRIPTION. MAKER . PART NO. DESCRIPTION. QUANTITY.
1. FUSE. LEGRAND. 013310. 2 EA.
lOA. I I!~ II
- -
2. DIODE JOG. 1N5408. 2 EA.
--D--
3. -
E E
- r-
F
DESIGNED BY
J.Y.KIH
CHECKED BY
B.H.LEE
I APPROVED BY
S.K.WOO
I FILE NAME
DOOSAN
I DATE
2010- JUN-22
SCALE
N/S F
TITLE
MATERIAL LIST AND SPAR E.
d7
GPC DWG NO.
EOZ 63 DB I~DITION SHEET
117
1 I 2 I 3 I I I I I T I I I I 6 I 7 I 8
1 I 2 I 3 I 4
t~fir•f. i'ER:<tision note I Date lsignatureJ Checked
77
B
71
I l
+ ALARM & TRIP TABLE + -
DESCRIPTION ALARM TRIP

2
L.OLOW (bar), (kg/ em ) 1.2 [
PRESSURE (kPa) 120
~ ~
C.F.W HIGH TEMP (0C) 102
L.O HIGH TEMP (OC) 120
- 1--
OVER SPEED (RPM) 2016-2070
I-t + -
D
\_4-03 HOLE
1--
1
B£tSI6:11ml ay I CHECKED BY I APPROVED BY I DOOSAN
MODEL I MATERI AL SCALE
F C'JU.ll 11-N C.K.PARK 13/ AUG/2015 AL 1/1 F
\
TITLE
ALARM & TRIP TABLE
j
GPC \ 17
DWG NO.
E03 10 DS EDITION
01
SIZE
A4
t I I I I I I I I I I 4
3 4 5 7
A 200 220 A
B B
c c
D D
0
~
a=~ a=~ NOTE.
0 ~otl
= ~otl
=
1. CASE I STEEL ' PAINT I 7 .5 BG 7/2
0 2. AUTOMATIC BATTERY CHARGER .
E 3. CONTROL PO'w'ER<BA TTERY CHARGER) E
YARD CABLE GLAND. 4. SHOCK ABSORBER.
- AC PO'w'ER SOURCE CABLE : JIS 20B X lEA. 5. EARTH BOLT .
MAKER CABLE GLAND.

- BATTERY CHARGE CABLE: 1 JIS 15c:: X 2EA.
F DESIGNED BY
Y.T,KIM
APPROVED BY
S.K.WDD
SCALE
112
F
TITLE
GPC DWG NO SHEET

112
2 3 6 7
3 4 5 7
Checked
BATTERY CHARGER.
A A
-v +V
BATIERY CHARGER
-v FAIL. ALARM SIGNALS. AUTOMAT IC BATTERY CHARGER.
+V ,...._.±:1.
B+ 8- BATIERY CHARGE~ MODEL BCSMP-240E
AC POWER. CUTOUT SIGNAL. r-
-
r- R - I I
INPUT AC110-240V. 50/60 Hz.
-
,-- T - -
SMPS I BATIERY
OVER VOLT. K3 OUTPUT : DC24V 1DA.
KMC
B - ~~i~ m~ 6r'
IDA ~f4
IDA
A. C. BATIERY CHARGING B
-E POWER. LOW VOLT. CUT OUT K2
IR TIEl
INIL IE I
l l l I PI I
/
I Nl l
1 l Rl Rl Rl r~ Kl
I P2 I N21P3 1N31 l sol s, l s2jsJ!s4 1ss s6 1s7 1ss l m m i AI I A2 1SPI IsP21 I
DISPLAY CABLE.
I
[
(rr ~ ~ I I I 8)(8)(8)(8JI(8JI(8)(8)(8)(8)(8l
LJ JJ I I I I I [
ONNECTION CABLE-
'1_ S/SW IJMD-10.
I~
CONTROL PINER f-J TO. CONTROL PANEL.
[JT-~
IIII IIIII
I 2 e e e e e e e e e e
~~ ~~
Fl SA
F2 SA
~
~
0 AUTOMATI C BATTERY CHARGER 0
l
D.C.W..T.
I
laaBJ OPOVEII )
R T
! ! On.JlloTCIWIG!liG. )
~ 15C 15C D.C.IW.

0 [QUM. CIWIGiliG. )
N
-- 0 IATIERY Lilli va.T. )
laaBJ
::t
0
"'...,c 0 IATIERY liVER VQ.T, )
E :>0 ~ ), 0 IATIERY CMo\R!illr; C1ROJil E1R1R)

E
"'w Rl
I I I
PO\IER DNGJN;IIlll£ lNF T£S:T
>w
~ ::t "'"' +BATTERY :ATTERY
D D D
"' -
u 0..
-
STARTING BATIERY
~ KMC 0
F DESIGNED BY
Y.T.KIH
APPROVED BY
S.K. WOO
SC ALE
N/S
F
TITLE
CONNECTION DIAGRAM.
GPC OWG NO. SHEET
111
2 3 6 7
3 4 5 7
A A
B B
CONNECTION DIAGRAM.
BATIERY SWITCH BOX.
[ I· BATTERY swTCI'l BOX ·I 25C\ 25C

[
1
-~[ }
TO. STARTING 25C _/ L2SC FROM. BATTERY.
MOTOR. BATT. SWITCH
HYUNDAI 225A 2P.
D I· KEFP ON ·I D
E E
*NOTE
1. MATERIAL STEEL 2.3 t

2. I.P. : IP44
F DESIGNED BY APPROV ED BY SC ALE F
3. PAINT COLOR 7.5 BG 7/2. Y.T.KIH S.K.WDD 112
GPC DWG NO SHEET

111
2 3 6 7
2 3 4 7
Checked
A A
I-- -- · · -- -
I- . · - ..
I- . · - ··
·· -- ==
CD
B v B
~~
(IJ
1:== -------- =:!

I- -- · · -- -
[
I-- .
I-- . -- ··
· · -- ·· · == [
~~ (275>
--- =:!
D I I D
565
I 270
315
I
E E
DESiGNED BY- - APPROVED BY SCALE

F Y.T.KIH S.K.\o/00 1:2 F
TITLE
GPC 0\o/G NO. SHEET

111
2 3 6
1 I 2 I 3 I 4
I
~evNo Revision note I Date Si gnat ur~ Chr:t;kerl
A A
TERM I NAL
- L 'W '--
In ,J ~I ~~(QJ·I
I
B :r: B
I-
:r:
- ':--
c NOTE
- -
,(
1 . QUANTITY
0 12 VOLT SYSTEM 1 EA I SHIP
~
~ • 24 VOLT SYSTEM 2 EA I SHIP - r--
2. BATIERY SPECIFICATION
Type Complete Sealed & Maintenance Free

0 Voltage 12 VOLT 0
Container & Cover Material fire retardant ABS
Max. Discharge Current 900 A
Internal Resistance
25"C Full Charge 1.9m0
- r-
10 HR 100 150 200
CAPACITY (AH)
5 HR 92 137 183
L 433 518 518
E Dimension
w 168 268 268
,E
H 202 202 202 '
(mm)
TH 212 212 212 I
Weight (kg) 35 49 65
- Application D
• D It--
DESIGNED BY I CHECKED BY I APPROVED BY I FILE NAME I DATE I N/S

SCALE
F J.Y. Woo B.H.Lee 05 Jan 07 ALL 04 Jan 07 F
TITLE
BATTERY
GPC \ 17
OWG NO.
E10 20 A I EDITION
2
I 1/t
SH£f1
1 I I I I I I I I I 4
3 4 7
Chockod
A A
FROM ESBD
AC 220V, 1~ . 60Hz
120
TICI-2X1 .5 (20a)
_31~
B B
0
@
( ~ (
R TERM INAL BLOCK
D D
COOLANT HEATER THERMOSTAT

(1000\o/o.tt) <OPEN •49•
E NOTE
CLOSE •38•) E
I. TERMINAL ARRANGEMENT ' R, S, G
2. ENCLOSURE PROTECTION ' IP~5
3. CONNECTION DIAGRAM D'JG SHOULD BE ATTACHED INSIDE Of J/B COVER.
DESIGNED BY APPROVED BY SCALE

F B.H.LEE S.K.\<100 N/S F
TITLE
JUNCTION BOX
GPC OWG NO.
E1080D
SHEET
1/1
2 3 6 7
f.)C: CODE
Gfmhae Korea P10
1/1
GPC
Gimhae Korea
CODE
P10 01 D
Standard 5efi<\l.ioe Tool
Na. Name Sketch Size Q'ty Remark
3®'' ~s:· 1
1 Ratchet Handle ~ - ------'!
..- 1'12!' "' 10" 1
J' Flexible Handle _ , 1fl.l' )t' 15" 1

I
31Sl" )(1
4
'
l Socket ·••'- · ·~
-~···
(a, 1~ t:tt, t3mm)
1'/T "'(115, 17 19, 1
5
2G~ 27mm}
3"13' 3.''
)f 1
4 Extension Bar 3.'8!' 6:'
)(I 1
6 ·' 11$2?' )(> 5'' 1
tffZ' XI 1()" 1
-
Combination
5
Wrench
r
... ,... .. ...,. .,, n g, 1·0, 113·, t5, 'f7,
t•9,2~24mm
8
.a Adjustable Wrench -:::_v, 'Jii"• •

i2" 1
7 Driver & )6 '101:} 1

~~ ~-.~
iii)
a Filter Wrench
() l~ 1
g, Snap Ring Plier (- ~.r

---..._._ ~em 1
1£J Tool Box IJI•lt-E1''x.i7" 1

'.
'
:~
, (
:!
.,
l I
!r
~·
' I
GPC
Gimhae Korea
CODE
P10 10 D
Spare Parts for Engine
Quantity
No. Name Sketch Part No. Remark
Working Spare
/Set /Ship
1
Gasket,
Cyl. Head
m .
3 6
65.03901 -
0070A I
GJ
Gasket, 65.03905-
2 3 6
Valve Cover 0022
V-Belt 65.96801-
3 1 2
(2X 13X 1500) 0084
I
4
Cartridge,
Fuel Filter 'I
I ~
~·7 7
'~
/
I 2 4
65.12503-
5025A
Cartridge, - 65.05510-
~~
~)
5 ,I ~ 1 2
Oil Filter ~ ··r / 50228
65.99710-
6 Turning Device 1"'~-n
tcf_-JG 1
0002
Box, Spart Pa rt
L/ ___ ~1
7 (With Locking 1 '
Device)
301204- '
8 Relay 1 1
ll 00009
II.
1
CODE
P10 20 L
Spare Parts for All ~tow. ~._21 M 3)
FIName Sketch
«<uantity
~t~· g,
/Sd
S'paf&
/9rif1
Part No. Remark
r,
v
~~~
'•
' 1< Ball Bearing r t 6315-2RS
) ~
:
;
I
r1
'i
'
' ' 1
\
'I
' !
1! '
'
'
;
1
GPC
Gimhae Korea
CODE
P1031 D
Spare Parts for Electric apparatus.
Quantity
No. Name Sketch Remark
Working Spare
/Set /Ship
2 2 5A
Battery
Charger
Fuse
4 4 10A
Auto
2 2 10A Control
Panel
Auto Control
2 Diode :: 2 1N5408
.~ ~ . ::z::-.::: Panel
3 Fuse Puller ~0~

~~
Spare Part Box

4 With Suitable
Locking Device
1
GPC
www.gpckorea.com
#217 Jinsan-daero,
Tel : 82-55-343-9870
Jinyeong-eup, Gimhae-city,
Fax : 82-55-343-9875
Gyeongnam, Korea
E-mail : gpc@korea.com
2nd STARTER
Spring Starter
Contents
Getting Started 2
The Startwell Starter 3
Your Starter Type 4
Installation 4
Operation 6
Unwinding 6
Slow Engine Cranking 6
Dual Starting Engines 6
Cold Starting 7
Trouble Shooting 7
Position Code Procedure 8
Appendix I Starter Sizes 10

Appendix II Specifications 10
Appendix Ill Parts & Tool List 11
Appendix IV Important Operating
Instructions 13
Appendix V Anticlockwise Starter
Operation 14
Appendix VI Routine Testing of
Startwell Starter 15
1
Startwe/1 Getting Started - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Startwe/1 Getting Started
1ii
.c c:
0
B '2
"'
0:: a:
~ <I) .><! <I)
>
!: ·c: 0 >
u 0
0
....J (§
.., ..."" It) <D
Getting Started
Thank you for purchasing the Startv.lell Mechanical Starter.
The starter should provide you with thousands of maintenance free engine starts. If for any
reason you do experience any problems with your starter please write, or telephone us
directly, contact your local agent who will be happy to resolve your problem or visit our
website for more information at www.startwell.com.
This booklet provides you with all the information you should need to install and operate your
Startv.lell Starter.
Contents of Box
Starter
Winding Handle,
Getting Started Operator's Handbook,
• Operating Instruction Stickers, as required
• Check Card
• Bolts/Nuts/Spacer, as required
....
<I)
>
<I)
Contact Information: >-....J
'0 c.
0 ·c:
!Ill-
Startv.lell Engineering UK Limited
5 Crystal Centre, Crystal Way,
Elmgrove Road, Harrow,
Middlesex, HA 1 2HP
United Kingdom.
Tel: +44 (0)20 8863 4450

Fax: +44 (0)20 8863 441 0
Email: info@startwe/1. com
2 3
Startwe/1 Getting Started - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Startwe/1 Getting Started
Your Starter Type
Replacing the Original Starter:
You can check the starter type from the name plate situated at the top of your Startwell Remove the existing electric, pneumatic or hydraulic starting device, ensuring that you retain
Starter. any spacers already present, unless the starter model that you have already has a spacer
included with it.
Make sure that while removing the old starter you do not disconnect the fuel shut-off valve.
Part Number IPN.l
On some applications there may be an electrical engine shut-off valve. This can either be
This code identifies the
operated by direct supply from the battery or converted to manual shut-off.
starter range, direction
of rotation and finish.
Startwell Design:
You may find when replacing your current starter with the Startwell Starter that there is a
difference between the numbers of teeth on the two pinions. This is a design feature adapted
Serial Number ISN.l
to make a larger body diameter Startwell Starter
This is a unique number
replaces a smaller diameter electric starter. This
identifying your starter. Fig. 1
is achieved by offsetting the spigot and mounting
holes of the starter from its centreline and
increasing the number of teeth to compensate for
N -MINI this.
D - MIDI
DH -HEAVY DUTY MIDI Pre Installation checks:
x-
1
-MAXI The Startwell Starter is designed so that when
sx -SUPER MAXI installed on the engine, in the unwound position,
example:
I
there is between 3 and 5 mm clearance between
SOC 001 1P the pinion face and the flywheel ring gear. To
ensure that the clearance is correct, press the
'check card' (provided) against the ring gear and
s
CIA
XXX
-Siartwell T
-clockwise I anti clockwise--------' T
- starter 10 number for specific engine range------'
tJ ensure the flange mounting face sits in the green
area. (See Fig. 1)
1 -Design c h a n g e - - - - - - - - - - - - - - - - - - - - ' Flywheel Ring Gear

Fig 2
~ } - 'Premium' for adverse condit i o n s - - - - - - - - - - - - - - - - - '
- 'Eco' for normal conditions
Alternative: measure the mounting face to p1mon face
dimension 'X', and the mounting face to ring gear depth 'Y'.
The distance Y-X should be between 3 and 5 mm. (See Fig 2)
Installation Mounting
Final Preparation: Face
CAUTION: Do not attempt to wind and trip the starter unless it is To complete the installation tighten the nuts or bolts
fitted on an engine. The unit will break if it is held in a vice (whichever is appropriate for your application) to the torque
,/
energised and released. The warranty will NOT BE VALID recommended by the engine manufacturer.
The Startwell Starter is easy to install and operate. It requires no special skills or tools. You The starter is assembled so that in the majority of applications
should, however, still read the following step-by-step instructions before fitting or operating the winding handle is in a position suitable for you to wind the
the starter. starter comfortably. If this is not the case the angle of the
winding handle position can be changed to suit your needs.
Rotation: See Position Code Procedure, page.a.
a) The SNC, SOC, SDCH , SXC, SXCH and SSXC starter ranges are designed for anti-
clockwise rotation engines only, viewed from the flywheel end. In other words, the starter
replaces clockwise rotation electrical, pneumatic or hydraulic starters. (See Appendix II).
See Appendix V for modified operation of anticlockwise starter. The Operating Instruction Sticker should be stuck close to the
engine, so that it is clearly visible to the starter operator.
Engine Space:
Check that you have sufficient room on the engine crankcase to fit the starter.
(See Appendix I)
4 5
Startwe/1 Getting Started - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Startwell Getting Started
Operation applies to vehicles fitted with a Stamwll starter that are being 'bump' started e.g. for1<1ifts,
tractors.
1. If the starter is fitted on a tractor or mechanical handling vehicle, such as a fork lift
truck or a loader, ensure that the gearbox is in the neutral position. Cold Starting
2. Ensure that the fuel is turned OFF.
3. Using the winding handle, rotate the winding adaptor until the WHITE spring is When starting at ambient temperatures below o•c, it will be necessary to use some form of
visible in the window. Move the trip lever to the trip position. starting aid. Starting can be achieved through various forms of ether-assisted aids which are
4. The engine will rotate but not start. This will ensure that the starter is operating available in aerosol cans or as auto start kits.
normally. To cold start proceed with normal starting operation. Prior to tripping, spray the ether into the
5. Check the fuel valve is in the 'ON' position and that fuel is reaching the fuel pump. air intake, or if your engine is fitted with an auto start kit inject the ether inside the inlet
6. Adjust the throttle to between 1/2 and 3/4 open. manifold. If the engine fails to start, repeat the whole operation immediately. The engine
7. The trip lever (with the red knob) , of the starter, must be in an upright position. If should now start.
this is not the case, pull the reset knob (black). The trip lever will immediately
spring to its upright position. Trouble Shooting
8. When starting an engine fitted with an in-line pump for the first time, it may be (Components described in this section are illustrated in 'The Stamwll Starter, pg.3)
necessary to press the excess fuel button on the pump.
Operation of your Stamwll Starter should be trouble free, as long as the starter has been
g_ Fit the Cranking handle and wind the handle in a clockwise direction until red or fitted correctly (see installation), and the correct engine and starter operation is adhered to
white springs are visible through the inspection windows (See Appendix II for (see operation). If a problem does occur it is often possible for the operator to identify and
number of turns). With the white spring visible the starter is ready to start a warm correct the situation.
engine. With red springs visible the starter is ready to start a cold engine.
10. To start your engine, push the trip lever down through go•. Faulty Winding Mechanism
11. If the engine does not start repeat the above steps. Your engine will normally start On turning the winding handle two turns in a clockwise direction the winding adapter should
within three attempts. rotate smoothly, thus causing the drive pinion to move forward and engage with the flywheel
ring gear. Further rotation should cause the spring pack to gradually compress as viewed
IMPORTANT: Do not attempt to start the engine with an electric or through the body inspection window.
other starter while the Startwell Starter is wound and engaged
FAULT CAUSE ACTION
Unwinding -Set Trip Lever to Vertical Position Winding adaptor is jammed the bevel pinion is broken The bevel pinion must be
If after fully winding the starter it is necessary to unwind and de-energize it, simply unwind so that cranking handle will and is locking the drive replaced and the drive gear
the crank handle in an anti-clockwise direction. It may be necessary, at first, to exert extra not turn gear rotation checked for damage
force to disengage the clutch. Continue unwinding until green springs are visible through the Shims (part no. 20026) must
the meshing between the
inspection windows. At this point the starter pinion will also retract to its rest position. Winding adaptor's rotation is be added or removed from
bevel pinion and drive gear
'stiff or not-smooth between the rear housing
is too tight
Slow Engine Cranking bearing and the drive gear
Winding adaptor rotates but
The Stamwll Starter can be used to slowly crank an engine, for the adjustment of tappets, The bevel pinion or input
the spring core does not the bevel pinion or the input
pump timing or equipment coupled to your engine. With the red trip lever in the upright shaft must be replaced
compress and the pinion and shaft is broken
(downward for anticlockwise starter) position turn the winding handle clockwise for two turns. core pack does not rotate.
This will engage the pinion with the ring gear. Now trip the lever through go•. The black reset the drive ratchet is broken
knob will pull in and lock the red trip lever in this position. The engine can now be turned Winding the adaptor does Fit new ratchet or circlip as
or the circlip has come
slowly with the winding handle, and any adjustments, to the engine, may be made. Once not cause the spring pack to appropriate
loose
slow cranking is completed you should pull the black reset knob and either fully wind to start compress or the drive pinion
the pinion is jammed on the
the engine (see Operation) or unwind to disengage the pinion (see Unwinding). to move forward to Burring can be removed with
drive shaft due to burring
engagement (the drive a grinding stone or a new
on five start thread or due
Dual Starting Engines (See Appendix IV for important information) pinion does however rotate) drive shaft fitted
to excessive rust
Operation is normal up to Adjust lock to correct height,
Where the engine has the facility to be operated using two starters (electric starter and the
compression of spring pack, the lock height is incorrect using lock height gauge (part
Stamwll starter) , the Startwell starter must have its pinion disengaged from the engine
but starter then discharges no. ST 123A),
flywheel when the alternative starter is being used. The pinion is disengaged by turning the
prematurely before pack is the lock and/or ratchet are
winding handle in an anticlockwise direction, until no further unwinding is possible. This also Replace wom component(s)
fully compressed worn
6 7
Startwe/1 Getting Started - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Startwe/1 Getting Started
Jammed Starter Position Code Table
Code Angle'+' Code A1!9le '.'
FAULT CAUSE ACTION 1A 0 1A 0
28 8.6 6G 8.6
3C 17.1 SF 17.1
The drive shaft or drive nut Set Trip Lever to vertical 40 25.7 4E 25.7
The starter jams during
threads are worn causing position. Turn the Winding 5E 34.2 3D 34.2
compression of the spring
the ball bearings to jam Adaptor anti-clockv.;se, 6F 42.9 2C 42.9
pack or fails to discharge on
between the nut and the until the green spring is 1G 51.4 18 51.4
tripping
shaft visible through the 2A 60 6A 60
v.;ndow. 38 68.6 5G 68.6
4C 77.1 4F 77.1
lEthe starter still cannot be Place the starter in a strong wooden box and contact 50 85.7 3E 85.7
discharged Startwell for further instructions. 6E 94.2 20 94.2
1F 102.9 1C 102.9
2G 111.6 68 11 1.6
WARNING Do not attempt to dismantle a jammed starter as this is extremely
dangerous and requires expert attention. Keep your fingers away from the 3A 120 SA 120
pinion. Only lift the starter by the red trip lever. Contact your local agent. 48 128.6 4G 128.6
5C 137.1 3F 137.1
60 145.7 2E 145.7
Position Code Procedure 1E 154.2 10 154.2
2F 162.9 6C 162.9
The v.;nding handle position relative to the angle of the nosepiece can be rotated through 3G 171.4 58 171.4
360• , in 8.5° steps, to achieve the best v.;nding position. Starters are made to a pre-set 4A 180 4A 180
position in the factory that should be right for your application. If, however, you require an
alternative position follow the steps below:
1. For the factory built position code , refer to outline or Clockwise is '+' angle
general arrangement drav.;ng . Anti-dock is'-' angle
2. For an alternative position code, decide on the angle Datum
between the release lever and input adaptor to suit your line
application (e.g. your selected angle= +10°). ~+
3. Select the nearest position code from the table below (e.g. r---1
8.5°+ =28) .
4. To achieve the selected (28) position code , align the hole
next to the letter '0' at the front end of the body, against
the hole designated '2' on the front housing . Use the
correct through bolt to secure the front mounting bracket,
the housing and the body in this position. (Note: For
starter v.;thout separate mounting bracket secure housing Fig. 4 Fig. 5 Fig. 6
assembly to the body) .
Note: The six through holes on the front housing are designated by numbers 1 to 6
5. Place the rear housing on the body and align the radial clockv.;se, looking from the rear of the housing (fig.6) . The seven radial tapped holes on the
hole '8' against the letter '0' on the body. Secure the body rear housing are designated by letters A to G clockv.;se, looking from the rear of the housing
and the rear housing in this position. (fig.4). On the starter body, only two of the holes at either end are in line. These are marked
Fig. 3 Position v.;th '0' next to each hole (fig 5).
6. Fit the remaining screws and tighten to a torque of 6-8 Code 28
Nm.
8 9
Appendix 1: Starter Sizes Appendix Ill
Parts List
Body diameter, 01
@ 0
D
Maximum rea.r to mountin flan e distance, L
L(mm) D1 (mm) D2(mm)

MINI 259 110 114
MIDI 285 115 118
HEAVY DUTY 285 115 127
MAXI 329 117 130
HEAVY DUTY MAXI 329 133 136
SUPER MAXI 346 133 140.5
Appendix II: Starter Specifications

HEAVY
HEAVY SUPER
Range MINI MIDI MAXI DUTY
DUTY MAXI
MAXI
Clock SNC soc SDCH sxc SXCH ssxc
Model A/Clock SNA SDA SDAH SXA SXAH ssxc
SAE 1, SAE 1, SAE 1, SAE 1, SAE 1,
SAE 1
Mounting Flange SAE2, SAE2, SAE2, SAE2, SAE2, 1. Mounting Flange 18 Input Adaptor 56. Lock Stop
SAE4
SAE3, SAE3, SAE3 SAE3 SAE3 1A. Mounting Bracket 19. Fricticn Washer 57. Release Lever
2. Lock Housing 20. Input Ratchet 58. Lock Nut
Litre I
0.5 1.1 1.3 1.5 2 2.3 3. Body 21 . 1nput Shaft 59. Hand Grip
cylinder 4. Window 22. Thrust Washer 60. Reset Assembly
Capacity Max no. 5. Washer 23. Bush 61 . Gasket
4 6 6 6 6 6 (8) 6. Screw 24. Input Gear 62. Cover Plate
cylinders
7. Rear Housing 25. E.Ciip 63. Spring Washer
Pinion 8. Plug 26.Shlm 46. Swivel Pin 64. Screw 65,66,67,68
123 156 171 171 198 199
Max (Nm) 9. Screw 27. '0' Ring 47. Lock Pin 69. Bellows
Torque Winding 10. Shim 28. Drive Gear 48. Lock 70. Hand Grip
81 87 95 95 102 109 11. Support Plate 29. Drive Spring 49. Bush 71. Rear Plug
(Nm) 12. Nut 30. Drive Ring 72. Distance CoUar
50. Bush
Weight (Kg) 12 16 18 20 22 25 13. Lock Washer 31. Drive Nut 51 . Link Assembly 73. Cranking Handle
14. Stud 32. Ball Bearing 52. Release Shaft 74. Distance Piece
Turns to 15. Catch Spring 33. Cage 53. Return Spring
7.5 10 10 13.5 14 16
fully wind 16. '0' Rings 34. Drive Shaft 54. '(j Ring
17. Catch 35. Cirtlip 55. Lock Washer
10 11
Parts Ustfor Tool Kit Appendix IV: Important Operating Instructions
Part no. Description Storage Mounting
SWT 138/2 Base Plate Feet 1
It has come to our attention that on
SWT 138/1 Base Plate 2 some vessels during regular periodic
SWSH Socket Headed Screw 3 maintenance on the emergency Gen-
SWT 121 Spacer 4 sel, the Startwell stand-by starter types
SXC047 and SXCH047 are being
SWT 138/3 Pillar 5 tested vmen fitted on the storage
SWT 122 Press Tool 6 bracket next to the engine.
SWT 138/4 Pressure Plate 7
This is causing serious internal damage
SWT 138/5 Handle Assembly 8 to the starter and resulting in premature
failure vmen later used on the engine.
SWT 123 Lock Setting Gauge
SWCP1 External Circlip Pliers The starter should NOT be tested on the storage bracket under any
circumstances. The starter may only be operated when properly fitted to the
engine.
Any damage caused by this action will not be covered under warranty.
This bulletin does not apply to starters fitted permanently on any engine.
Instructions for 'Dual -Start Engines'
On engines fitted with dual starting system, such as

electrical and manual starter, the manual starter
must not remain engaged with Flyvmeel vmen starting
with the electric starter. Or vmen the engine starts
automatically with electrical starter (such as on a ships
emergency generator)
To ensure the starter is not engaged, leave the trip-

lever in the trip position vmen the starter is not in use.
This will ensure that the starter pinion is not engaged
with the engine flyvmeel
Failure to follow this action may damage the Starter.

Any damage caused by this action will not be covered
under warranty.
12 13
Appendix V: Anti-clockwise starters Appendix VI: Routine Testing of Startwell Starter
zWI/) ci
z
-z
,_
0 It is important to establish that the p1mon has returned to its rest position (out of
Wen ::> . Engagement) after routine testing has been carried out. See instructions on the right.
~ ffi:5 0 0
. :::l 0 ~=~ ~
zON
.W
~ifz zt-t- Whilst winding, if the engine DOES rotate then please follow the procedure below;
~~i§ ::>~<:5
fn I ~ffi~
Z....JQ-
uw<n ~offi
::t!:CI> ~
6:1~
:.:=t: O!/lz 1. With the 'Trip' lever this time in 'Reset Position' unwind the starter anti-<:lockwise 2-
0 .J~Z
z z:;:-
<CS<:<n ::>zw
U.::>a:
3tums
al iii Iii :::> i8~ 2. The Pinion will retract back to its Rest position (out of Engagement).
-'...Jen tr...J:Z: ~a:~ 3. Once the above steps have been carried out, with the Trip Lever in 'Trip' position,
50:.&! 0 :::JU<n w 0 a: ·
wind the starter clock-wise to ensure the Pinion is disengaged with flywheel ring-
0..~ 1- t-a:Cl .JQ<( ·
wz Zwi-
0 _. tza: :::I(J)(/) gear.
w ::lO.. 4. Rotate the winding handle a few more tums.
e:. O<n w <( (.!) !
(.) zwz 5. Observe that the GREEN spring is rotating and there is no rotational movement of
e>ffia: , the engine crankshaft.
za:o.
Ww(J) 6. If the engine crankshaft rotates, remove the starter from the engine.
:;EIDI 7. Contact Startwell Engineering, supplying full details by email to info@startwell.com
01-!::
h: 0:(/)3
~ u.::>l-
::l ;::en a::Ea:
e:. WI-<(
IMPORTANT NOTICE
0 0
....
J:
1-
a:
~Cit;
<(W(.) IMPORTANT NOTICE
,_u w
...-.. >ui
t>aa:
~
-
~
wz
...;,-
I()
~ffit>
-.....;.. en , (!) After routine testing has been
Q;Z
z a:W OzW carried out with the manual
~ .... :;EWuj starter, the drive pinion must be
:::! 0
J:
u....
w
a: ~~w disengaged from the flywheel
J: a:"(/) ring-gear.
~ en
::l
ow=>
(I)
a. w~o To ensure that the drive pinion
.J<(I- is NOT engaged, the following
f-1-1-
Z(J)o. steps must be taken:
<((.!):E
='Ezw
(J)_I-
crJt
Step 1:
fil
a: B!t!;( Ensure the engine is turned Off
~
a. ::!vi~ 1-(J)I-
a: !zeno OwO
j(U ::l:5t- ZuZ Step2:
we><n ozo Trip Lever
~-~ ~
::l(/J
u..a: !!!~~ 000 must be in •
~~ s:Cl<(
:.:-:.:
II II II 'Trip Position' ~
21;~ ';tl
ww u<nz
>a: 9!f;?
oa:
~
;:EO uenu Step 3:
5tr
·O
~~0 Wind the starter at
;p~
r, "'
0~
mo
~!:..
u<n:x:
oe>~
i=:
:::>
least 5 turns with
the handle.
z~o
...J H:::E
...J
::l
0..
o<nw
z a:
(§ Whilst winding, the
~ engine should NOT
rotate.
14 15
5 Crystal Centre, Crystal Way, Tel: +44 (0}20 8863 4450

Elmgrove Road , Harrow Fax: +44 (0}20 8863 4410
Middlesex, London HA1 2HP Email: info®startwell.com
3856 en · 2011 .01 / h
LSA 46.2-4 POLES

ALTERNATORS
Installation and maintenance
LEROY-SOMER I Installation and maintenance I 3856 en -2011 .01 / h
LSA 46.2-4 POLES

ALTERNATORS
This manual concerns the alternator which you have just purchased.
We wish to draw your attention to the contents of this maintenance manual.
SAFETY MEASURES WARNING SYMBOLS
Before using your machine for the first time, We wish to draw your attention to the
it is important to read the whole of this following 2 safety measures which must be
installation and maintenance manual. complied with :
All necessary operations and interventions a) During operation, do not allow anyone
on this machine must be performed by a to stand in front of the air outlet guards,
qualified technician. in case anything is ejected from them.
Ourtechnical support service will be pleased b) Do not allow children younger than 14
to provide any additional information you to go near the air outlet guards.
may require.
A set of self-adhesive stickers depicting the
The various operations described in this various warning symbols is included with
manual are accompanied by recommenda- this maintenance manual. They should be
tions or symbols to alert the user to the positioned as shown in the drawing below
potential risk of accidents. It is vital that you once the machine has been fully installed.
understand and take notice of the different
warning symbols used.
WARNING
(WARNING) The alternators must not be put into
service until the machines in which they
are to be incorporated have been
Warning symbol for an operation capable declared compliant with Directives EC
of damaging or destroying the machine and plus any other directives that may be
or surrounding equipment. applicable.
Note: LEROY-SOMER reserves the right to

modify the characteristics of its products at
any time in order to incorporate the latest
technological developments. The informa-
Warning symbol for general danger to tion contained in this document may
personnel. therefore be changed without notice.
Copyright 2005 : MOTEURS LEROY-

SOMER
This document is the property of:
MOTEURS LEROY SOMER.
Warning symbol for electrical danger to It may not be reproduced in any form without
personnel. prior authorization.
All brands and models have been registered
and patents applied for.
2
LEROY-SOMER I Installation and maintenance I 3856 en -2011.01/h
LSA 46.2-4 POLES

ALTERNATORS
CONTENTS
1 -RECEIPT .............................................................................................................•.•.•.....•.••. 4
1.1 -Standards and safety measures .... .. .. ..... ...... ........................ ..... .................. ........... ...... 4
1.2 -lnspection ........... ..... ....... .... ..... ... ..... .... ........ ... ... .... ... ....... ... ................... ... ............ ........ 4
1.3 - Identification ........................ .. ................ ........ ...... .... ....... ..... .... ... ........ .......................... 4
1.4- Storage ..... ........ .. ...... ..... ............. .... ....... ... ... .... .... ......... ...... ... ............ .......................... 4
1.5- Applications ........... ....... ... ........................... ....... ..... ....... .......................... ..................... 4
1.6- Contraindications to use .......... ..... ................................... .. .. ........ ..... .............. .. ......... ... 4
2- TECHNICAL CHARACTERISTICS ........................................••.....•.•..•............................... 5

2.1 - Electrical characteristics ........ .... .... ........................... ..... ........ .... ......... ............ .............. 5
2.2- Mechanical characteristics ... ... ....... ... ............. .... .... ... .. ... ... ........... .............................. .. 5
3 -INSTALLATION ..............................................•................................................................... &

3.1 -Assembly ....... .. ................. ... ............... .... .. ... ....... ....... .... ..... ... ... .... .. .... ...... ... ..... .......... .. 6
3.2- Checks prior to first use ....... ........ .. ...... .... ............. ....... .... .... .. ..... ........... ....................... 7
3.3- Terminal connection diagrams ....... ........... ... ..... ....... .......... .. ........... ... .. ... .... .................. 7
3.4- Commissioning ................................ .......................................................................... 10
3.5- Setting up ............ .. .............................. .. ......... .. .... .................. .. .................................. 10
4- SERVICING - MAINTENANCE .............................................................................•..•...•.•.. 11

4.1 -Safety measures ... ..... ........ ... ....................................... ... ...... ..... ...... .............. ... .. .. ..... 11
4.2 - Routine maintenance ................ ..................... .. .. ..... ...... ..... ........... ............................. 11
4.3- Fault detection ...... .... ........ ... ............................ .......... .. .... ........ ... .. ........ .. .................... 11
4.4- Mechanical defects ................ ....... .................................. ....... ...... ..... ..... ....... .... ......... 12
4.5 - Electrical faults ........ .... ....... .... .. .. .... ............ ............................................... ................. 12
4.6- Dismantling, reassembly .......... ............................... ....... ...... ..... ........ ........ ..... ...... ...... 14
4. 7- Installation and maintenance of the PMG .. ........ .... ...... .... .... ... ... ....... ................. ... ...... 16
4.8- Table of characteristics ...... ........... .... .. ......... ... ...... .. .... ....... ....................... ..... ... .......... 17
5 -SPARE PARTS ...............................................................................•....•.......•......••....•....... 18

5.1 - First maintenance parts ................... ............... ...... ..... ..... ....... .... ...... ... ........... .......... ... 18
5.2- Technical support service ... .... .. ... ...... ..... .. ............ ........ ... .... ..... ... ............................... 18
5.3 -Accessories ...... ..................... ........... .. ... .............. ... ........ ... .... .. ......... ... ........ ...... ..... .... 18
5.4 - Exploded views, parts list and tightening torque ...... ... ... ..... ... ... .. ...... ....... ....... ... ........ . 19
EC declaration of incorporation ....................................................•........................•........... 22
3
LEROY-SOMER I Installation and maintenance ] 3856 en -2011 .0 11 h
LSA 46.2 - 4 POLES

ALTERNATORS
1-RECEIPT • C : excitation system
(C : AREP I J : SHUNT or PMG)
1.1 -Standards and safety • 614 : winding number I number of poles.
measures
Our alternators comply with most 1.3.1 -Nameplate
international standards. So that you can identify your machine
See the EC Declaration of Incorporation on quickly and accurately, we suggest you
the last page. write its specifications on the nameplate
below.
1.2 -Inspection
On receipt of your alternator, check that it 1.4- Storage
has not suffered any damage in transit. If Prior to commissioning , machines should
there are obvious signs of knocks , contact be stored :
the transporter (you may be able to claim - A"'!ay from humidity(< 90%); after a long
on their insurance) and after a visual penod of storage, check the machine
check, turn the machine by hand to detect insulation (section 3.2.1). To prevent the
any malfunction. bearings from becoming marked, do not
store in an environment with significant
1.3 -Identification vibration.
The alternator is identified by means of a 1.5 -Application
nameplate fixed on the machine (see
These alternators are mainly designed to
drawing).
Make sure that the nameplate on the produce electricity in the context of
applications involving the use of
machine conforms to your order.
The machine name is defined according to generators.
various criteria , for example :
1.6 - Contraindications to use
LSA 46.2 MS C614-
• LSA: name used in the PARTNER range Use ofthe machine is restricted to operating
M : Marine conditions (environment, speed, voltage,
C : Cogeneration power, etc) compatible with the characteri-
T : Telecommunications stics indicated on the nameplate.
• 46.2 : machine type
• MS : model
LEROY-SOMER I Installation and maintenance J 3656 en -201 1.01/h
LSA 46.2 - 4 POLES

ALTERNATORS
2- TECHNICAL CHARACTERISTICS 2.2 - Mechanical characteristics
1.1 -Electrical characteristics - Steel frame
-Cast iron end shields
The LSA 46.2 alternator is a machine
- Protected ball bearings, greased for life
without sliprings or revolving armature
- Mounting arrangements:
brushes, wound as "2/3 pitch", 6 or 12-
IM 1201 (MD 35) foot and flange mounted,
wire, with class H insulation and a field
single-bearing with SAE coupling disc.
excitation system available in either
IM 1001 (B 34) double-bearing with SAE
SHUNT, AREP or «PMG» version (see
flange and standard cylindrical shaft
diagrams and AVR manuals).
extension.
2.1.1- Electrical options - Drip-proof machine, self-cooled
-Stator temperature detection sensors - Degree of protection: IP 23
- Bearing sensors (PTC, PT100, etc)
- Space heater 2.1.1 -Mechanical options
Interference suppression conforms to - Air inlet filter
standard EN 55011, group 1, class B - Regreasable ball bearings
(Europe). - IP 44 protection
MAIN FIELD STATOR : 12-v.ire (mat1<ing T1 toT 12)

(sHUNT SYSTEM
T1 T7 T2 TB T3 T9
EXCITER
l•_- F
=eI:ld__
1=~*~~~~~~~~~~
.. 1 ==tliiii~~
i ;if1.' T4~T10
: T5 T11 T6 T12
Power supply I Del eclion
MAIN FIELD STATOR : 6 or 12-wire (mar1<ing T1 toT 12)

( AREP SYSTEM
T1 7 T2 TB T3 T9
EXCITER
T4 T10 T5 T1 1 T6 T12
Voltage reference
MAIN FIELD STATOR : 6or 12-wire (mar1<ing T 1 to T 12)

( PMGSYSTEM
T2 TB T3 T9
EXCITER
T5 T11 T6 T12
Voltage reference
5
LEROY-SOMER I Installation and maintenance I 3856 en -2011.01/ h
LSA 46.2 - 4 POLES

ALTERNATORS
3 -INSTALLATION 3.1.2 - Coupling
Personnel undertaking the various 3.1.2.1 -Single-bearing alternator
operations indicated in this section must Before coupling the machines, check that
wear personal protective equipment they are compatible by:
appropriate for mechanical and electri- - undertaking a torsional analysis of the
cal hazards. transmission ,
- checking the dimensions of the flywheel
3.1 -Assembly and its housing, the flange, coupling discs
and offset.
(WARNING)
When coupling the alternator to the
All mechanical handling operations prime mover, do not use the fan to turn
must be undertaken using suitable the alternator or rotor.
equipment and the machine must be The holes of the coupling discs should
horizontal. Check how much the machine be aligned with the flywheel holes by
weighs (see 4.8.3.) before choosing the cranking the engine.
lifting tool. Make sure the alternator is securely
bedded in position during coupling.
3.1.1 -Handling Check that there is lateral play on the
crankshaft.
The generously-sized lifting rings are for
handling the alternator alone. They must not 3.1.2.2 -Double-bearing alternator
be used to lift the genset. The choice of - Semi-flexible coupling
lifting hooks or handles should be determined Careful alignment of the machines is
by the shape ofthese rings. Choose a lifting recommended, checking that the lack of
system which respects the integrity and the concentricity and parallelism of both parts
environment of the alternators. ofthe coupling do not exceed 0.1 mm.
This alternator has been balanced with a
1/2 key.
3.1.3 -Location
The room where the alternator is placed
must be ventilated to ensure that the
ambient temperature cannot exceed the
data on the nameplate.
3.2- Checks prior to first use

3.2.1 -Electrical checks
During this operation, do not allow Under no circumstances should an

anyone to stand under the load. alternator, new or otherwise, be operated
if the insulation is less than 1 megohm
for the stator and 100,000 ohms for the
other windings.
6
LEROY-SOMER I Installation and maintenance J 3856 en -2011.011h
LSA 46.2 - 4 POLES

ALTERNATORS
There are 2 possible methods for restoring - the standard direction of rotation is clock-
the above minimum values. wise as seen from the shaft end (phase
a) Dry out the machine for 24 hours in a rotation in order 1 - 2- 3).
drying oven at a temperature of 110 •c For anti-clockwise rotation, swap 2 and 3.
(without the regulator). -the winding connection corresponds to the
b) Blow hot air into the air intake, having site operating voltage (see section 3.3).
made sure that the machine is rotating with
the exciter field disconnected. 3.3- Terminal connection diagrams
Note: Prolonged standstill: In order to avoid
these problems, we recommend the use of To modify the connection, change the
space heaters, as well as turning over the position ofthe stator cables on the terminals.
machine from time to time. Space heaters The winding code is specified on the
are only really effective if they are working nameplate.
continuously while the machine is stopped. 3.3.1 -Terminal connection: 12 wire
(WARNING) The connection accessories are detailed in
section 5.3.3.
Ensure that the alternator has the
degree of protection matching the
defined environmental conditions.
3.2.2- Mechanical checks
Before starting the machine for the first time,
check that: Any intervention on the alternator
- all fixing bolts and screws are tight. terminals during reconnection or checks
-the cooling air is drawn in freely. should be performed with the machine
-the protective grilles and housing are cor- stopped.
rectly in place.
Connection codes Voltage L.L Factory connection
Winding 50 Hz 60Hz
6 190-208 190-240 L3(W)
N
7 220
L2(V)
8 190-208
L1(U)
R 250 voHage detection :
ffi.
0 => (TB) I 110 V => (T11)
~ R 450 voHage detection :
0 => (T3) I 220 V => (T2)
T1 L1(U) Winding 50 Hz 60Hz

@ 6 380-415 380-480
3-phase H
n 7 440
N
8 380-416
R 250 voHage detection :
0 => (TB) I 110 V => (T11)
T2 & R 450 voHage detection :
0 => (T3) I 380 V => (T2)
L3(W) L2(V)
9 500
li\ In case of reconnection, ensure that AVR voltage detection is correct I

£.U The factory can supply a set of flexible shunts and special connection links as an option for making these connections. (').
7
LEROY-SOMER I Installation and maintenance I 3856 en -2011 .01/h
LSA 46.2 - 4 POLES

ALTERNATORS

Winding 50 Hz 60 Hz
1 phase 6 220 - 240 220 - 240
7 240-254
8 220-240
R 250 voltage detection :
L L 0 => (T4) I 110 V => (T1)
Vobge LM • 1/2 vobge LL 0 => (T10) I 220 V => (T1)
Winding 50 Hz 60Hz
® 6 220 - 240 220 - 240
1 phase
or 7 240-254
3-phase
8 220-240
T10
L2M 0 =>(T8) 1110V=>(T11)
L R 450 voHage detection :
0 => (T3) I 220 V => (T2)
Voltage LM • 112 voltage U Operati ng phase s L2 M . L3 (W) single phase
Winding 50 Hz 60Hz
@
6 220 - 240 220 - 240
1 PH L3(W)
7 250-260
L2(V)
8 200 220- 240
L R 250 voHage detection :

0 => (T8) I 110 V => (T11)
0 => (T3) I 220 V => (T2)
Vobge LM • 1/2 vokage LL
Rl. In case of reconnection, ensure that AVR voltage detection is correct !

ill The factory can supply a set of flexible shunts and special connection links as an option for making these connections. (•).
8
LEROY-SOMER I Installation and maintenance j 3856 en -2011.011 h
LSA 46.2 - 4 POLES

ALTERNATORS
3.3.2- Terminal connection: 6 wire (not possible with the R 250)
@ L1(U) Vvlnding 50 Hz 60Hz

T1 L3(W)
3-phase 68 3BO- 415 3BO- 4BO
78 440 L2M
H N 88 3BO- 416
L1(U)
T2
& R 450 voHage detection :
0 => (T3) I 380 V => (T2)
N
Vvlnding 9 : R 450 voltage detection

L3(W) L2(V) 98 + transformer (See specific diagram)
Vvlnding 50 Hz 60Hz
®
1 phase or 3-phase
L1(U)
68 220-240 220 - 277
(*)
L3(W)
78 240-254 L2M
88 220-240
L1(U)
Ji\ R 450 voltage detection :

~ 0 => (T3) I 220 V => (T2)
L3(W) L2(V) Operating phases : L2 (V), L3 (W) single phase
In case of reconnection , ensure that the AVR voltage detection is correct I
The factory can supply a set of flexible shunts and special connection links as an option for making these connections. (*).
3.3.3- Option connection diagram

R 791 T interference suppression kit (standard forCE marking) Remote voltage potentiometer
Connections
0@0 lu ll II
Jy
··~ ·~~~~
Black --~·T2 T2 T2
Black --~.T3 T3 T3
Blue .._f- N N -4-
White . - ' - ...,!,.. ...,!,.. ...,!,..
I
,...
~
I ST4
Voltage aqustment
via remote potentiometer
__ Current transformer connection (optional)
, _~,
In - Secondary 1 A
~" '
P1 6-wire
Coupling D & f'o.. PH 1
In - Secondary 1A (coupl. D)
~no 12-wire
Neutral Neutra l
link link
Anti condensation heater Thermistor (PTC) temperature
: 102
I 250W- 220 v I I
~ ~~~ g::; Ph3
130 C blue wire
150C black wire
180 C red/White wire
9
LEROY-SOMER I Installation and maintenance J 3856 en - 2011.01/ h
LSA 46.2 - 4 POLES

ALTERNATORS
3.3.4 -Connection checks 3.4- Commissioning
Electrical installations must comply with The machine can only be started up and
the current legislation in force in the used if the installation is in accordance
country of use. with the regulations and instructions
Check that: defined in this manual.
- The residual circuit-breaker conforms to The machine is tested and set up at the
legislation on protection of personnel, in factory. When first used with no load, make
force in the country of use, and has been sure that the drive speed is correct and
correctly installed on the alternator power stable (see the nameplate). With the
output as close as possible to the alternator. regreasable bearing option, we recommend
(In this case, disconnect the wire of the greasing the bearings at the time of
interference suppression module linking the commissioning (see 4.2.2).
neutral). On application of the load, the machine
-Any protection devices in place have not should achieve its rated speed and voltage;
been tripped. however, in the event of abnormal operation,
-lfthere is an externaiAVR, the connections the machine setting can be altered (follow
between the alternator and the cabinet are the adjustment procedure in section 3.5). If
made in accordance with the connection the machine still operates incorrectly, the
diagram. cause of the malfunction must be located
- There is no short-circuit phase-phase or (see section 4.4).
phase-neutral between the alternator output
terminals and the generator set control 3.5- Setting up
cabinet (part of the circuit not protected by
circuitbreakers or relays in the cabinet) .
-The machine should be connected with the
busbar separating the terminals as shown in
the terminal connection diagram.
The various adjustments during tests
must be made by a qualified engineer.
Ensure that the drive speed specified on
the nameplate is reached before
commencing adjustment
After operational testing, replace all
access panels or covers.
TheAVR is used to make any adjustments
to the machine.
10
LSA 46.2 - 4 POLES

ALTERNATORS
4- SERVICING - MAINTENANCE 4.2.3 - Electrical servicing
4.1 -Safety measures Commercially-available volatile degreasing
Servicing or troubleshooting must be agents can be used.
carried out strictly in accordance with (,_W_'A_R_N_IN_G_J
instructions so as to avoid the risk of
accidents and to maintain the machine in
its original state. Do not use: trichlorethylene, perchlo-
rethylene, trichloroethane or any alkaline
A\
products.
All such operations performed on the

alternator should be undertaken by These operations must be performed at a
personnel trained in the commissioning, cleaning station, equipped with a
servicing and maintenance of electrical vacuum system that collects and flushes
and mechanical components, who must out the products used.
wear personal protective equipment The insulating components and the
appropriate for mechanical and electrical impregnation system are not at risk of
hazards. damage from solvents. Avoid letting the
Before any intervention on the machine, cleaning product run into the slots.
ensure that it cannot be started by a manual Apply the product with a brush, sponging
or automatic system and that you have frequently to avoid accumulation in the
understood the operating principles of the housing. Dry the winding with a dry cloth . Let
system. any traces evaporate before reassembling
4.2- Routine maintenance the machine.
4.2.1 -Checks after start-up 4.2.4 - Mechanical servicing
After approximately 20 hours of operation,
check that all fixing screws on the machine (wARNING)
are still tight, plus the general state of the
machine and the various electrical Cleaning the machine using water or a
connections in the installation. highpressure washer is strictly prohi-
bited. Any problems arising from such
4.2.2 - Bearings treatment are not covered by our
As standard, the alternator is fitted with warranty.
permanently greased bearings. As e3:n Degreasing: Use a brush and detergent
option, they may be regreasable. It IS (suitable for paintwork).
advisable to lubricate the alternator during Dusting: Use an air gun.
operation. Time intervals and quantity of If the machine is fitted with air inlet and outlet
grease are given in the table below. filters, the maintenance personnel should
clean them routinely at regular intervals. In
NDE/DE bearing 6316 C3 6315 C3 the case of dry dust, the filter can be cleaned
Quantity of Qrease 33g 30Q using compressed air and/or replaced if it is
Regreasinq interval 4000 H 4500 H clogged .
After cleaning the alternator, it is essential to
Lubrication intervals are given for grease check the winding insulation (see sections
type: LITHIUM - standard - NLGI 3. 3.2 and 4.8).
In the factory, the grease used for lubrication
4.3 - Fault detection
is: ESSO - Unirex N3.
Before using another grease, check for If, when commissioned, the alternator does
compatibility with the original one. Monitor not work normally, the source of the
malfunction must be identified (see sections
the temperature rise in the bearings (see
4.4 and 4.5).
section 4.4).
11
LEROY-SOMER I Installation and maintenance I 3856 en - 2011 .01/h
LSA 46.2 - 4 POLES

ALTERNATORS
4.4- Mechanical defects
Fault Action
Excessive temperature rise in one or - If the bearing has turned blue or ~the grease has turned black, change the bearing
both bearings (bearing temperature more -Bearing not fully locked (abnonnal play in the bearing cage)
Bearing
than 80 ' C) with or without abnormal - Check the end shield alignment (flange not properly fitted)
bearing noise
-Air flow (intake-outlet) partially clogged or hot air is being recycled from the alternator
Excessive temperature rise in the
Abnormal or engine
alternator housing (more than 40' C
temperature -Alternator operating at too high a voltage (> 105% of Un on load)
above the ambient temperature)
-Alternator overloaded
- Misalignment (coupling)
Excessive vibration - Defective mounting or play in coupling
Vibration - Rotor balancing fault (Engine- Alternator)
Excessive vibration and humming noise -Phase imbalance
coming from the machine -Stator short-circuit
-System short-circuit
- Mis-paralleling
Possible consequences:
Alternator damaged by a significant
Abnormal -Broken or damaged coupling
impact, followed by humming and
noise -Broken or bent shaft extension
vibration
-Shifting and short-circuit of revolving field winding
-Fan fractured or coming loose on shaft
- Irreparable damageto rotating diodes, AVR, surge suppressor
4.5- Electrical faults

Fault Action Effect Check/Cause
The alternator builds up and its
voltage is still correct when -Lack of residual magnetism
Connect a new battery the battery is removed
No voltage of 4 to 12 volts to The alternator builds up but its voltage -Check the connection of the voltage reference to the AVR
at no load on terminals E- and E+, does not reach the rated value when -Faulty diodes
start-up respecting the polarity, the battery is removed -Armature short-circuit
for 2to 3 seconds The alternator builds up but its - FaultyAVR
voltage disappears when the battery -Field windings open circuit (check winding)
is removed -Revolving field coil open circuit (check the resistance)
Check the AVR connections (AVR may be faulty)
-Field windings short-circuited
Correct speed -Rotating diodes burnt out
Voltage too -Revolving field coil short-circuited
Check the drive speed
low -Check the resistance
Increase the drive speed (do not touch the AVR voltage pol (P2)
Speed too low
before running at the correct speed)
Voltage too AdjustAVR voltage Adjustment ineffective FaultyAVR
high potentiometer
-Check the speed: possibility of cyclic irregularity
Adjust the
Vottage If no effect: tiy normal or fast stability - Loose connections
AVR stability -FaultyAVR
oscillations modes (ST2)
potentiometer -Speed too low when on load (or AVR LAM set too high)
Vottage Voltage between E+ and E- (DC)
Run at no load and -Check the speed (or AVR LAM set too high)
correct at no SHUNT /AREP/PMG< 10V
check the voltage
load and too - Faulty rotating diodes
between E+ and E-on Voltage between E+ and E-
low when on -Short-circuit in the revolving field coil. Check the resistance.
theAVR SHUNT /AREP/PMG> 15V
load - Faulty exciter armature. Check the resistance.
Check the AVR, the -Exciter winding open circuit
Voltage surge suppressor,
disappears The voltage does not return to the -Faulty exciter armature
the rotating diodes, and -FaultyAVR
during rated value
replace any defective - Revolving field coil open circuit or short-circuited
operation
components
12
LEROY-SOMER J Installation and maintenance 1 3656 en -2011.01/h
LSA 46.2 - 4 POLES

ALTERNATORS
4.5.1 -Checking the winding Assembly A: Connect a 12 V battery in
You can check the winding insulation by series with a rheostat of approximately
performing a high voltage test. In this case, 50 ohms- 300 Wand a diode on both exciter
you must disconnect all AVR wires. field wires (5+) and (6-).
(WARNING)
Damage caused to the AVR in such
conditions is not covered by our
warranty.
4.5.2 ·Checking the diode bridge

A diode in good working order should allow
the current to flow only in the anode-to-
cathode direction. Assembly 8: Connect a "Variac" variable
A C power supply and a diode bridge on both
Anod e e ~~ e Cathode exciter field wires (5+) and (6-).
c c c Both these systems should have
characteristics which are compatible with
the field excitation power of the machine
(see the nameplate).
3) Run the unit at its rated speed.
4) Gradually increase the exciter field
current by adjusting the rheostat or the
variac and measure the output voltages on
L1 - L2 - L3, checking the excitation voltage
and current at no load (see the machine
nameplate or ask for the factory test report).
When the output voltage is at its rated value
and balanced within 1% for the rated
4.5.3 ·Checking the windings and excitation level, the machine is in good
rotating diodes using separate working order. The fault therefore comes
excitation from the AVR or its associated wiring (ie.
sensing, auxiliary windings) .
ASSEMBLY B
During this procedure, make sure that

the alternator is disconnected from any
external load and inspect the terminal
box to check that the connections are
fully tightened. Variac
1) Stop the unit, disconnect and isolate the

AVRwires.
2) There are two ways of creating an
assembly with separate excitation.
13
LEROY-SOMER I Installation and maintenance I 3856 en -2011 .01 / h
LSA 46.2 - 4 POLES

ALTERNATORS
4.6 -Dismantling, reassembly 4.6.4- Access to connections and the
(see sections 5.4.1. & 5.4.2.) regulation system
Access directly by removing the top of the
(WARNING) cover (48) ortheAVR access door (466).
During the warranty period, this 4.6.5 - Replacing the NDE bearing
operation should only be carried out in
- Remove the box lid (48) and the NDE panel
an LEROY-SOMER approved workshop
or in our factory, otherwise the warranty (365) and remove the 2 screws from the part
(122).
may be invalidated.
- Disconnect the stator outputs (T1 to T12).
Whilst being handled, the machine
- Disconnect the auxiliary winding wires
should remain horizontal (rotor not
AREP (X1 ,X2,Z1 ,Z2).
locked in position). Check how much the
- Disconnect the exciter wires (5+ ,6-).
machine weighs (see 4.8.3) before
- Remove the air inlet louvre (51).
choosing the lifting method.
If using a single-bearing or double-bearing
machine with the regreasable bearing
option:
- Remove the bearing (78) thrust screws
(72) .
- Remove all4 screws (37).
- Remove the shield (36).
-Take out the antifriction bearing (70) using
a puller with a central screw (see drawing
below).
4.6.1 -Tools required

To fully dismantle the machine, we
recommend using the tools listed below:
- 1 ratchet spanner+ extension
- 1 torque wrench
- 1 setofflatspanners:8mm , 10mm, 18mm
-1 socketset:8, 10, 13, 16, 18,21 , 24, 30mm - Fit the new antifriction bearing onto the
- 1 socket with male ferrule: 5 mm shaft after heating it by induction to
- 1 puller approximately 80 ·c.
- Mount the new preloading (wavy) washer
4.6.2 -Screw tightening torque (79) + the new "0 " ring seal (349) in the
See section 5.4. shield (36) and coat the bearing seat with
adhesive paste (see After Sales Service).
If using a single-bearing or double-bearing
4.6.3 -Access to diodes
machine with the regreasable bearing
-Open the air intake grille (51). option :
- Disconnect the diodes. - Screw a threaded rod into the thrust
- Check the 6 diodes, change the diode bearing (78).
bridges if necessary. - Refit the end shield on the machine using
a dowel and nut in the shaft extension (see
drawing).
14
LSA 46.2 - 4 POLES

ALT.ERNATORS
- Slide the threaded rod into the shield hole - Slide the threaded rod into the shield hole
to make it easier to assemble (see basic to make it easier to assemble (see basic
diagram). diagram).
- Tighten the bottom thrust bearing screws
4 78 36
Threaded rod
(78), remove the threaded rod and fit the
other screws.
I -Tighten the 6 shield screws (31).
-Refit the air outlet grille (33).
4.6.7- Dismantling the rotor assembly

- Remove the NDE shield (36) as described
in section 4.6.5.
- Remove the DE shield (30) as described
in section 4.6.6 if it is a double-bearing
machine.
-Support the DE rotor (4) with a strap or with
a support constructed in accordance with
the following drawing.
-Move the strap as the rotor moves in order
to distribute the weight over it.
- Fit the thrust bearing screws (78), remove
the threaded rod, fit the other screw and
tighten up the assembly.
-Tighten the 4 bearing screws (37).
- Reconnect wires.
-Fit the 2 support screws (122).
- Fit the air inlet louvre (51).
- Replace the cover.
(WARNING)
When dismantling the shields, you will
need to change the antifriction bearings,
the "0" ring seal, the preloading (wavy)
washer and adhesive paste.
4.6.6- Replacing the DE bearing

-Remove the air outlet grille (33).
- Remove the 6 screws (31) from the DE
shield and the 3 screws (62) from the inner When dismantling the rotor involves
bearing retainer. changing parts or rewinding, the rotor
-Remove the shield (30). must be rebalanced.
-Take out the ball bearing (60) using a puller
with a central screw (see section 4.6.5). 4.6.8- Reassembling the machine
- Fit the new bearing, after heating it by
induction to approximately 80 ·c. - Mount the rotor (4) in the stator (1) (see
- Screw a threaded rod into the thrust drawing above) taking care not to knock the
bearing (68). windings.
-Refit the shield (30) on the machine.
15
LEROY-SOMER I Installation and maintenance I 3856 en - 2011 .01/ h
LSA 46.2 - 4 POLES

ALTERNATORS
If using a single-bearing or double-bearing To replace, follow the instructions in reverse
machine with the regreasable bearing order.
option:
(79) + the new "0" ring seal (349) in the
shield (36).
- Screw a threaded rod into the thrust
bearing (78).
- Refit the shield (36) on the machine using
diagram).
-Slide the threaded rod into the shield hole
to make it easier to assemble (see diagram).
- Fit the thrust bearing screws (78), remove
the threaded rod , fit the other screw and
-Tighten the 4 bearing screws (37).
-Reconnect exciter wires E+, E-.
- Finish reassembling the cover.
-Refit the flange (30) on the stator (1).
- Tighten the screws (31).
If using a double-bearing machine:
(79) + the new "0" ring seal (349) in the 4.7 - Installation and maintenance of
shield (36). the PMG
- Refit the shield (36) on the machine using For the LSA 46.2, the PMG reference is:
PMG2.
diagram). See the PMG manual ref : 4211 .
- Tighten the 4 shield screws (37).
- Reconnect exciter wires E+, E-.
- Finish reassembling the cover.
- Screw a threaded rod into the thrust
bearing (68) .
- Refit the shield (30) on the machine.
- Slide the threaded rod into the shield hole
to make it easier to assemble (see basic
diagram).
- Fit the thrust bearing screws (68) , remove
the threaded rod, fit the other screw and
-Tighten the 6 shield screws (31) .
- Refit the air outlet grille (33).
- Check that the machine assembly is
correctly mounted and that all screws are
tightened.
4.6.9- Dismantling and reassembly of
the filters
- Remove the grille (417) then take out the
filter (418). Change the filter if necessary;
please refer to section 4.2.5 for cleaning the
filter.
16
LEROY-SOMER I Installation and maintenance I 3856 en - 201 1.01/h
LSA 46.2 - 4 POLES

ALTERNATORS
4.8 -Table of characteristics 4.8.2 -Voltage of auxiliary windings at
Table of average values no load
Alternator - 4 poles - 50 Hz - Standard
winding No. 6. LSA46.2 Auxil wdg : X1 , X2 Auxil wdg : Z1 , Z2
(400V for the excitation values)
The voltage and current values are given for 50 Hz 70V 10V
no-load operation and operation at rated 60Hz 85V 12V
load with separate field excitation .
All values are given to within ± 10% and may
be changed without prior notification (for 4.8.3- Table of weights
exact values, consult the test report). (values given for information only)
4.8.1 - LSA46.2 average values LSA46.2 Total weight (kg) Rotor (kg)
Resistances at 20 •c (0) M3 600 250
LSA46.2 Stator LIN Rotor Field Armature M5 700 260
M3 0.022 0.23 8.8 0.035 L6 800 290

M5 0.0182 0.24 8.8 0.035 L9 850 320
L6 0.0148 0.264 8.8 0.035 VL12 1000 380
L9 0.01 2 0.295 8.8 0.035
VL12 0.0085 0.343 10 0.037
Resistance of AREP auxiliary windings

at20 •c (O)
LSA46.2 Auxil wdg : X1 , X2 Au xil wdg: Z1 , Z2

M3 0.24 0.4
After operational testing, it is essential to
M5 0.215 0.36
replace all access panels or covers.
L6 0.185 0.36
L9 0.19 0.32
VL12 0.17 0.32
Field excitation current i exc (A)

Symbols : "i exc": excitation current of the
exciter field
LSA46.2 No load At rated load

M3 1.1 4
M5 1.1 3.8
L6 1.1 4.1
L9 1.2 4
VL12 1.1 3.5
For 60 Hz machines, the "i exc" values are

approximately 5 to 10 % lower.
17
LEROY-SOMER I Installation and maintenance I 3856 en -2011 .01/ h
LSA 46.2 - 4 POLES

ALTERNATORS
5- SPARE PARTS In the event of failure to comply with this
5.1 -First maintenance parts advice, the manufacturer cannot be held
responsible for any damage.
Emergency repair kits are available as an
option.
They contain the following items: 5.3 -Accessories
5.3.1 - Space heater for use when
Emergency kit SHUNT ALT 472 KS 001 stopped
AVR R 250 - The space heater must run as soon as the
Diode bridge assembly - alternator stops. It is installed at the rear of
Surge suppressor - the machine. Its standard power is 250W
Emergency kit AREP ALT 461 KS 001 with 220V or 250W with 11 OV on request.
AVRR450 -
Diode bridge assembly -
Surge suppressor -
Single-bearing kit ALT 471 KB 002 Warning: the power supply is present
Non drive end bearing - when the machine has stopped.
«O»ring -
Preloading (wavy) washer - 5.3.2- Temperature sensors with
thermistors (PTC)
Double-bearing kit ALT 461 KB 001
These are thermistor triplets with a positive
Non drive end bearing - temperature coefficient installed in the
Drive end bearing - stator winding (1 per phase). There can be a
«0»ring - maximum of 2 triplets in the winding (at 2
Preloading (wavy) washer - levels: warning and trip) and 1 or 2
thermistors in the shields.
5.2- Technical support service These sensors must be linked to adapted
sensing relays (supplied optionally) .
Ourtechnical support service will be pleased
to provide any additional information you Cold resistance of cold thermistor sensors:
100 to 250 0 per sensor.
may require.
When ordering spare parts, you should 5.3.3- Connection accessories

indicate the complete machine type , its - 6-wire machines : coupling (F)
serial number and the information given on - 12-wire machines: coupling (A), (F .F), (F)
the nameplate.
Address your enquiry to your usual contact.
Part numbers should be identified from the

exploded views and their description from
the parts list. After operational testing, it is essential to
Our extensive network of service centres replace all access panels or covers.
can dispatch the necessary parts without
delay.
To ensure correct operation and the safety

of our machines, we recommend the use of
original manufacturer spare parts.
18
LSA 46.2 - 4 POLES

ALTERNATORS
5.4- Exploded view, parts list and tightening torque
5.4.1- LSA46.2 single-bearing
19
LEROY-SOMER I Installation and maintenance j 3856 en -2011 .01/ h
LSA 46.2 - 4 POLES

ALTERNATORS
5.4.2- LSA 46.2 double-bearing
20
LEROY-SOMER j Installation and maintenance 1 3856 en -2011 .01/ h
LSA 46.2 - 4 POLES

ALTERNATORS
Screw Torque Screw Torque

Ref. Qty Description Ref. Qty Description
0 N.m 0 N.m
1 1 Stator assembly - - 90 1 Exciter field - -
4 1 Rotor assembly - - 91 4 Fixing screws M6 10
15 1 Fan -
- 100 1 Exciter armature - -
21 1 Lifting ring -
- 120 1 Terminal plate support - -
22 1 Shaft extension key - - 122 1 Plate support - -
28 1 Earth terminal M10 20 124 1 Terminal plate M12 35
30 1 Drive end shield - - 177 2 AVR support bracket - -
Voltage regulator
31 6 or4 Fixing screws M14 80(*) 198 1
(AVR) - -
33 1 Protective grille -
- 284 1 Circlips - -
34 2 Fixing screws M6 5 320 1 Coupling sleeve - -
36 1 Exciter end shield - - 321 1 Sleeve key - -
37 4 Fixing screws M12 50 322 3 Coupling disc - -
41 1 Cover front panel - - 323 6 Fixing screw M16 170
48 1 Cover top panel - - 325 - Spacer shim - -
Diode bridge
49 - Cover screws M6 5 343 1
assembly
M6 4
Protection varistor
51 1 Air intake grille - - 347 1 (+PCB) - -
53 1 Plug - -
349 1 "0 " ring - -
60 1 Drive end bearing - - 364 1 AVR support - -
62 3 or4 Fixing screws M8 20 365 1 Cover rear panel - -
68 1 Inner bearing retainer - -
367 2 Side panel - -
70 1 Non drive end bearing - 371 -4 Damper - -
71 1 Cover - - 416 1 Filter - -
72 2 Fixing screws MB 20 417 1 Filter support - -
78 1 Inner bearing retainer - -
466 2 AVR inspection door - -
Preloading (wavy)
79 1
washer
- -
(*) 80 N.m in M /190 N.m in l , Vl
21
LSA 46.2-4 POLES

ALTERNATORS
Electric Power Generation Division
Declaration of CE compliance and incorporation
This Declaration applies to the generators designed to be incorporated into machines complying with the
Machinery Directive Nr 2006/42/CE dated 17 May 2006.
MOTEURS LEROY-SOMER MLS HOLICE STLO.SRO MOTEURS LEROY-SOMER

Boulevard Marcellin Leroy SLADKOVSKEHO 43 1, rue de Ia Burelle
16015 ANGOULEME 772 04 OLOMOUC Boite Postale 1517
France Czech Republic 45800 St Jean de Braye
France
Declares hereby that the electric generators of the types LSA 36 - 37- 40- 42.2- 43.2-44.2-46.2-47.2-
49.1 - 50.2- 51 .2, as well as their derivatives, manufactured by Leroy Somer or on Leroy Somer's behalf,
comply with the following International Standards and Directive :
· EN and IEC 60034 -1 and 60034 -5

- ISO 8528- 3 • Reciprocating internal combustion engine driven alternating current generating sets.
Part 3. Alternating current generators for generating sets '
- Low Voltage Directive Nr 2006/95/CE dated 12 December 2006.
Furthermore, these generators, designed in compliance with the Machine Directive Nr 2006/42, are therefore
able to be incorporated into Electrical Gen-Sets complying with the following International Directives :
- Machinery Directive Nr 2006/42/CE dated 17 May 2006

- EMC Directive Nr 2004/1 08/CE dated 15 December 2004, as intrinsic levels of emissions and
immunity are concerned
WARNING :
The here above mentioned generators should not be commissioned until the corresponding Gen-Sets have
been declared in compliance with the Directives Nr 2006/42/CE et 2004/1 08/CE, as well as with the other
relevant Directives.
Leroy Somer undertakes to transmit, in response to a reasoned request by the national authorities, relevant information on
the generator.
Technical Managers
P Betge- J.Begue
4152 en- 2010.11/ d
22
LSA 46.2 - 4 POLES

ALTERNATORS
23
nRLEROY®
~SOMER
LEROY·SOMER 16015 ANGOULEME CEDEX ·FRANCE

338 567 258 RCS ANGOUL~ME
www.leroy-somer. com
lEROY®
SOMER
4342 en· 2010 .03 1 a
R450
AVRs
Installation and maintenance
'------
LE
__R_O_Y_-S
_O__
M_E_R_________ ~n-s-ta-l a-t-io_~_a_~_d_sm_o_in-ten__a-nc_e
_________4_3-42_e_n_
- 2_o-1o_o_3_,a___ ==l
_ AVRs j
This manual concerns the alternator AVR which you have just purchased.
We wish to draw your attention to the contents of this maintenance manual. By following
certain important points during installation, use and servicing of your AVR, you can look
forward to many years of trouble-free operation.
SAFETY MEASURES
Before using your machine for the first time ,

it is important to read the whole of this
(WARNING J
installation and maintenance manual.
All necessary operations and interventions Warning symbol for an operation capable
on this machine must be performed by a of damaging or destroying the machine
qualified technician .
or surrounding equipment.
Our technical support service will be pleased
to provide any additional information you
may require .
The various interventions described in

this manual are accompanied by
recommendations or symbols to alert the
user to potential risks of accidents. It is vital Warning symbol for general danger to
that you understand and take notice of the personnel.
various warning symbols used.
Warning symbol for electrical danger to

personnel.
Note: LEROY-SOMER reserves the right to

modify the characteristics of its products
at any time in order to incorporate the
latest technological developments. The
information contained in this document may
therefore be changed without notice .
rRlEROY ·
2 ~ SOMER
E EROY-SOMER Installation and maintenance
R450
AVRs
CONTENTS
1 -GENERAL INFORMATION ......... .......... ...................... ............................... .. ... ..... ............ . 4

1.1 - Description .......... ....... ................. ........ ...... ...... ..... ............ .. .. ........... ... .... ..... ................. 4
1.2- Identification ..... ..... ... .. .... ... ........... ... ... ......... .... ... ........ .... ..... ... .. ... ... .. ........ .......... ......... . 4
1.3 - Tools ..... ............. ....... ...... ...... ............ ... ... ........ .... ... ... ..... .. ... .......................... ... ... .... .... .. 4
2 - POWER SUPPLY ............................................................. ............................................. ..... 5

2.1 - AREP excitation system .. .. ..... .. ........ .. .... .. ... .. ........... .. .... ... ................. ... .... ....... .... .. ...... 5
2.2- PMG excitation system ..... ...... .. .......... ....................... ... ...................... ..... .... ......... .. ...... 6
2.3 - SHUNT or separate excitation system ............. .. ....... ............. .... ....... ... ........ ...... .. ......... 7
3- TECHNICAL CHARACTERISTICS .................................................................................... 8

3.1 - Electrical characteristics ....... .......... ..... ... ..... .......... ...... ........... ... ... .. ....... ..... .... ............. . 8
3.2- Configurations ....................... ... .... ..... ...... ..... ...... .. ...... ... .... ............................. .. .. ..... ..... 8
3.3 - U/F and l-AM functions ........ ............. .. .. ........... ...... ..... ........ .... .. ............. ............ .. ....... 12
3.4- Typical effects of the LAM with a diesel engine with or without a LAM (U/F only) ........ 12
3.5- AVR options ................................... ..... .. .. ................................ ............................... .... 13
4- INSTALLATION- COMMISSIONING ............................................................................... 14

4.1 -Electrical checks on the AVR .......... ...... ..................................... .. .......... .... .. ............... 14
4.2- Setting up ...... .............. ... ............................................... ... ... .... .... .......... ................ ..... 14
4.3 - Electrical faults ................................................... ...... .... ..... .... ..... .. ................. ...... .... ... 17
5- SPARE PARTS .. .... ................................... ................... .. ........... ........................................ 18

5.1 - Designation ........................................................... ..... ............... .... ....... ... .... .. ....... ...... 18
5.2 - Technical support service .................. ................................... ...................................... 18
All servicing or repair operations performed on the AVR should be undertaken by

personnel trained in the commissioning, servicing and maintenance of electrical and
mechanical components.
Copyright 2005: LEROY-SOMER MOTORS

This document is the property of:
LEROY-SOMER
It may not be reproduced in any form without prior authorization.
All brands and models have been registered and patents applied for.
3
LEROY-SOMER I Installation and ma intenance I 4342en - 201003/a
R450
AVRs
1 -GENERAL INFORMATION of characteristics and dimensions.

1.1-Description
- R 450: with "Faston" connectors and
The R450 AVR is supplied in a casing single- phase sensing .
designed to be mounted on a panel with
dampers. -R 450M: with "Mate N Lok™ " connectors
- Operating temperature : 20°C to+ 70°C. and single-phase sensing.
- Storage temperature: 55°C to +85°C.
- Shocks on the base: 9 g depending on the - R450T: with "Mate N Lok™ " connectors
3 axes. and three-phase sensing.
- Vibrations: less than 10 Hz, 2 mm
half-peak amplitude 10 Hz to 100 Hz: 100 1.3- Tools
mm/s, above 100 Hz: 8 g. The "Mate N Lok™ " connectors tools
references are the following :
(WARNING) - crimping pliers: RefTYCO 654.149.1
The AVR is IPOO, it must be incorporated - Extractor: Ref TYCO 539.972.1
in an environment which ensures it a
IP20 protection . (WARNING)
1.2 -Identification Connectors must be unlocked before
There are 3 different versions available: unpluging
These 3 AVRs are exactly identical in terms
fl\?LEROY'
4 ~ SOMER
Installation and maintenance 4342 en- 2010 03 t a
.~~-L--------~~~--~
R450
AVRs
2- POWER SUPPLY to the alternator main voltage (Shunt

Both the AREP & PMG excitation systems characteristic) , the second one has a
are control led by the AVR . voltage proportional to the stator current
(compound characteristic: Booster effect) .
2.1 - AREP excitation system The power supply voltage is rectified and
With AREP excitation , the electronicAVR is filtered before being used by the AVR
powered by two auxiliary windings which monitoring transistor.
are Independent of the voltage sensing The rotating switch should be in the SHUNT/
CirCUit AREP position (see 3.2.3).
The first wind inn has a voltage proportional
STATOR : 6 wires ( T1 to T6)

MAIN FIELD STATOR : 12 wires ( Tt to Tt2)
( AREP SYSTEM
rr::?LEROY'
~ SOMER 5
LE ROY-SOMER I Installation and maintenance I 4342 en- 2010 03/ a
R450
AVRs
2.2 - PMG excitation system The AVR monitors the alternator output
With PMG excitation , a permanent magnet voltage by adjusting the excitation current.
generator (PMG) added to the alternator The rotating switch should be in the PMG
supplies the AVR with voltage which is position (see 3.2.3) .
independent of the main alternator winding .
These two excitation principles provide the
machine with a short-circu it current overload
capacity of 3 IN for 10 s.
STATOR : 6 wires ( T1 to TS)

MAIN FI ELD STATOR : 12 wires ( T1 to T12)
"·
flf?LEROY-
6 !:=J SOMER
LEROY-SOMER _[ Insta llation and maintena nce I 4342 en - 2010 03/ a
R450
AVRs
2.3- SHUNT or separate excitation

system
With SHUNT excitation , the AVR is powered
by the main winding (1 OOV to 140V - 50/60
Hz) by using X1 , X2 on theAVR.
The rotating switch should be in the SHUNT/
AREP position (see 3.2.3) .
STATOR . 6 wires ( T1 i T6)

STATOR : 12wlres ( T1 i T12)
TB
!~~o,..-l]
'·~·,} J
fl:?LEROY"
t::=J SOMER 7
LEROY-SOMER l Insta llation and maintenance l 4342 en- 2010.03/ a
R450
AVRs
3- TECHNICAL CHARACTERISTICS
3.1 -Electrical characteristics (WARNING)
- maximum power supply: 150V - 50/60 Hz The allowed adjustment range is ±5%;
- Rated overload current: 10 A- 10 s when the setting exceeds these limits,
- Electronic protection : please check that it is conform with the
power table.
- In the case of a short-circuit, the excitation
current is reduced to a value less than 1A 3.2.1.2 - Quadrature droop:
after 10 s Quadrature droop adjustment via
- In the event of loss of voltage reference , potentiometer P4 within a range :
the excitation current is reduced to a val e - from 0 to 8% with a PF=0 .8 for 400V
less than 1Aafter1sforAREP/SHUNT, 10s applications .
for PMG. - From 0 to 14% with a PF=0 .8 for 240V
-In the event of overexcitation , the current applications .
is reduced as indicated in the next diagram - From 0 to 8% for 110V applications with a
(see 3.4 .1.4). step-up transformer (ratio of 4) placed on
-Fuses: F1 on X1 and F2 on Z2 10A, 250V. the voltage reference.
- Voltage sensing The potentiometer P4 has a non linear
R450: response. Then , when a 1A secondary CT is
• 0-11 0 Vterminals = 95 to 140 V connected the effective range starts from
• 0-220 V terminals = 170 to 260 V the the second 1/3 of P4 range and in the
• 0-380 V term inals = 340 to 528 V case of a 5A secondary CT the effective
R450 M & T: range starts from the first 1/3.
• Low range: < 320V When a 5ACT is used , the adjustment range
• High range : > 320V is higher, so P4 must be set to the first 1/4
For other voltages , a transformer should be (anti-clockwise) and then progressively
used .
increase it. - - - - - -...
- Voltage regulation :± 0.5%.
- Current sensing: (parallel operation) : input (WARNING)
S1, S2 intended for 1 C.T. < 2.5 VA cl1, The CT must be connected .
secondary 1 A or 5 A.
3.2.1.3- Stability:
3.2- Configurations: Stability adjustment via potentiometer P2 .
Selection of rotating switch according to the
3.2.1 -Settings machine type and the response time as
3.2.1 .1 - Voltage indicated in paragraph 3.2.3.
Voltage adjustment via potentiometer P1 in
the ranges described in the table below: 3.2.1.4- Excitation limitation :
Excitation limitation adjustment via
For 50 and 60 Hz Max. potentiometer P3 as described below.
HiQh range Un ~ 530 V The excitation current limitation threshold in
Medium range Un ~ 252 V steady state is set by a potentiometer at
Low ranQe Un ~ 140 V 11 0% of the rated value . The adjustment is
made by the operator during the on-load test
at rated power by tuning the potentiometer.
11-'?lEROY-
8 I..'::.~ SOMER
LEROY-SOMER I Installation and maintenance I 4342 en- 2010.03/ a
R450
AVRs
between 0.5 and 0.7 A (shutdown).

(WARNING) In all operating conditions the maximum
excitation current must be limited to
The limitation threshold must be 9A± 0.5A.
adjustable between 1 and 5.5 A
Overrun indications:
When the excitation current exceeds this
value, a counter is activated at the speed of One green LED:
one record per second for 90 s. When this
time is elapsed, the current is reduced to the - Lights up when the excitation current is
value of the rated excitation current. If in the below the continuous operation threshold
meantime the excitation current drops It signals the AVR normal operation.
below the threshold value, the counter
counts down at the same speed. -Turns off when the excitation current ceiling
used to obtain short-circuit operation is
Operation between 3 and 6 In when reached and when the excitation current is
short-circuited: reduced to the shutdown value.
The excitation current ceiling during a
short-circuit equals 2.9 times the fixed - Flashes when the over excitation counter
threshold when setting the permitted is decrementing.
excitation ceiling in continuous operation.
When the threshold is exceeded for a period
= 10 s the current is reduced to a value
I exc(A)
Diagram 1
Maximum ceiling I exc
9.5 ..........................................................................................................................................
7.5 ·········································································~-----~·-·······················
Activation of ;::=--- -l t(s)

[
90s tempo. ) roecrea5eoteos~:-~~....,.:,.--.!J
: Activation of ~o 5 1Os tempo. elapsed :
~ tempo. shutdown application
Red ted coooooooooooo6eoeoeoooffoeoeo•oeoeo~•••••••••l

Greented (000000000000QOOOOOOOOQlOOOOOOOOOOOOQOOOOOOOOO)
n~<?LEROY"
t..=JSOMER 9
R450
AVRs
3.4.3 - Power
- R729 module: same as R726 with
r'~LAM additional functions.
-- ----- ----~--
• Detection of a diode fault.
• 4-20 mA input.
Variation In the load • Possibility of kVAR regulation.
~ Time
-Voltage control: with an isolated
D.C. current source applied to the terminals
16 2s 3s
used for the external potentiometer:
• Internal impedance 1.5 kO.
3.5 -AVR options • A variation of ± 0.5 V corresponds to a
- Current transformer for parallel opera- voltage adjustment of± 10%.
tion of..... ./1 A or 5 A according to the poten-
tiometer P4 position.
- Voltage transformer
(adaptation)
- Remote voltage adjustment potentio-
meter:
470 0, 0.5 W min: adjustment range± 5%
(range limited by internal voltage
potentiometer P1). (A 1k0 potentiometer
can also be used to extend the adjustment
range). ~
The potentiometer input must be

isolated. Do not connect it to the ground.
- Module R 731 only available with "Fasten"

version: 3-phase voltage sensing 200 to 500
V, compatible with parallel operation in
balanced installations.
- Module R 734 only available with "Fasten"

version: 3-phase current and voltage
sensing for parallel operation on unbalanced
installations (unbalance> 15%).
- R 726 module: regulation system changed

to "4-function" (see the maintenance manual
and connection diagram).
•PF regulation (2F) .
•Equalization of voltages before
paralleling (3 F).
• Possibility of coupling to the mains of
alternators already running in parallel (4F).
n\?LEROY'
I.=JSOMER 13
E.EROY-SOMER Installation and maintenance 4342en- 2010.03/a
R450
AVRs
4-INSTALLATION-COMMISSIONING a) Initial potentiometer settings (see table

4.1 -Electrical checks on the AVR. below)
- Check that all connections have been Action Factory setting Pot.
made properly as shown in the attac.~hed
t1
Voltage 400V-50Hz
wiring diagram. minimum fully (0. 380 v
anti-clockwise input)
-Check. the rotating switches selectio11s
-frequency,
- type of alternator,
-normal position (response time),
Stability Not set
(centre position) 9
-external potentiometer,
- rated voltage,
Excitation ceiling
· Factory-sealed
10A
maximum @
- secondary current of the CT used, Voltage quadrature droop
-type of excitation.
- R450 optional operating modes
(//operation with C.T.)
• 0 quadrature droop fully
anti-clockwise
Not set
(fully
anti-clockwise) t1
4.2- Setting up Stability adjustments in standalone
operation
b) Install a D.C. analogue voltmeter (needle
dial) cal. 100 Von terminals E+, E- and an
A.C. voltmeter cal. 300- 500 or 1000 Von
the alternator output terminals.
The various adjustments during tests
c) Check the rotating switch selection.
must be made by a qualified engineer. It
is es~ential that the drive speed d) Voltage potentiometer P1 at minimum,
specified on the nameplate is reac;hed fully anti-clockwise.
before commencing adjustment. After
operat,onal testing, replace all ac1.:ess e) Stability potentiometer P2 around 1/3 in
panels or covers. from the anti-clockwise stop.
The AVR is used to make any
adjustments to the machine. f) Start the engine and set its speed to a
frequency of 48 Hz for 50 Hz, or 58 for
4.2.1 -Setting up the R450 60Hz.
(WARNING) g) Set the output voltage to the desired

value using P1.
- Rated voltage UN for solo operation
Before using the AVR, make sure that
(eg. 400 V)
the rotating switches have been -Or UN+ 2 to 4% for parallel operation with
correc~ly configured with AREP/SHUNT C.T.(eg.410V-)
or PMG excitation If the voltage oscillates, use P2 to make
adjustments (try both directions), observing
the voltage between E+ and E- (approx.
10 V D.C.). The best response time is
obtained at the limit of the instability. If no
stable position can be obtained, try selecting
the fast position.
nPLEROY-
14 eJSOMER
LEROY-SOMER Installation and maintenance
R450
AVRs
h) Check LAM operation: depending on the 4.2.2 - Max. excitation adjustment
rotating switch selection. (excit~tion ceiling)
In standard setting, the potentiometer P3 is

i) Vary the frequency (speed) around 48 or
in maximum position.
58 Hz according to the operating frequency,
and check the change in voltage from that However, for applications requiring an
observed previously(- 15%). overload protection (see 3.2.1.4), the
excitation ceiling must be adjusted by using
j) Readjust the speed of the genset to its the following procedures inAREP and PMG.
rated no-load value. -Connect the AVR to the alternator
-apply joad to 110% of rated machine rated
Adjustments in parallel operation at PF=0.8, the green led is on and the red
Before starting work on the alternator, make one is off.
sure that the speed droop is identical for all -record the excitation current value
engines.
-adjust P3 until obtaining the red led flashing,
k) Preset for parallel operation (with C.T. the green one is always on.
connected to 81, 82) -decrease the load to 100% and make sure
- Potentiometer P4 (quadrature droop) in that the red led is off.
1/4 position in the case of 5A CT and at 1/2 - Increase the load at 115%, check that the
position in the case of 1A CT. red LED flashes during 90 seconds and that
Apply the rated load (PF = 0.8 inductive). the excitation current is brought back to the
The voltage should drop by 2 to 3% (400 V). above ;adjusted value (lex adjusted).
If it increases, check that neither V and W
nor 81 and 82 have been reversed. The user can use the followin!l table to
adjust the excitation ceiling according the
alternator type.
I) The no-load voltages should be identical
for all the alternators intended to run in Position of I exc (A)
parallel. P3
- Couple the machines in parallel.
8h 1
- By adjusting the speed, try to obtain 0 kW
power exchange. 9h 1.55
-By altering the voltage setting P1 on one of 10h 1.95
the machines, try to cancel (or minimise) the
current circulating between the machines.
- From now on, do not touch the voltage
11 h
12h
2.5
3.15
12H
settings.
m) Apply the available load (the setting is

13h
14h
3.65
4.25
sH{J[),6H
only correct if a reactive load is available)
- By altering the speed, match the kW (or 15h 4.7 P3
divide the rated power of the units 16h 5.15
proportionally)
- By altering the quadrature droop
potentiometer P4, match or divide the NB: In the case of a permanent short-circuit,
currents. the excitation current must reach 2.9 x lex
adjusted, during 1 second in AREP or 10
seconds in PMG and shuts down to a value
less than 1A
[J(?LEROY·
/~SOMER 15
LEROY-SOMER .I Installation and maintenance 4342 en- 2010.03/ a
R450
AVRs
4.2.3 -Special type of use
(WARNING)
The excitation circuit E+, E- must not be
it
If field weakening is used, provide field
forcing.
left open when the machine is running:
this will irreparably damag~ the AVR.
4.2.3.1 - R450 (SHUNT) field weakening 4.2.3.3- R450 field forcing
E:cciter field winding
Field forcing
BVolt
The exciter is switched off by disconnecting
the AVR power supply (1 wire- X 1 or X2) ..,._t_.,.
Contact rating: 16 A- 250 V A.C. 1 . . . - - - - - I L - - - L - - . _ . Time
Applications BVolt Timet
Guaranteed voltage build-up 12(1A) 1-2 s

4.2.3.2 - R450 (AREP/PMG) field
Parallel operation, de-energjzed 12 (1A) 1-2 s
weakening
Parallel operation, at standstill 12 (1A) 5-10 s
Frequency starting 12 (1A) 5-10 s
Sustained voltage on overload 12 (1A) 5-10 s
The exciter is switched off by disconnecting

the AVR power supply (1 wire on each
auxiliary winding) - contact rating 16 A -
250VA.C.
Connection is identical for resetting the AVR
internal protection.
ne?LEROY"
16 f...':::..) SOMER
LEROY-SOMI=R I Installation and maintenance I 4342 en- 2010.03/ a
R450
AVRs
4.3 -Electrical faults

Fault Action Measurements Check/Cause
The alternator builds up and its - Lack of residual magnetism
voltage is still correct when the
battery is removed
No voltage at Connect a new battery The alternator builds up but its -Check the connection of the voltage
no load on of 4 to 12 V to terminals voltage does not reach the rated reference to the AVR
start-up E- and E+, respecting value when the battery is removed
-Faulty diodes
the polarity, for 2 to 3
-Armature short-circuit
seconds
The alternator builds up but its - FaultyAVR
voltage disappears when the - Field windings disconnected
battery is removed - Revolving field coil open circuit. Check the
resistance
Check the AVR connections (AVR may be
faulty)
Correct speed - Field windings short-circuited
Voltage too Check the cJrive speed - Rotating diodes burnt out
low - Revolving field coil short-circuited
-Check the resistance
Increase the drive speed
Speed too low (Do not touch theAVR voltage pot. (P1)
before running at the correct speed)
Voltage too AdjustAVR voltage Adjustment ineffective - FaultyAVR

high potentiometer - 1 faulty diode
Voltage AdjustAVR stability If no effect: try normal/fast -Check the speed: possibility of cyclic
oscillations potentiometer recovery modes irregularity
-Loose connections
- FaultyAVR
- Speed too low when on load
(or U/F knee-point set too high)
Voltage between E+ and E- -Check the speed
Voltage Run at no load and AREP/PMG < 10 V (or U/F knee-point set too high)
correct at no check the voltage Voltage between E+ and E- -Faulty rotating diodes
load and too between E+ and E-on AREP/PMG > 15 V - Short-circuit in the revolving field coil.
low when on theAVR Check the resistance
load(*) -Faulty exciter armature
(*)Caution: For single-phase operation, check that the sensing wires coming from theAVR are correctly connected to
the operating terminals.
Voltage Check theAVR, the The voltage does not return to the -Exciter winding open circuit
disappears surge suppressor, the rated value -Faulty exciter armature
during rotating diodes, and - FaultyAVR
operation (**) replace any defective -Revolving field coil open circuit or
components short-circuited
(**)Caution: Internal protection may be activated (overload, open circuit, short-circuit)
Caution: After operational testing or

troubleshooting, replace all access
panels or covers.
n\?LEROY"
t..::=JSOMER 17
R450
AVRs
5 -SPARE PARTS
5.1 - Designation
Description Type Code
Voltage regulator R450
{AVR)
Voltage regulator R450M

{AVR)
Voltage regulator R450T

{AVR)
5.2- Technical support service

Our technical support service will be pleased to
provide any additional information you may
require.
When ordering spare parts, you should indicate

the AVR type and code number.
Address your enquiry to your usual contact.
Our extensive network of service centres can

dispatch the necessary parts without delay.
To ensure correct operation and the safety of our
machines, we recommend the use of original
manufacturer spare parts.
In the event of failure to comply with this advice,
the manufacturer cannot be held responsible for
any damage.
nRLEROY"
18 ~SOMER
LEROY-SOMER Installation and maintenance 4342 en- 2010.03/ a
R450
AVRs
Dr:?LEROY"
L'=JSOMER 19
nc-?LEROY®
~SOMER
MOTEURS LEROY-SOMER 16(115ANGOUL~ME CEDEX-

FRANCE
338 567 258 RCSANGOUL~ME

S.A. au capital de 62 779 000 euro
www.leroy-somer.com
Doosan lnfracore 9501 06-00002
e.!f-%-&~..g.. r-'f-~ {!~ ~~7]% ·~Hl AD086TI, AD136TIJ ~~7].9.] l-]-%.!f-%% ~7fl.£9} .!f-%ll, .!f-%1ti~~
~'?.}%~~%]-~~til:}.
1. ¥-5.9.1 9-.gOII Cfl "B~Ol

.!f-%% 9-~W u:JloJ]~ o]-i!j]l-]-'5.}% ~7]-5]-oj 7]-77]--8:- "'il:l]~ -'\l!Ei.£ ~E,j--5]-oj 9-{l;.]..Q...
oJ]. 1) 1)- l:l] .9.] ~ -61 : AD086TI ------,~ {1 '8 r.:i ~ £j oJ] :z.j-'?.}
2) ;;!J] 3::. 1ti ~ : EBPEG800001 - - - '
3) ljL % 1ti ~ : 65.02101-0056B
4) ljL % ~ : .3.~.3. ~ 3::.'13%
5) ~ i:!J : 1
6) 9-~7.]-.9.] 9-~ ~ .Aj~
2. ¥-5~~~ .5'!.-E ~'g;j

?.] ;.j 1ti ~ : ~7fl.£.9.] :z.r .!f-%% .±f.A]-5]-~ lti~~tit::J-.
lf- % 1ti ~ : .!f-%oJl ~C9 {! ..lliH:l~ ~ ti t::J-.
ljL % ~ : .!f-%.9.] ~ ;g ~ ti q..
3::.'13%~ -T;.j-5]-~ .!f-%~ 'ifoj] r. J % ~~..Q..uj, r. J .!f-%o] 3::.'13%~ 7d.JfoJ]~ ::1. -T-Ajlj!-
%oJ] r • • J o]lf.;.].£101 'V.'Ertit::J-.
i:!J : .!f-%o] J-]-%£]..ll <V_~ rp:Jl~.9.] ~i:!JJ o] 7].A~£101 'V.~tit::J-.
~. 3::.'13%.9.] -T-Aj .!f-%..g.. ::1. 3::.'13% 1t:Jl~.9.] 'Ti:!J 0 ]ll;.]£]01 'U~tit::]-.
AD086TI : -'¥-~ {!~ ~~7]% ~~
AD136TI : -'¥-~ {!~ ~~7]% ~{!
"'i l:l] ~ .:UE. : o]-i!j]9} ~..g.. J-il:l]~ 7]~%o] 7].Afl£]01 'V.~tit::J-.
B : ::J...!f-%~ ~.!f-;.]7]7] .!fl-&fl ~?.] 7]-~6)-~o] ~..B..-5]-E..£ 'tA.£ ~E,J"-5]-oj 9-{);.]..2...
D : \:!"% .ill~~7]-.!f-%..9....£ ::J...!f-%% ..¥.~~ 3::'13%..9....£ .ill~-5]-oj 9-{);.]..2...
A : 3::.78% 'EJ %..9....£, l-]-%-5]-~ "1'-i:!Jo] oij ~7]o]-t::]- AJo]~ 31% J:f.A]Wtil:}.
S : ~1)-*%]-;.] 3::.'13£]~ .!f-% 0 ] 0 }\!, 'Tel. "'il:l]~%..9....£ ~~£]~ .!f-%~ ll;.]Wtit::J-.
G : o1 .!f-%..g.. %~( Grade)~cj 7]- ~..B..~ .!f-% ~ ti t::J-. utcl-"'i 3::. '13 £1 01 7.] ~ %t:!l.!f-%.9.] %~
.1!} ~..g.. %~..9....£ ~~"5]-oj 9-11}.1..2...
OP : %1! 1!]- §. lf-%% JIA]'Uti t::J-.
EX : ~l;ll.~ ~-'c}.!f-%% .±EA]Wtil:}.
OS : ..2..li1 "'r 0 ]Z: .!f.%~ lf.J,]Wt..Jt::J-.
US : ~r.:i J-j-o]Z:.!f-%% lf.J,]'Ut..Jt::]-.
(OS, US-E-lf€- ;.j<~J o]4-oJ].!f-%% .ill~;.] "'r%£1-E-.!f-%~til:}.)
: "-il:l]~ ~~ 0 ] ~7]-~~ .!f-%~tit::J-.
~ ~ -Aj : .!f-%1ti~~oJ]ll7]~ .!f-%.il} ~~oJ] ~..g.. 7-];.]Jti~(-lf.;.]).£ lf.7]~ .!f-%J-]-o]oJ] ~~-Aj% lf.J,]
-5]-~..Q..uj, :z.j- 7]~.9.] .9-ju]~ o]-i!j]9} ~~tit:]-.
v : ~.!f-%JJ} -T.!f-%% 01~ 3Jo]t..J- "'r%W ~ <V.~tit::J-.
o : ~.!f-%% "'r%w <T- \"d~tict . .::r.!f-%% "'r%~ i"-11}.1..2...
c : .::r.!f-%~ "'r%w ~ \"d~tict. u:tcJ-"-i ~lf-%..9....£ .ill~~ i"-1l;.J..2_.
N : -T.!f-%JJ} ~.!f-%Zl-oJl ~~;.<Jo] \"d~t..Jt::J-. ~%~7loJl ~~ .!f-%% "'r%~ 9-11;.1..2...
l:l] ..ll : .!f-%.9.] %Ai] ~~o]L.j- %..ll Fig.No. %o] 7].Afl£]01 'V.~tit::J-.
•.!f-%..g.. ~%] ~78.!f-%% "'l-%-5]-..ll.!f-%1ti~.£ ~'i:l x'El%~ *%U1!~ ~'?.}% o]%-5]-{);.]..2...

e.!f-%-&~.9.] t.J1%..g_ OJ]..ll\"d 0 ] Jt!7d~ 'T 'U..9...E..£ t.J1%oJ] tJ1~ 7.]-Aij~ ~.9.jl-j-"5J-..g_ 0 }E.Ei }.lJ:l]~ -'\J!Ei.£ ~E,J"%]-A]
7] l:l]-ij;ft..Jl:}.
2008. 12.
FOREWORD
• This parts list is shown the equipment components parts of rDOOSAN Marine Generator Engine AD086TI,
AD136TIJ .
1. HOW TO ORDER PARTS

When ordering parts, please specify the following items as shown in the following example.
Ex. 1) Model of Machine : AD086TI ----~---_-_-_-_,....,f--- Shown on cylinder block
2) Machine Serial No. : EBPEG800001
3) Part No. : 65.02101-00568
4) Description : Crank shaft ass'y
5) Q'ty :1
6) Purchaser's Name and Address :
2. HOW TO USE THIS PARTS LIST

Key No. : Key No. Shows the referring number of illustration.
Parts No. : Part No. is it's own number.
Description : Part name. There is printed information such as size, specification with the part name or not.
Components parts of one assembling part are shown with r • J mark and shown below of an
assembling part. Also, if the components parts marked ~ • J consist of further components
parts, these further component parts are with r • • J .
Q'ty : "Q'ty" shows the quantity used for one machine, however "Q'ty" of component parts shows the
quantity used for one assembling part.
AD086TI : DOOSAN MARINE GENERATOR ENGINE
AD136TI : DOOSAN MARINE GENERATOR ENGINE
Service code :Abbreviation is service code of parts has its own meaning as shown below.
B : The parts with this abbreviation show that they require some work on them before in-
stalling in the machine.
D : The part with this abbreviation is a component of an assembling part and is not available
independently. The assembling part containing this part should be orderd.
R : The part with this abbreviation shows that the quantity of the part is changed depending
on the machine, such as an adjusting shim etc.
S : This part is specially pmvided as a service pm·t, which was not provided in the machine
before shipping from the factory.
G : This part needs special care(grade control) to perform the maintenance job. Before order,
the grade of the paart should be confirmed(It should be same with the grade of matching
part.)
OP : Optional parts.
EX : Specific design parts.
OS : Over-sized parts.
US : Unde1·-sized parts.
(Part with abbreviation "OS" or "US" is described on the line below the standard sized
part).
: The part with this abbreviation is not supplied for NS.
I CA : ICA shows the interchangeability between the original and the improved parts.
The improved part shows below the original part and with same key No.
(key No. shows by r- J .)
Abbreviations used in this column are as follows ;
Y : This part with "Y" in the ICA column can be used original and improved part.
0 : This part with "0" in the ICA column can not use improved part, use only this part.
C : This part with "C" in the ICA column can be used instead of improved part but not vice
versa.
N : This part with "N" in the ICA column can not use interchange, use only part of Serial No.
Remark : There is printed detail description, refference number or not.
• When repairing, it is recommended to use our standard parts.

• Researching the parts from part No., see the rparts IndexJ in finish of this parts list.
• Parts may be altered in a constant effort to improve machines. Then, it is recommended that customers contact
our after service center.
Dec. 2008.
~t ~l
CONTENTS
Fig. 001 ~ '1:! cl ~ ~ ····································· · Cylinder Block-················································· 2

002 qo] PJ 7] e>i 7'11 oj A ····························Timing Gear Case············································· 4
003 ~c}o] tl. i>}Jf-~ ········ ··········· · ··· ·········Flywheel Housing············································· 6
004 '1l 44- ~~ 71 ~ ······························· Water Chamber Cover······································· 8
005 .!:!. c] cl ············································· Breather · · · · · · · · · · · · · · ·· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 10
006 -T% J-] A <il ········ ···· ·· ··· ···· ···· ······ ··· ···· Driving System··············································· 12
007 {). '1:! cl '8-l].:':::. · · · •••••••· •· · · · · · •••••· · · · ••· · · · ••••• Cylinder Head · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 16
008 ~'l:!cl '8-l].:':::. 71~ ·······························Cylinder Head Cover······································· 18
009 qo] PJ J-j A Ei] · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · Timing System .... · .... · ...... · .... · .. · .... · ...... · .. · ...... · 20
010 .2.. ~ ~~ ......................................... Oil Pump ........................................................ 24
011 .2.. ~ O:j .:i!}-7] .......... · · .............. · ........... Oil Filter· ....................................................... 26
012 .2.. ~ '1JZf7] ...................................... Oil Cooler ...................................................... 28
013 .2.. ~ lll!. ............................................ Oil Pan .......................................................... 30
014 '1lzt4- JI}- 0 ]~(1) ............................... Cooling Water Pipe(l) ..................................... 32
015 '1l44- JI}-o] ~(2) ............................... Cooling Water Pipe(2) ..................................... 34

016 '1l44- JI}-o]~(3) ............................... Cooling Water Pipe(3) ..................................... 36
017 '1l44- ~ n ...................................... Water Pump ................................................... 38
018 '1l4 !@ ..... · ...................................... Cooling Fan .................................................... 40
019 ll~ 7] o~ 1.-j lf c (1) ............................... Exhaust Manifold(!) ........................................ 42
020 ll~ 7] ofl Y lf.:'::.(2) .............................. · Exhaust Manifold(2) ........................................ 44

021 ~7] ufll..-jlf c ................................... Intake Manifold ............................................... 46
022 .:i!}-"E-7] (1) ......................................... Turbo Charger(!) ........................................... 48
023 .:i!}-"E-7] (2) ......................................... Turbo Charger(2) .................................... · ...... 50
024 i'-7] '1JZf7] ...................................... Inter Cooler ................................................... 52
025 ~A} X.~ ·········· ····· ····· ......... ······ ...... Injection Nozzle· ....... ··········· .................... ······· 54
026 ~A} JI}-o] ~(1) .................................. Injection Pipe(l) ............................................. 56
027 ~A} JI}-o] ~(2) .................................. Injection Pipe(2) ............................................. 58
028 ~A} ~ n (1) ..................................... Injection Pump(l) ........................................... 60
029 ~A} ~ ~(2) ........ · ........ · .................. · Injection Pump(2) .......................................... · 62
030 ~A}~~ -T% 7]<Ji ........................... Injection Pump Drive Gear ............................... 64
031 ~A}~~ u}-&EJ(l) ........................... Injection Pump Mounting(!) ............................. 66

032 ~A} ~ ~ u}-& EJ (2) .. · ........................ Injection Pump Mounting(2) .. · .......................... 68
033 '*~ 7,:! E~(l) .................................. Engine Control(!) ........................................... 70
Fig. 034 ~~ ~ E~(2) ··································Engine Control(2) ··········································· 72
035 '?:!li li}o] ~(1) ··· ················· ····· ......... Fuel Pipe(l) ···· ···· ··· ··· ·· ··· ·· ··· ·· ··· ·· ··· ····· ····· ····· ·· 74
036 '?:!li li}o] ~(2) · · · · · · · ·· · · · · · · ·· · · · · · · ·· · · · · · · · ·· Fuel Pipe(2) · · · · · · · · · · · · · · · · · · · · · · · · · · ·· · · · · ·· · · · · · ·· · · · · · · ·· · · 76
037 '?:!li c:xj.:t!}-7] ······································Fuel Filter······················································ 78
038 ~~7] P}-&EJ ···································Alternator Mounting········································ 80
039 ~~7] · ·· · ····· ····· ·· · ·· · · ··· ··· · ····· · ···········Alternator······················································ 82
040 .A]% ~%7] ······································Starter··························································· 84
041 oJ]I:l]% · · · · · · · ·· · · ·· · · · · · · · · · · · · · · · · · · ·· · · · · · ·· · · · · · Spare Parts · · ·· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·· · · · 86
• ~cz.!.H.(Index)
• !j!~ ~ Aitfl~ t1!Ei(Parts & Service Center)
• Applications for DOOSAN Engine
• a-H.2.1 XI~W(Worldwide Network)

F. ~ rtJ C'i ..5!.2-1
lg,001 CYLIND =-, ER BLOCK
1
~
2-10
2
~~c~ ~~
Fig,001 CYLINDER BLOCK
*~(Q'ty)
;J;IAII!!:2 ¥~l!f.2 HI
Ailfl~ :2!~ ~
Key No. Part No.

l=t
.,- :a:
'i!!i ~ Description AD AD
086 136
~ =
s.c ICA Remarks
Tl Tl
1 65.011 01-6046J ~eJCi -§§! ::E'EJ~ CYLINDER BLOCK ASS'Y 1 -
- 65.011 01-6040N ~eJC-j -§§! ::E'EJ~ CYLINDER BLOCK ASS'Y - 1
2 65.011 01-0040R · ~eJC-j -§§! · BLOCK ; CYLINDER 1 1 D
3 65.91606-0037 · .:aOj ~ci .:I ·PLUG; CORE 9 9
4 65.0441 0-001 7 . t!l ~ ¥*1 · BUSH ; CAM SHAFT 4 4 B
5 65.011 05-1173C · till Oi ra t!f #1 · CAP ; BEARING #1 3 - D
- 65.011 05-1172B . till Oi ra t!f #1 · CAP ; BEARING #1 - 3 D
6 65.011 05-1176C . till Oi ra t!f #3 · CAP ; BEARING #3 2 - D
- 65.011 05-1160F · till Oi ra t!f #3 · CAP ; BEARING #3 - 2 D
7 65.011 05-1174C . till Oi ra t!f #4 · CAP ; BEARING #4 1 - D
- 65.011 05-1156D · till Oi ra t!f #4 · CAP ; BEARING #4 - 1 D
8 65.011 05-1175C · tiliOi ra t!f #7 · CAP ; BEARING #7 1 1 D
9 65.9171 0-0035B . .Jl~ ra ·RING; LOCATING 14 14
10 65.90020-0035B . till Oi ra t!f ~~ ·BOLT; BEARING CAP 14 14
11 65.91 001-0013A .i!.Oj -E! PIN; CORE 2 2
12 65.91 020-001 3 ~Ci.:J. PLUG 1 1
13 65.90310-0048 ~Ci.:J. LfAf SCREW; PLUG M10x1.5 6 6
14 06.56180-0714 AI~ ra RING ; SEAL A1Ox15 6 6
15 65.01201-0050 ~ eJ C-j 2.fol Li LINER ; CYLINDER 6 6
16 65.90310-0091 ~Ci.:J. LfAf SCREW; PLUG M12x1.5x20 1 1
17 06.56190-0704 AI~ ra RING ; SEAL A12x18 1 1
18 65.96601 A0042 !2!!~ 7-jt:l-j ;f~~ GASKET ; END COVER 1 1
19 65.91605-5003 .i!.Oj ~ 7j ~j COVER ; CORE HOLE 1 - s
- 65.91605-0006B !2!!~ 7-jt:l-j COVER; END - 1
20 06.01913-3115 J§~ ±EJ~ BOLT ASS'Y M8x25 2 -
- 06.01913-3114 ~~ ::E'Ei~ BOLT ASS'Y M8x22 - 2
21 65.90201-0037 ~ItjJO!Ai ~~ BOLT; SPACER 1 -
- 06.06225-0704 ~Ej~ ~~ BOLT ; STUD M8x20 - 1
22 06.16731-21 07 ~~ra .2.fA~ WASHER ; SPRING AS 1 1
23 06.11063-8214 -&zt L-j~ NUT; HEX. M8 1 1
24 65.90310-0109 ~Ci.:J. LfAf SCREW ; PLUG M16x2 1 1
25 06.56190-0709 AI~ ra RING ; SEAL A16x22 1 1
26 65.01601-6005A 2.~ ~~CliO! .':r.-§- ::E'EJ~ OIL SPRAY NOZZLE ASS'Y 6 -
- 65.01 601-6003C 2.~ ~~CliO! .':r.-§- ::E'EJ~ OIL SPRAY NOZZLE ASS'Y - 6
27 65.05405-6001 ~2.1 ~ 'IJ!~ ::E'EI ~ RELIEF VALVE ASS'Y 6 6
28 06.08092-2403 ~Ci.:J. LfAf SCREW; PLUG M12x1.5 1 1
29 06.56190-0704 AI~ ra RING ; SEAL A12x18 1 1
30 65.41530-0200 ~-E~ 0 f~'a ~2.f~ BRACKET ; FRONT MOUNTING 1 1
31 65.90201-0006 ~Ej~ ~~ BOLT ; STUD M12x1.5x35 1 1
32 06.16731-21 09 ~~ra .2.fA~ WASHER ; SPRING A12 1 1
33 06.11 064-9216 -&zt Li~ NUT ; HEX. M1 0 1 1
34 65.90001-0088 -&zt ~~ BOLT; HEX. 2 2
35 65.41530-0199 ~-E~ of~'a ~2.f~ BRACKET ; FRONT MOUNTING 1 1
36 65.90001-0088 -&n
., st
2E - BOLT; HEX. 3 3
3
E~OI~ 71~ 7-IIOIA
Fig,002 TIMING GEAR CASE
4
E~OI~ 71~ 7liOIA
Fig,002 TIMING GEAR CASE
*~(Q'ty)
XIAII!!:2 ¥~~.2 Ill
Ailfl~ :2!!~ :i!.
Key No. Part No.
t::t
"'T"
:a:
i!i ~ Description AD AD
086 136
li =
s.c ICA Remarks
Tl Tl
1 65.01304-001 ON E~Oj~ 7j0j 7i!Oi~ CASE ; TIMING GEAR 1 1
2 65.91010-0018 Cf.!f-~ t\ PIN; DOWEL 2 2
3 65.01903C0021 EfOj~ 7j0j ;lijoj~ 7f~~ GASKET ; TIMING GEAR CASE 1 1
4 06.01913-3113 ~~ ~El* BOLT ASS'Y M8x20 5 5
5 06.06225-0704 ~E~~ ~~ BOLT; STUD M8x20 1 1
6 06.16731-21 07 ~E.i@:) £fA~ WASHER ; SPRING A8 1 1
7 06.11 063-8214 -&ZJ" Li ~ NUT; HEX. M8 1 1
8 06.01943-3317 .g~ ~~~ BOLT ASS'Y M12x1.5x30 4 4
9 65.90201-0048 ~E~~ ~~ BOLT; STUD 1 1
10 06.06225-0809 ~E~~ ~~ BOLT ; STUD M1 Ox35 4 4
11 06.06225-0810 ~E~~ ~~ BOLT ; STUD M1 Ox40 2 2
12 65.01903B0113 Efoj~ 7j0j 7i!Oi~ 7f~~ GASKET ; TIMING GEAR CASE 1 1
13 06.22022-0907 ~~ ~ PIN ; PARALLEL 6M6x1 0 2 2
14 65.01305-5028C EfOj~ 7j0j ;lijoj~ 7~1:1~ COVER ; TIMING GEAR CASE 1 1
15 06.01923-2914 ~~ ~El* BOLT ASS'Y M6x22 13 13
16 65.0151 0-0157 2.~ Aj~ SEAL; OIL 1 1
17 65.01903B0029 EfOI~ 7j0j 7i!OI~ 7f~~ GASKET ; TIMING GEAR CASE 1 1
18 65.01307-5002 ~ ~ COVER 1 1
19 06.01923-2918 -§~ ~EI~ BOLT ASS'Y M6x35 9 9
20 65.90201-0146 ~E~~ ~~ BOLT ; STUD M6x16 2 2
21 06.1 501 0-2309 ~£fA~ WASHER ; PLAIN 6.4 2 2
22 06.16731-2105 ~E.i@:) £fA~ WASHER ; SPRING A6 2 2
23 06.11 063-8212 -&ZJ" Li ~ NUT; HEX. M6 2 2
24 65.19202-5015 2.JE.'a ~3 HOOK ; LIFTING 1 1
25 65.91701-0273 ~-§:itj i@:J RING ; STOPPER 1 1
26 06.01013-9517 -&n
-, .!i!.E
2- BOLT ; HEX. M16x60 1 1
27 65.54903A0013 7f~~ GASKET 1 1
28 06.01913-3215 ~~ ~El* SOLT ASS'Y M1 Ox25 4 4
5
~2~01~ 5~.!¥-~
Fig,003 FLYWHEEL HOUSING
2 5
cttr rb ,
Nl? 4 ~
10
6
~2~01 ~ <5~.!f-~
Fig,003 FLYWHEEL HOUSING
*~(Q'ty)
J;IAII!!~ ·~\:!::!~ :a:
Ailll~ :l!f~ Ill .:i!
~
t:l
"'T" i5" Description AD AD .i .:.
Key No. Part No. 086 136
Tl Tl
s.c ICA Remarks
1 65.01401-027 4 ~2.fOI~ iif~~ HOUSING ; FLYWHEEL 1 1
2 65.01903A0207 -i2.fOI!! iif~~ 7f~~ GASKET; FLYWHEEL HOUSING 1 1
3 65.96002-0003 :il.!f- 1Jj CAP; RUBBER 1 1
4 65.90201-0049 ~Ei~ ~~ BOLT; STUD M12x1.5x35 1 1
5 65.96002-0005 :il.!f- 1Jj CAP; RUBBER 1 1
6 06.16731-2109 ~E.iS .2.fJ..~ WASHER ; SPRING A12 1 1
7 06.11 063-9216 &:z.J- Li~ NUT ; HEX. M12x1.5 1 1
8 06.01943-3319 ~~ ~EJ~ BOLT ASS'Y M12x1. 5x40 9 9
9 65.91710-0016 ~-§Itj iS RING ; STOPPER 2 2
10 65.0151 0-0037 .2.~ AI~ SEAL; OIL 1 1
7
~ zt.:.? ~ tH 7~ tH
Fig,004 WATER CHAMBER COVER
8
~zt? ~1::1~ 7~1::1~
Fig,004 WATER CHAMBER COVER
:XIAII!!:2 *~(Q'ty)
·~~:2: Ailll~
Key No. Part No.

,..
t::l :a:
i5" ~ Description AD AD
086 136
Tl Tl
=:2!tM
.ns.c ICA
111 2
Remarks
1 65.01705-0002B ~:z{=]' ~1:1-j 7-jl::l~ COVER; WATER CHAMBER 1 1
2 65.01907A0002 .2.~ ~:z{71 7f~~ GASKET ; OIL COOLER 1 1
3 06.15010-2311 ~ 2fA1 WASHER ; PLAIN 8.4 12 12
4 06.16731-2107 ~Ei5 2fA1 WASHER ; SPRING AS 12 12
5 06.01923-3115 .g~ .:EiE:I* BOLT ASS'Y M8x25 14 14
6 65.90201-0149 ~E~.!::, .g~ BOLT; STUD M8x25 12 12
7 06.11063-8214 &:z..'" Li~ NUT; HEX. M8 12 12
9
1::::1 2.1 C.-i
Fig.005 BREATHER
{lt:!Ci an=. 7-jl:fj

CYLINDER HEAD COVER
10
1:::1 2.1 [.~
Fig,005 BREATHER
*~(Q'ty)
;t;IAI!!!:2 ¥~~£: Ailll~ :2@~ Ill :i!
:a:
~
t::l
"'T" i5" Description AD AD 3! .:.
Tl Tl
s.c ICA Remarks
1 65.01 801-5099C .::.2.!Ci ~~~ BREATHER ASS'Y 1 1

2 65. 96501-0033B 0-~ 0-RING 1 1
3 06.01923-3113 ~~~~~ BOLT ASS'Y M8x20 3 3
4 06.67020-0105 £.:::::: -§-~E. CLAMP; HOSE 1 1
5 65.96301-0276 .::il.!f. £.:::::: HOSE ; RUBBER 1 1
11
.:r-s AIA'E!J
Fig.006 DRIVING SYSTEM
40 23 24
41 ~
24 25 26
42
39 (\
46
25
27
49 48 47
9110 14115
11 16
12 17
13 18
12
~~ AIA'E!J
Fig,006 DRIVING SYSTEM
*~(Q'ty)
J:IAI!!!:2 ·~~~ ...
I
:a:
Ailll~ :2!!~
ll .:.
HI .:i!.
Tl Tl
s.c ICA Remarks
1 65.021 01-0056B 3~3 5i SHAFT ; CRANK 1 1 D
2 65.02115-0040K 3~3 5i 7loj GEAR ; CRANK SHAFT 1 1
3 06.22022-0912 .i~f~ ~ PIN ; PARALLEL 6M6x20 1 1
4 65.01110-6120 Oil '2.] till oj 'a BEARING ; MAIN 7 - us
- 65.01110-6351 Oil '2.] till oj 'a BEARING ; MAIN - 7 us
5 65.01110-6352 . Oil '2.] till oj 'a · BEARING ; MAIN 0.25MM - 1 us
6 65.01110-6353 · 011'2.1 tiiiOJ'a · BEARING ; MAIN 0.50MM - 1 us
7 65.01110-6354 · 011'2.1 tiiiOJ'a · BEARING ; MAIN 0.75MM - 1 us
8 65.01110-6355 · 011'2.1 tiiiOJ'a · BEARING ; MAIN 1.OOMM - 1 us
9 65.01150-0015 ~2-i:~.§. tiiiOJ'aW.!f.l BEARING ; THRUST(UPPER) 2 2 us
10 65.01150-0019 · ~2-J~§. tiiiOJ'aW¥) · BEARING ; THRUST(UPPER) 0.25 1 1 us
11 65.01150-0020 . ~2-J~§. tiiiOJ'a(~.!f.) · BEARING ; THRUST(UPPER) 0.50 1 1 us
12 65.01150-0021 · ~2-J~§. tiiiOJ'aW.!f.l ·BEARING; THRUST(UPPER) 0.75 1 1 us
13 65.01150-0022 . ~2-J~§. tiiiOJ'a(~¥) · BEARING ; THRUST(UPPER) 1.00 1 1 us
14 65.01150-0016A ~2-J~§. tiiiOJ'a('8-f.!f.) BEARING ; THRUST(LOWER) 2 2 us
15 65.01150-0023A · ~2-J~§. tiiiOJoa('a-f.!f.) · BEARING ; THRUST(LOWER) 0.25 1 1 us
16 65.01150-0024A . ~2-J~§. tiiiOJ'a('8"f¥) · BEARING ; THRUST(LOWER) 0.50 1 1 us
17 65.01150-0025A . ~2-j ~§. till oj 'a ('8-f.!f.) · BEARING ; THRUST(LOWER) 0. 75 1 1 us
18 65.01150-0026A · ~2-J~§. tiiiOJ'a('8"f.!f.) · BEARING ; THRUST(LOWER) 1.00 1 1 us
19 65.02201-7032 -t!% ~971 DAMPER; VIBRATION 1 1
20 65.02201-7033 . -t!% ~971 ·DAMPER; VIBRATION 1 1
21 65.02201-7034 . -t!% ~971 ·DAMPER; VIBRATION 1 1
22 65. 90020-0062B &n ..., .!i!.E
2- BOLT; HEX. M10x20 6 6
23 65.02301-5184 -!2.fOI!l ~El¥ FLYWHEEL ASS'Y 1 1
24 65.02301-0313 · ~2.fOii ·FLYWHEEL 1 1
25 65.02310-001 OA . AI% ~%71 'a 7IOJ · GEAR ; STARTER RING 1 1
26 06.22022-1 01 0 ~~ E! PIN ; PARALLEL 8x16 1 1
27 65.90001-0084 &n ..., .!i!.E
2- BOLT; HEX. M14x1.5x40 6 6
28 06.16731-2110 ~E'a .2.fA~ WASHER ; SPRING A14 6 6
29 65. 02401-6018B t!I:!J'S .£E. ~El¥ CONNECTING ROD ASS'Y 6 -
- 65.02401-6101 F t! I:!J 'a .£E. ~El ¥ CONNECTING ROD ASS'Y - 6
30 65.02401-0005 . t! I:!J 'a .£E. · ROD ; CONNECTING 1 - D
- 65.02401-0030 . t!I:!J'S .£E. · ROD ; CONNECTING - 1 D
31 65. 90020-0009D . t!I:!J'S .£E.~§. ·BOLT; CONNECTING ROD 2 2
32 65.02405-0010 . t! I:!J 'S .£E. ¥*1 · BUSH ; CONNECTING ROD 1 - B
- 65.02405-0015C . t! I:!J 'a .£E. ¥*1 · BUSH ; CONNECTING ROD - 1 B
33 65.91301-001 0 · Cf.!f~ EJ ·PIN; DOWEL 2 2
34 65.02410-0010 t! I:!J 'a .£E. till oj 'a BEARING ; CONNECTING ROD 6 6 us
35 65.02410-0011 . t! I:!J 'a .£E. jjjl oj 'a · BEARING ; CONNECTING ROD 0.25MM 1 1 us
36 65.02410-0012 . t! I:!J 'S .£E. jjjl oj 'a · BEARING ; CONNECTING ROD 0.50MM 1 1 us
37 65.02410-0013 . t!I:!J'S £E. jjjiOJ'a · BEARING ; CONNECTING ROD 0. 75MM 1 1 us
38 65.02410-0014 . t!I:!J'S £E. till OJ 'a · BEARING ; CONNECTING ROD 1 .OOMM 1 1 us
39 65.02501-0214B :rri~E PISTON 6 -
- 65.02501-0507 :rri~E PISTON - 6
40 65.02503-0054 ~ 'a RING; TOP 6 6
13
-11~ AI~~
40
23 24
41
~
42 24 25
39
\\
46 25
f\
27
49 48 47
9110 14115
11 16
12 17
13 18
14
T~ AIA'E!J
*~(Q'ty)
J:IAII!!~ ¥~'i!t~ Ailll~ ~@~Ill 2
s.c=ICA Remarks
:a:
~
t:l
"'T'" i!i Description AD AD
.:a.
Tl Tl
41 65.02503-0120 2~f ~ RING; 2ND 6 6
42 65.02503-0115 2.~ ~ RING; OIL 6 6
43 65.02502-0206 :iii ~-E t! PIN; PISTON 6 6
44 65.02502-0010 . :iii ~-E t! · PIN ; PISTON 1 1
45 65.02502-01 06 . :iii ~-E t! · PIN ; PISTON 1 1
46 06.29020-0126 'E:J*
co ~I RING ; SNAP 42x1. 75 12 12
47 65.02601-0153 v-~~ ~2.1 PULLEY ; V-BELT 1 1
48 65.90701-0088 £f A1 WASHER 1 1
49 06.02106-0619 .:::::~Oil~!§;~ BOLT; SOCKET HEAD 8 8
15
~ iC:!c~ ~IE
Fig,007 CYLINDER HEAD
1
~
2-7
11
tj-8
16
~ i[J C-i '6~1 E
Fig,007 CYLINDER HEAD
*~(Q'ty)
XI All!!£. ·~~.2 Ailll~ £.!!~Ill .:l!
t::l
"'T"
:a:
iS ~ Description AD AD .l!..:
Tl Tl
s.c ICA Remarks
1 65.031 01-6087B ~i:JC-j 511~ ~iEJ~ CYLINDER HEAD ASS'Y 3 3
2 65.03101-1087 A · ~ i:JC-j 511~ · HEAD ; CYLINDER 1 1
3 65.03201-1011 A · ~!::. ;fol~ · GUIDE ; VALVE 4 4 B
4 65.03203-1 028D . ~.:::. AI~(~H71) ·SEAT; VALVE(EXHAUST) 2 2 B
5 65.03203-1 029G · ~!::. Al~(-&71) ·SEAT; VALVE(INTAKE) 2 2 B
6 06.15091-0319 . .:aoj ~21 ::J. ·PLUG; CORE 7 7
7 65.91 001-0013A . .:aoj E! ·PIN; CORE 2 2
8 06.22022-0909 ~~ E! PIN ; PARALLEL 6M6x14 6 6
9 65.03901-0070A ~i:JC-j 511~ 7f~~ GASKET ; CYLINDER HEAD 3 3
10 65.90021-0007 ~21~ -fi-.2. ~~ BOLT; COLLARED DUO. 24 24
11 06.06225-0809 ~E1~ ~~ BOLT; STUD M10x35 2 2
17
~ iC! C-i '6-11 c: 7~ ~
Fig.OOB CYLINDER HEAD COVER
18
~i(:!c~ '6-11 c 7~~
Fig,008 CYLINDER HEAD COVER
*~(Q'ty)
;t;IAII!!.i ¥ ~ ~L:2 Ailll~ Ul~lll .:i!
Key No. Part No.
1::1
"T" ~ ~ Description AD AD
086
Tl
=ICA Remarks
136 .ns.c
Tl
1 65.03401-0021 H ~t:JCi 511.:=. 71~ COVER ; CYLINDER HEAD 1 1
2 65.03401-0056A ~t:JCi 511.:=. 71~ COVER ; CYLINDER HEAD 1 1
3 65.03401-60448 ~t:JCi 511.:=. 71~ ~iEJ~ CYLINDER HEAD COVER ASS'Y 1 1
4 65.03905-0022 ~t:JCi 511.:=. 711::1~ 7~~~ GASKET ; CYLINDER HEAD COVER 3 3
5 65.90020-0073 ~21==- &:z.t ~~ BOLT ; COLLARED HEX. 6 6 D
6 65.90701-0202 .£~ A'/ WASHER 6 6 D
7 65.03905-0023A ~t:JCi 511.:=. 7~~~ GASKET ; CYLINDER HEAD 6 6 D
8 65.01810-5011 2.~ ~~ t!l ~iEJ~ OIL FILLER CAP ASS'Y 1 1
19
E~OI~ Al-6~
Fig.009 TIMING SYSTEM
17
~
18-33
27
r)o~
18
22
20
9~ Q
25
~~ f--,
29 28 ~ 71 ~H 71
INTAKE EXHAUST
41
20
E~OI~ Al6~
Fig,009 TIMING SYSTEM
*~(Q'ty)
J:IAII!!:2 ¥§'i!!£. A111l~ :Ut~lll ,j!
Key No. Part No.

.,...
1:01 :a:
iS ~ Description AD AD
086 136
l! =
s.c ICA Remarks
Tl Tl
1 65.04101-0041 ~71 ~~ VALVE; INTAKE 6 6
2 65.041 01-0026 . ~71 ~~ ·VALVE ; INTAKE 1 1
3 65.04101-0037 ·-!71 ~~ ·VALVE ; INTAKE 1 1
4 65.04101-0042 ~H71 ~~ VALVE; EXHAUST 6 6
5 65.041 01-0027 . ~H71 ~~ · VALVE ; EXHAUST 1 1
6 65.04101-0038 . ~H71 ~~ · VALVE ; EXHAUST 1 1
7 65.041 02-6019 ~~~~'a~~~ VALVE SPRING ASS'Y 6 6
8 65.041 02-6002 . ~~~~'a~~~ ·VALVE SPRING ASS'Y 1 1
9 65.041 02-6020 . ~~~~'a~~~ · VALVE SPRING ASS'Y 1 1
10 65.041 02-0027 ~~~~'a SPRING; VALVE 6 6
11 65.041 02-0007 . ~~~~'a ·SPRING ; VALVE 1 1
12 65.041 02-0028 . ~~~~'a ·SPRING ; VALVE 1 1
13 65.041 03-0013 ~~~~'a 2.IE:IIOILi RETAINER ; VALVE SPRING 12 12
14 65.04103-0009 ~~~~'a Al5, SEAT; VALVE SPRING 12 12
15 65.04104-0006 ~~ .I!.Ei COTTER ; VALVE 24 24
16 65.04902-0013 ~~ ~'EI AI~ SEAL; VALVE STEM 12 12
17 65.04200-6025E ~71 gj- ?1.1 ~ ~~~ ROCKER ARM & SHAFT ASS'Y 3 3
18 65.04201-5013E . ~71 gj- ~~~ · ROCKER ARM ASS'Y 4 4
19 65.04201-0006K .. ~7i gj- .. ARM ; ROCKER 1 1
20 65. 93020-0032C .. !f.*' .. BUSH 1 1
21 65.04205-0003A . ~~ Lf.Af · SCREW ; ADJUST 4 4
22 65.90501-0003 · -&:z.t Li5. · NUT ; HEX. M1 Ox1.0 4 4
23 65.04203-5009 . ~71 gj- ~ ~~~ ·ROCKER ARM SHAFT ASS'Y 1 1
24 65. 04203-0009A .. ~71 gj- ~ .. SHAFT ; ROCKER ARM 1 1
25 65.90302-0012 .. .I!.oj -§2-I.:J. .. PLUG; CORE 2 2
26 65.04202-0017A . ~71 gj- ~2.f~ · BRACKET ; ROCKER ARM 2 2
27 65.97601-0055 . %!'~~~'a · SPRING ; COMPRESSION 1 1
28 65.90710-0039 · £f A9 ·WASHER 2 2
29 06.29010-0120 . 'EJ% 'a ·RING; SNAP 2 2
30 65.90020-0056 . &:z.t -§-5. · BOLT ; HEX. M12x1 .5x80 2 2
31 06.01013-9221 ·-&:z.t-§-5. · BOLT; HEX. M1 Ox80 2 2
32 06.16731-2108 ·~~'a £fA9 ·WASHER; SPRING A1 0 2 2
33 06.15030-0514 · :g £fA9 · WASHER ; PLAIN 10.5 2 2
34 65.04301-0005 ~~ Ef~ TAPPET ; VALVE 12 12
35 65.04302-5010 -¥-*1 £~ ROD; PUSH 12 12
36 65.04401-0014E t!l ~ SHAFT; CAM 1 1
37 65.90720-0099 ~2-1~5. £fA9 WASHER ; THRUST 1 1
38 65.98112-0038 -£iC!!:AI FLANGE 1 1
39 65.90001-6003 -§-5, ~~~ BOLT ASS'Y M6x14 2 2
40 06.22022-1016 :g~ lB PIN ; PARALLEL 8M6x36 1 1
41 65.04501-0057 t!l ~7loj GEAR ; CAM SHAFT 1 1
42 06.01913-3120 -§-5, ~~~ BOLT ASS'Y M8x45 4 4
43 65.04505-5008A ofol~ 7joj ~~~ IDLE GEAR ASS'Y 1 1
44 65.04505-0005 · ofol~ 7joj ·GEAR; IDLE 1 1
45 65.04507-0003A · ofol~ 7loj ¥*1 · BUSH ; IDLE GEAR 1 1
21
E~OI ~ AI A'E!J
17
~
18-33
r~~
18 27
22
9~
20 ~~~
25
~~ •t--21
29 28 ~ 71 ~H 71
INTAKE EXHAUST
41
22
E~OI~ AI~'EY
XI All!!£: ¥~~~ *~(Q'ty) Ail! I~ £:!!~Ill .:&!.
Key No. Part No.

,.
t::l :a:
i5' ~ Description AD AD i!.
086 136 s.c
=ICA Remarks
Tl Tl
46 65.04506-0008 ofol~ 7101 ~ PIN ; IDLE GEAR 1 1
47 65.90720-0019 ~2-1~5. £fA~ WASHER ; THRUST 1 1
48 06.01914-3126 ~5. ?Ei61~ BOLT ASS'Y M8x75 2 2
23
F. .2. ~ n~ ::u:
IQ,01 0 OIL PUMP
,---19
I
'-18
24
.:;:r.~ JZ
.2. 01
2 I::I-
Fig.01 0 OIL PUMP

*~(Q'ty)
J;IAII!!:l ¥11~.2
,..... ~ ~ Description AD AD
Ailll~ .2!t~
.n .:.
Ill .:i!.
Tl Tl
s.c ICA Remarks
1 65.05100-6022 .2.~ ~E. 3::'El~ OIL PUMP ASS'Y 1 1
2 65.05102-0014 . .2.~ ~E. '5f~~ · HOUSING ; OIL PUMP 1 1
3 65.05104-5004 . .2.~ ~E. 7101 3::'El~ · OIL PUMP GEAR ASS'Y 1 1
4 65.05104-5003 . .2.~ ~E. 7101 ~'El~ · OIL PUMP GEAR ASS'Y 1 1
5 06.22022-0909 . :g~ ~ · PIN ; PARALLEL 6M6x14 1 1
6 65.05103-5015 . 711:1-l 3::'El~ · COVER ASS 'Y 1 1
7 65.05103-5012 . 711:1-l 3::'El~ · COVER ASS'Y 1 1
8 65.05410-0025 . ~.!:!,~£:!X~ · PLUNGER ; VALVE 1 1
9 65.97601-0110 . ~.!:!. ~E.'a ·SPRING; VALVE 1 1
10 65.90310-0104 • ~2:-j.:::J. q,q · SCREW ; PLUG 1 1
11 06.01013-9118 . &Zl' -§-~ · BOLT ; HEX. M8x65 4 4
12 65.90510-0012 . ·~H':I'bi'XI Li~ · NUT ; CLEVELOC 4 4
13 65.05201-0037 · .2.~ ~E. T-~ 7101 · GEAR ; OIL PUMP DRIVE 1 1
14 06.29141-0207 . 't!"<g- 71 · KEY ; WOODRUFF 3x13x5 1 1
15 06.16050-0311 · ~3. £fA1 · WASHER ; LOCK 1 1
16 06.11 053-9217 · &ZJ" Li~ ·NUT; HEX. M14x1.5 1 1
17 06.22022-0907 :g~ E! PIN ; PARALLEL 6M6x1 0 2 2
18 06.01013-9215 &Zl' -§-~ BOLT; HEX. M1 Ox50 2 2
19 65.90801-0018 ~3. £fA1 WASHER ; LOCK 2 2
20 65.05200-6034 ofol~ 7101 ofiflEJ 3::'El~ IDLE GEAR MOUNTING ASS'Y 1 1
21 65.05204-0036 · ofol~ 7101 ·GEAR; IDLE 1 1
22 06.31420-0314 . -§- Hll 01 'a · BEARING ; BALL 2 2
23 06.29020-0132 . 'E:l% 'a · RING ; SNAP 55x2 2 2
24 65.05205-0018 · ofol~ 7101 ~ · PIN ; IDLE GEAR 1 1
25 06.29010-0125 . 'E:l% 'a · RING ; SNAP 30x2 1 1
26 65.90030-0009 . :::::::~ 011=- -§-~ · BOLT ; SOCKET HEAD M1 Ox60 1 1
25
.2.~ ~1!1-71
Fig,011 OIL FILTER
1
h
2- 11
26
.2. ~ 0~ l!.l-71
Fig,011 OIL FILTER
*~(Q'ty)
Ill
XIAII!!.t
Key No.
¥~1:!:!Ji!
Part No.
...
1::1 :a:
086
Ailll~ .2@~
=ICA Remarks
136 .ns.c
~
Tl Tl
1 65.05501-7064B 2.~ Ofi!f/l ~EI~ OIL FILTER ASS'Y 1 1
2 65.0551 0-5022B · 7f~2.IXI ~EI~ · CARTRIDGE ASS'Y 1 1
3 65.05503-5042 . 2.~ O:j:iJ.I-71 til~ ~EI~ · OIL FILTER HEAD ASS'Y 1 1
4 65.05518-0003 ·~!:'.~\:!Xi · PLUNGER; VALVE 1 1
. A II 2.1
5 65.97601-0065 --a ·SPRING 1 1
6 65.9031 0-0057 -~2-j.::ILfAf · SCREW ; PLUG M1 Ox1.5 1 1
7 06.56190-0716 . AI~ '5 · RING ; SEAL A21 x26 1 1
8 65.05518-0006 ·~!:'.~\:!Xi · PLUNGER ; VALVE 1 1
• A II 2.1
9 65.97601-0075 --0 ·SPRING 1 1
10 65.9031 0-0065 · ~2-j.::ILfAf · SCREW ; PLUG 1 1
11 06.56190-0726 . AI~ '5 · RING ; SEAL A26x31 1 1
12 65.05901 A0052 2.~ OiTif71 7f~~ GASKET ; OIL FILTER 1 1
13 06.01913-3122 .g~ ~EI~ BOLT ASS'Y M8x55 2 2
14 06.01913-3118 .g~ ~EI~ BOLT ASS'Y M8x35 2 2
27
.2. ~ 'c!f zt71
Fig,012 OIL COOLER
23
1
~ 22
2-20
19
11
28
.2.~ ~zt/l
Fig.012 OIL COOLER
J;IAII!!.2 *~(Q'ty)
¥~\!!~
,..... = i5' ~ Description AD AD .ns.c
HI .:il
AiHI~ :l!t~
=ICA Remarks
Tl Tl
1 65005601-71378 2.~ ~:Z.,'-71 ~iE:l~ OIL COOLER ASS'Y 1 1
2 65005604-5030 0 2. ~ 1
cFPI tr42-~ 0HOUSING ; OIL COOLER 1 1
3 6509031 0-0136A 0 ~2-l.:::J. LfAr 0SCREW ; PLUG 1 1
4 06056190-0718 0AI~ 'E! oRING; SEAL 1 1
5 06031641-0429 o~l§l~ 0BALL ; STEEL 1 1
6 65097601-0004 o~~'E! 0SPRING 1 1
7 65090310-0003 0 ~2-l.:::J. LfAr 0SCREW ; PLUG M26x105 1 1
8 65005611-0001 0~ oPIN 1 1
9 06 056190-0728 0AI~ 'E! oRING ; SEAL A26x32 1 1
10 650 05606-5020 02.~ 1
cFPI ~~112!!~ 0ELEMENT ; OIL COOLER 1 1
11 65096601-0018A 0 ~~A:I7r~~ 0GASKET ; FLANGE 2 2
12 06002090-0418 0 ~~Oil~~~ 0BOLT ; SOCKET HEAD 4 4
13 06015030-0513 0 ~ .2.rA~ oWASHER ; PLAIN 8.4 4 4
14 0601611 0-01 06 0 ~~'E! .2.rA~ 0WASHER ; SPRING AS 4 4
15 65o05605-0028A 02.~ ~:Z.J-71 7{~ °COVER ; OIL COOLER 1 1
16 650 06301-0160 o ~:z.J-9 :urol~ 0PIPE; COOLING WATER 1 1
17 65096601-0029 o £~XI7r~~ oGASKET ; FLANGE 1 1
18 06001923-3112 0 ~.§. 3:.~~ 0BOLT ASS'Y M8x18 4 4
19 65005902-000SA 0 2.~ ~:z.J-71 71~ 7r~~ 0GASKET ; OIL COOLER COVER 1 1
20 06001923-3126 . ~.§. 3:~~ 0BOLT ASS'Y M8x75 8 8
21 650 90001-6011 -§:.§. ~~~ BOLT ASS'Y M10x70 2 2
22 060 01924-3225 -§:§. ~~~ BOLT ASS'Y M10x70 2 2
23 65o05902A0011 2.~ ~:z.J-71 tr42-~ 7r~~ GASKET ; OIL COOLER HOUSING 1 1
24 650 96601-034 7 7r~~ GASKET 1 1
25 65091605-0110 -§2.f~~ 7{~~ COVER ; BLIND 1 1
26 06001913-3112 -§:.§. 3:: iE:J~ BOLT ASS'Y M8x18 4 4
29
.2. ol
2
:u:H
L..:!
Fig,013 OIL PAN
12
~
13- 17
11
30
.2. ~ ¥!!
Fig.013 OIL PAN
*~(Q'ty)
XI All!!£: ¥~!:!:!~
:a:
Ailll~ .2!t~ Ill .2
~
1:::1
I i5" Description AD AD i!. .:.
Tl Tl
s.c ICA Remarks
1 65.05801-5205A 2.~ ¥:!! PAN; OIL 1 1 s
2 65.05809-0012 2.~ ¥:!! £f.A1 WASHER ; OIL PAN 9 9
3 65.05809-0013 2.~ ¥:!! £f.A1 WASHER ; OIL PAN 2 2
4 65.05809-0014 2.~ ¥:!! £f.A1 WASHER ; OIL PAN 2 2
5 65.05809-0037 2.~ ¥:!! £f.A1 WASHER ; OIL PAN 1 1
6 65.90001-6005 :::::.~ -§- .§. ± 'E;j* SOCKET BOLT ASS'Y 2 2
7 06.01913-3115 -§-.§. ±'EJ* BOLT ASS'Y M8x25 25 25
8 65.90001-6006 :::::.~ -§-.§. ±'EJ* SOCKET BOLT ASS'Y 10 10
9 65.05904A0016 2.~ ¥:!! 7f:::'::~ GASKET ; OIL PAN 1 1
10 65.05806-6052 7fOIE. -*.!::'. ±iEI* GUIDE TUBE ASS'Y 1 1
11 65.05805-5137 A 2.~ ejj~ 7JIOIAI ±iEI* OIL LEVEL GAUGE ASS'Y 1 1
12 65. 05701-6023B 2.~ a"EJ IifOIE. ±iEI* OIL SUCTION PIPE ASS'Y 1 1
13 65.05701-5809B · 2.~ a"EJ IifOIE. ±iEI* · OIL SUCTION PIPE ASS'Y 1 1
14 65.057 40-001 6 · 2.~ a"EJ ILfOIE. .!::'.2.f~ · BRACKET ; OIL SUCTION PIPE 1 1
15 65.90510-0012 · ~EJ ~AI Li .§. · NUT ; CLEVELOC 1 1
16 06.01283-7114 . ~F.f -§-.§. ·BOLT; HEX. M8x22 1 1
17 06.1501 0-2311 . :g £f.A1 · WASHER ; PLAIN 8.4 1 1
18 06.01913-3113 -§-.§. ±. iEI * BOLT ASS'Y M8x20 2 2
19 06.01913-3111 -§-.§. ±iEI * BOLT ASS'Y M8x16 1 1
20 65.96601 B0019 2.~ a"EJ IifOIE. 7f:::'::~ GASKET ; OIL SUCTION PIPE 1 1
21 65. 05903B0003 'l:!'=!J'S ~~AI 7f:::'::~ GASKET ; CONNECTING FLANGE 1 1
22 65.05715-5001 'l:J'=!j{:! ~t!!AI ±iEI* CONNECTION FLANGE ASS'Y 1 1
23 06.02090-0422 :::::.~ 511 E. -§-.§. BOLT ; SOCKET HEAD M8x65 2 2
24 06.16731-2107 :::'::E'5 £fA1 WASHER ; SPRING AS 2 2
25 06.1501 0-2311 :g £f.A1 WASHER ; PLAIN 8.4 2 2
26 65.96601-0050 2.~ IifOIE. 7f:::'::~ GASKET ; OIL PIPE 4 4
27 65.05701-5153 2.~ IifOIE. ±~* OIL PIPE ASS'Y 1 1
28 65.05701-5230 2.~ IifOIE. PIPE; OIL 1 1
29 65.90001-6006 :::::.~ -§-.§. ±~* SOCKET BOLT ASS'Y 4 4
30 06.01923-3113 -§- .§. ±.~* BOLT ASS'Y M8x20 4 4
31 65.981 03-0019 ~± ifLI~ UNION ; BANJO 1 1
32 65.98150-0115 ~£-lf LfAf SCREW ; HOLLOW 1 1
33 06.56190-0732 AI~ '5 RING ; SEAL A30x36 2 2
34 65.9031 0-0148 ~2-j:J. LfAf SCREW; PLUG 2 2
31
~ zt .:f:. E~ 0 I .I.L
Fig,014 COOLING WATER PIPE(1)
32
~ ~.::? IL~OI.:!:.
Fig.014 COOLING WATER PIPE(1)
*~(Q'ty)
XIAII!!.i: ¥~!!!!!
,..... :a:
i5" ~ Description
Aflll~ .2!~
AD AD l!. =
086 136 s.c ICA
Ill .:i!
Key No. Part No. Remarks
Tl Tl
1 65.06301-0134C 1c!J Zl-9IIfOI E. PIPE; COOLING WATER 1 1
2 65.06903A0011 ic!J:zf9 IIfOIE 7f~~ GASKET; WATER PIPE 3 3
3 06.01923-3122 -§.§. ±iEJ~ BOLT ASS'Y M8x55 3 3
4 06.01923-3124 ~~ 3':'EJ~ BOLT ASS'Y M8x65 3 3
5 65.90320-0019 :gi:-j.:J. LfAf SCREW ; PLUG PT3/8 1 1
6 65.98131-0140 L-1 :g NIPPLE 1 1
7 06.56190-0728 AI~~ RING ; SEAL A26x32 1 1
8 65.98130-0259 Oi~E~ ADAPTER 1 1
9 06.08092-2404 :gi:-j.:J. LfAf SCREW ; PLUG M14x1.5 1 1
10 06.56190-0706 AI~~ RING; SEAL A14x20 1 1
11 06.08092-2405 :gi:-j .:J. LfAf SCREW ; PLUG M16x1 .5 1 1
12 06.561 90-0709 AI~~ RING ; SEAL A16x22 1 1
13 65.06301-0083 'c!J Zl-9 IIfOI.!!. PIPE ; COOLING WATER 1 1
14 04.27405-1 908A 2.![! .£~ HOSE ; RUBBER 2 2
15 06.67020-0109 .£~ -§-~E. CLAMP; HOSE 4 4
16 65.06301-5400 lc!J Zl-9 IIfOI E. PIPE ; COOLING WATER 1 1
17 04.27405-0904 2.![! .£~ HOSE ; RUBBER 1 1
18 06.67020-0106 .£~-§-~E. CLAMP; HOSE 2 2
19 65.96301-0589 2.![! .£~ HOSE ; RUBBER 1 1
20 06.67020-0106 .£~-§-~E. CLAMP; HOSE 2 2
21 65.96301-0259A 2.![! .£~ HOSE ; RUBBER 1 1
22 06.67020-0106 .£~-§-~E. CLAMP; HOSE 2 2
33
34
~zt? li~OI.u.
*~(Q'ty)
AlAI!!!£ ¥~t!f~
...
"T"
:a:
i5' ~ Description AD AD .n =.t!!M
Ailll~ HI ,j!

Tl Tl
s.c ICA Remarks
1 65.06301-5399 cFt? n:fol ~
1
PIPE ; COOLING WATER 1 -
2 65.06903A0014 DHL-1 ~~ 7-1 ~j
~H71 7f~~ GASKET ; EXHAUST MANIFOLD COVER 1 -
3 65.97 480-0232 ~ Ci HOLDER 1 -
4 06.01913-3117 ~.§. ~El~ BOLT ASS'Y M8x30 2 -
5 06.01913-3115 ~~~iEJ~ BOLT ASS'Y M8x25 4 -
6 65.96301-0579 ::il.Ef- :2.~ HOSE ; RUBBER 1 -
7 65.97440-0100 :2.~ ~'E!I~(~~2j) CLAMP; HOSE(BAND TYPE) 4 -
8 65.06401-6039 =r.g ~:~PI ~iEJ~ THERMOSTAT ASS'Y 1 -
9 65.96301-0580 ::il.Ef- :2.~ HOSE ; RUBBER 1 -
10 06.67020-0109 :2.~ ~'E!IE. CLAMP; HOSE 1 -
11 65.97 440-01 00 :2.~ ~'E!I~(~~2i) CLAMP ; HOSE(BAND TYPE) 1 -
12 65.06301-5824 'c!j :zf? n:fol ~ PIPE; COOLING WATER 1 -
13 65.96601-0050 2~ n:fol~ 7f~~ GASKET ; OIL PIPE 1 -
14 06.01913-3114 ~.§. ~El~ BOLT ASS'Y M8x22 2 -
15 65.96301-0281 ~2.1~ :2.~ HOSE ; SILICON 1 -
16 65.97 440-01 03 :2.~ ~'E!I~(~~2i) CLAMP; HOSE(BAND TYPE) 2 -
17 65.98150-0077 -i£-lf- LfAf SCREW ; HOLLOW 1 -
18 65.90310-0145 ~2:j:I LfAf SCREW; PLUG 2 -
19 06.561 90-0724 AI~~ RING ; SEAL A25x30 4 -
20 06.08095-4604 ~2:j:I LfAf SCREW; PLUG M14x1.5 1 -
21 06.56190-0705 AI~~ RING ; SEAL A14x18 1 -
22 06.08095-4604 ~2:j:I LfAf SCREW ; PLUG M14x1.5 1 -
23 06.56190-0712 AI~~ RING ; SEAL A18x22 1 -
24 06.08095-4606 ~2:j:I LfAf SCREW; PLUG 1 -
25 06.56190-0705 AI~~ RING ; SEAL A14x18 1 -
35
~ zt-? :u:~ol :u:
36
~ zt-? :rr~ oI .lL
*~(Q'ty)
,;I All!!~ ·~~.2 Ailfl~ :§:!!~ Ill .:il
Key No. Part No.
t:::t
T
:a:
086 136
.n =ICA Remarks
s.c
Tl Tl
1 65.06301-5399 ~ zt=r :u:fol E. PIPE ; COOLING WATER - 1
2 65.06903A0014 ~H71 DHL-1~~711::11 7f~~ GASKET ; EXHAUST MANIFOLD COVER - 1
3 65.97480-0232 ~ Ci HOLDER - 1
4 06.01913-3117 ~~ 35.i61~ BOLT ASS'Y M8x30 - 2
5 06.01913-311 5 ~~ 35.i61~ BOLT ASS'Y M8x25 - 4
6 65.96301-0579 Jl.!f .£.~ HOSE ; RUBBER - 1
7 65.97 440-01 00 .£.~ ~@E(~~~) CLAMP ; HOSE(BAND TYPE) - 4
8 65.06401-6039 =;::g 35.~71 35.i61~ THERMOSTAT ASS'Y - 1
9 65.96301-0580 Jl.!f .£.~ HOSE ; RUBBER - 1
10 06.67020-01 09 .£.~ ~@E CLAMP; HOSE - 1
11 06.67020-0108 .£.~ ~@E CLAMP; HOSE - 1
12 06.08095-4604 ~2-j:::J. LfAf SCREW ; PLUG M14x1 .5 - 1
13 06.56190-0712 Alcg,j OS RING ; SEAL A18x22 - 1
14 06.08095-4606 ~2-j:::J. LfAf SCREW; PLUG - 1
15 06.56190-0705 Alcg,J OS RING ; SEAL A14x18 - 1
37
'c!l zt-? ~ II:
Fig,017 WATER PUMP
21
1
~
2-20
19 7
14
8 9
38
L..U 7 k¢, li:f II
a--. , c -
Fig,017 WATER PUMP
J;IAI!!!£. ·~1!!:2 *W!O'tyl Aft! I~ .t!t~ Ill .i!.

Key No. Part No.
t::f
"'T"
:a:
086 136
.:a=
s.c ICA Remarks
Tl Tl
1 65.06500-6214A lc!Jzt-? ~~ ~iEJ~ WATER PUMP ASS'Y 1 1
2 65.06501-0075C . lc!j zt=r ~ ~ tfil-~ ·HOUSING; WATER PUMP 1 1
3 65.06520-6007 . Oll7fL...I~ AI~ · SEAL ; MECHANICAL 1 1
4 65.06506-0023 ·lc!Jzt-? ~~ gj-li!Jej ·IMPELLER; WATER PUMP 1 1
5 65.93410-0087 . ~ t:!liOi~ · BEARING ; BALL 1 1
6 06.29020-0132 ·'EJ%~ · RING ; SNAP 55x2 1 1
7 65.06504-0030A · v-~ ~ ~2.1 o-j ~ · HUB ; V-BELT PULLEY 1 1
8 65.06503-0078 · v-~~ ~2.1 · PULLEY; V-BELT 1 1
9 06.01013-9107 . ~zt ~~ · BOLT ; HEX. M8x50 6 6
10 06.16731-21 07 ·~~~£fA~ · WASHER ; SPRING A8 6 6
11 65.06512-0010 . lc!Jzt-? ~~ 7-j~ ·COVER; WATER PUMP 1 1
12 65.06901 A0019 · lc!Jzt=r ~~ 7f~~ ·GASKET; WATER PUMP 1 1
13 06.04201-8907 . ~zt ~~ · BOLT ; HEX. M6x14 3 3
14 65.98115-0011 . ~£il- TI-Ll~ · UNION ; HOLLOW 1 1
15 06.01013-9119 . ~zt ~~ · BOLT ; HEX. M8x70 1 1
16 06.16731-21 07 ·~~~£fA~ · WASHER ; SPRING A8 5 5
17 06.01013-9219 . ~zt ~~ · BOLT ; HEX. M1 Ox70 1 1
18 06.16731-21 08 ·~~'a £fA~ · WASHER ; SPRING A10 1 1
19 06.01013-9114 . ~zt ~~ ·BOLT; HEX. M8x45 3 3
20 06.01013-9120 -~:z.t~~ ·BOLT; HEX. M8x75 1 1
21 65.06901 A0020 lc!Jzt=r ~~ 7f~~ GASKET ; WATER PUMP 1 1
39
Fig,01 8 ~:z.t ~
COOLING FAN
40
'c!fzt ~
Fig,018 COOLING FAN
:lj:~(Q'ty)
J;IAII!:!.2 !j!§~.2 Ailll~ .Ut~HI ~
Key No. Part No.

t::t
-r
:a:
i!i '1J Description AD AD li
086 136
=
s.c ICA Remarks
Tl Tl
1 65.06611-01 58 ~ £t!!xl FLANGE; FAN 1 1
2 65.06601-5050 'c!l~~ FAN ; COOLING 1 1
3 06.01013-9127 -&~ -§-~ BOLT ; HEX. M8x120 6 6
4 06.16731-21 07 ~E.i6 .2.fA~ WASHER ; SPRING A8 6 6
5 65.90701-0087 .2.f A~ WASHER 6 6
41
I:IH71 cHL-I!:NIFOLD(1)
. 01 9 EXHAUST
Frg,
31 32
1
~
2-5
~7
,._(L:
g.---8
42
t:~H71 cHt...l~c
Fig,019 EXHAUST MANIFOLD(1)
*~(Q'ty)
;J;IAII!!~ ¥§~:2. AiHI~ .2!lM 111.:i!
Key No. Part No.
t:f
"T" ~ ~ Description AD AD
086 136
.l!.=
s.c ICA Remarks
Tl Tl
1 65.081 01-5015A ~PI DHL/-l~ ~iS~ EXHAUST MANIFOLD ASS'Y 1 -
2 65.081 01-0281 A . ~H71 °H L/ -l~ · MANIFOLD ; EXHAUST 1 -
3 65.90302-0050 . 5:20j ~<:i.:J. ·PLUG; CORE 7 -
4 65.9031 0-0149A -~2:-j.::J.LfAf ·SCREW; PLUG M26x1.5 1 -
5 06.56190-0726 . A/~ 'a · RING ; SEAL A26x31 1 -
6 65.91615-0020 -§2.f~~ 7i ~i COVER ; BLIND 1 -
7 65.96601-0056A ~H7/ ~~A/ 7f~~ GASKET ; EXHAUST FLANGE 1 -
8 06.01913-3217 ~~ ~EJ~ BOLT ASS'Y M1 Ox30 2 -
9 06.08092-2405 ~2:-j.::J. LfAf SCREW; PLUG M16x1.5 1 -
10 06.56190-0709 A/~ 'a RING ; SEAL A16x22 1 -
11 65.08901-0055 ~PI DHL/-l~ 7f~~ GASKET ; EXHAUST MANIFOLD 6 -
12 06.01013-9227 -&ZJ- -§- § BOLT ; HEX. M1 Ox120 6 -
13 06.16731-2108 ~E.'a £fA~ WASHER ; SPRING A10 6 -
14 65.90020-0006 1JiCJC-j 0//~ -§-§ BOLT ; CYLINDER HEAD 6 -
15 65.06301-0309 ~:z.J-9 :U:fO/E. PIPE; COOLING WATER 1 -
16 65.96601-0056A ~HJ/ ~~A/ 7f~~ GASKET ; EXHAUST FLANGE 1 -
17 06.01913-3217 -§-§~iS~ BOLT ASS'Y M10x30 2 -
18 65.06301-0308 ~ :z.J-9 :U:fO/ E. PIPE; COOLING WATER 1 -
19 65.97 401-0207 :U:fO/E. .giEj CLIP; PIPE 1 -
20 06.01913-3114 -§-§~iS~ BOLT ASS'Y M8x22 2 -
21 65.96301-0376 1j2./~ £.~ HOSE ; SILICON D45x55 2 -
22 65.97440-0100 £.~ .gif!jE.('tlj~gj) CLAMP ; HOSE(BAND TYPE) 4 -
23 65.19202-0039 2./E. 'E! ~.3. HOOK ; LIFTING 1 -
24 06.01733-4309 -&n 2E
..., st - BOLT ; HEX. M12x1.5x25 2 -
25 65.09901-0023 :L!f~7/7f~~ GASKET ; TURBO CHARGER 1 -
26 65.08112-5008A ~H71 DHL/-lE ~~§ ~!i!..!f- JOINT ELBOW ; EXHAUST MANIFOLD 1 -
27 06.08092-2405 ~2:-j.::J.LfAf SCREW; PLUG M16x1.5 1 -
28 06.56190-0709 A/~ 'a RING ; SEAL A16x22 1 -
29 65.90310-0123 ~2:-j.::J.LfAf SCREW; PLUG 1 -
30 06.06225-0706 ~EiE -§-§ BOLT; STUD M8x25 4 -
31 06.16731-21 07 ~E.iS £fA~ WASHER ; SPRING AS 4 -
32 06.11 063-8214 -&ZJ- Li § NUT; HEX. M8 4 -
33 65.09901-0022 :L!f~7/7f~~ GASKET ; TURBO CHARGER 1 -
43
~c
HH71 DH L-l -§-_ )
Fig,020 EXHAUST MANIFOLD(2
44
I::IH/1 DH L.l-§- t:
Fig,020 EXHAUST MANIFOLD(2)
*~(Q'ty)
J:IAII!!:2 ¥1:~.2
...
T
:a:
Ailll~ :2@~
.n .:
Ill .:i!
Key No. Part No. 086
Tl
136
Tl
s.c ICA Remarks
1 60.081 01-5030D ~H71 DH L-1-! E. MANIFOLD ; EXHAUST - 1
2 65.08901-0055 ~H71 DHL-I~E. 7f~~ GASKET ; EXHAUST MANIFOLD - 6
3 06.01013-9227 -&::zn~.§. BOLT ; HEX. M1 Ox120 - 6
4 06.16731-2108 ~E.'S .2.fA~ WASHER ; SPRING A1 0 - 6
5 65.90020-0006 ~t:!Ci 5JIE. g.§. BOLT; CYLINDER HEAD - 6
6 65.06301-0308 'c!j Zf? .iifOI E. PIPE; COOLING WATER - 1
7 65.96601-0056A ~H71 ~iC!!XI 7f~~ GASKET ; EXHAUST FLANGE - 1
8 06.01913-3217 g.§. ~'EI* BOLT ASS'Y M1 Ox30 - 2
9 65.06301-0309 'c!j Zf? nfol E. PIPE; COOLING WATER - 1
10 65.97 401-0207 .iifOIE. ~'EI CLIP; PIPE - 1
11 06.01913-3114 g.§. ~'EI* BOLT ASS'Y M8x22 - 2
12 65.96301-0376 ~2.1~ £.~ HOSE ; SILICON D45x55 - 2
13 65.97 440-01 00 £.~ ~iE!IE.(~E.~) CLAMP ; HOSE(BAND TYPE) - 4
14 65.19202-0039 2.1 E. 'a ~3. HOOK ; LIFTING - 1
15 06.01733-4309 -&Zf g.§. BOLT; HEX. M12x1.5x25 - 2
16 65.09901-001 SA JJ.f.g71 7f~~ GASKET ; TURBO CHARGER - 1
17 65.90201-0072 ~EiE. ~.§. BOLT ; STUD M1 Ox1.5x30 - 6
18 06.16731-2108 ~E.'S .2.fA~ WASHER; SPRING A10 - 6
19 06.11 063-821 5 -&Zf Li .§. NUT ; HEX. M1 0 - 6
20 65.08112-0027 ~H71 ~T- .iifOIE. PIPE ; EXHAUST OUTLET - 1
45
~71 cHL-I~c
Fig.021 INTAKE MANIFOLD
5
'
~6
~
~
3
46
.:a-71 cH L-1 ~ c
Fig,021 INTAKE MANIFOLD
*~(Q'ty)
J:IAI1!!.2 ·~~~ 1:::1
"'T"
:a:
i5 ~ Description
Ailll~ £!t~
AD AD j! .:.
Ill ~
Key No. Part No. 086 136 s.c ICA Remarks

Tl Tl
1 65.08201-5078 ~71 DHL...J~~ ~~~ INTAKE MANIFOLD ASS'Y 1 1
2 65.08902A0024 ~71 DHL...J~~ 7f~~ GASKET; INTAKE MANIFOLD 1 1
3 06.01923-3218 ~~~~~ BOLT ASS'Y M1 Ox35 8 8
4 65.90201-0167 ~.iiiiOIAi ~~ BOLT; SPACER 2 2
5 06.11 063-8215 ~::z{ Li~ NUT ; HEX. M1 0 2 2
6 06.16731-21 08 ~E.~ .2.fA~ WASHER ; SPRING A10 2 2
7 06.15030-0514 ~ .2.fA~ WASHER ; PLAIN 10. 5 2 2
47
I!~E-71
Fig,022 TURBO CHARGER(1)
19
·~1
10 7
10
48
l!f-8-71
*'a(Q'ty) Ail! I~ :Ul~ HI
~IAII!!i: ·~\:!:!~ ~
Key No. Part No.

-r 1::1 :a:
i5 ~ Description AD AD .l!.
086 136
=
s.c ICA Remarks
Tl Tl
1 65.091 00-7090 TifiPI ~~~ TURBO CHARGER ASS'Y 1 -
2 06.16731-2108 ~E.'EJ 2.fA~ WASHER; SPRING A1 0 4 -
3 06.11 063-921 5 ~:z{ Li~ NUT ; HEX. M1 Ox1.25 4 -
4 65. 96601-0046B -it!!XI 7f~~ GASKET ; FLANGE 1 -
5 06.01913-3114 -§-~ ~~~ BOLT ASS'Y M8x22 2 -
6 65.05701-5997 2.~ nfoiE. PIPE; OIL 1 -
7 65.98131-0037 ~.iijjOIAi LfAf SCREW; SPACER 1 -
8 65.98130-0130 oj'E!j E-j ADAPTER 1 -
9 06.78144-2403 -!£!f. LfAf SCREW ; HOLLOW M12x1.5 1 -
10 06.56190-0704 AI~ 'a RING ; SEAL A12x18 4 -
11 65.05701-5737 2.~ nfoiE. PIPE; OIL 1 -
12 65.05701-5736 2.~ nfoiE. PIPE; OIL 1 -
13 65.96601-0067 -it!!XI7f~~ GASKET ; FLANGE 1 -
14 06.01913-3114 -§-~ ~~~ BOLT ASS'Y M8x22 6 -
15 65.96301-0327 A .:il.!f. £~ HOSE ; RUBBER 1 -
16 65.97 440-01 03 £~ ~if!IE.(Itl!.:=:gj) CLAMP ; HOSE(BAND TYPE) 2 -
17 65.08202-0276 ~71~ STAKE ; INTAKE 1 -
18 65.96301-0315 .:il.!f. £~ HOSE : RUBBER 1 -
19 65.97 440-0094 £~ ~if!IE.(It'!~~) CLAMP ; HOSE(BAND TYPE) 2 -
20 65.97480-0658 -! Ci HOLDER 1 -
21 06.01924-3215 -§-~ ~~~ BOLT ASS'Y M10x25 2 -
22 06.16731-2108 ~E. 'a 2.fA~ WASHER; SPRING A1 0 2 -
23 06.11063-8215 ~:z{ Li~ NUT ; HEX. M1 0 2 -
49
:i!~-EPI
Fig.023 TURBO CHARGER(2)
17
19
~71 DHLf~~
~9
INTAKE MANIFOLD
3
2
9~
10 7 l ~ ~'E!Ci
10
'§'9
CYLINDER BLOCK
15
50
1!1-E-71
*~(Q'ty)
~I All!!£:
Key No.
·~~.2:
Part No.
...
1::1
=
086 136
Ailll~ .2!!~
i! =
s.c ICA
Ill .:il
Remarks
Tl Tl
1 65.09100-7149 ilfiPI ~EI~ TURBO CHARGER ASS'Y - 1
2 06.16731-21 08 :::::OE.~ .2.fA1 WASHER ; SPRING A10 - 4
3 06.11 063-821 5 &:z.t Li~ NUT; HEX. M1 0 - 4
4 65. 96601-0046B ~~A:I.7f::::::~ GASKET ; FLANGE - 1
5 06.01913-3114 -§§.~iS~ BOLT ASS'Y M8x22 - 2
6 65.05701-5488 2.~ ~-;;; :UfOIE. PIPE ; OIL DELIVERY - 1
7 65.98131-0037 :::::O.i!IIOIA-1 LfAf SCREW ; SPACER - 1
8 65.98130-0130 Oj'E!JE~ ADAPTER - 1
9 06.78144-2403 .£££f LfAf SCREW; HOLLOW M12x1.5 - 1
10 06.56190-0704 AI~~ RING ; SEAL A12x18 - 4
11 65.05701-5735 2.~ TifOIE. PIPE; OIL - 1
12 65.05701-5736 2.~ :ufoiE. PIPE; OIL - 1
13 65.96601-0067 -i~A:I .7f:::::O~ GASKET ; FLANGE - 1
14 06.01913-3114 -§§. ~EJ~ BOLT ASS'Y M8x22 - 6
15 65.96301-0327A .:il.!f. .£.:::::0 HOSE ; RUBBER - 1
16 65.97 440-01 03 .£.:::::: ~~E.('l!!EO."§) CLAMP ; HOSE(BAND TYPE) - 2
17 65.08202-0275 a-71-el- STAKE ; INTAKE - 1
18 04.27199-1803 .:il.!f. .£.:::::: HOSE ; RUBBER - 1
19 06.67020-0115 .£.::::::~~E. CLAMP; HOSE - 2
20 65.97 480-0657 ~ C-j HOLDER - 1
21 06.01924-3215 ~~ ~EI~ BOLT ASS'Y M1 Ox25 - 2
22 06.16731-2108 :::::OE.~ .2.fA1 WASHER; SPRING A1 0 - 2
23 06.11 063-8215 &:z.t Li~ NUT ; HEX. M1 0 - 2
24 65.90310-0033 ~C:j.:J. LfAf SCREW ; PLUG M1 Ox1.0 - 1
25 06.56180-0714 AI~ iS RING ; SEAL A1Ox15 - 1
51
-~PI ~zt71
Fig,024 INTER COOLER
:i!f~71
TURBO CHARGER
AD136TI
:i!f~71
TURBO CHARGER
52
~71 ~21"71
Fig,024 INTER COOLER
*~(Q'ty)
J;IAII!!.2 ·~~.2: Ail:ll~ .2!l~
Ill ,j!
Key No. Part No.

I
t:l :a:
086 136
.i =
s.c ICA Remarks
Tl Tl
1 65.09501-7002 ~71 'c!J:z.J-71 .:!:El~ INTER COOLER ASS'Y 1 1
2 06.01923-3113 -§~ .:!:El~ BOLT ASS'Y M8x20 18 18
3 65.09905-0006 ~71 'c!J:z.J-71 7~~~ GASKET ; INTER COOLER 1 1
4 65.09411-0202 ~ ~ INLET 1 -
- 65.09411-0201 ~ ~ INLET - 1
5 65.09904-0008 ~71 n~ol~ 7~~~ GASKET ; AIR PIPE 1 1
6 06.01924-3215 ~.!§.~iS~ BOLT ASS'Y M1 Ox25 4 4
7 65.96301-6003 .Jl.!f. .2:~ HOSE ; RUBBER 1 -
- 65.08220-0002A '2:!~ n~ol~ PIPE ; CONNECTION - 1
8 65.97 450-5003 v~ ~~~ CLAMP ; V-TYPE 2 -
- 65.96501-0058 o-~ 0-RING - 2
53
if. A~ X.~
Fig.025 INJECTION NOZZLE
~ 4
----r--~-~
----: IJ
~·
-=
::
-€,~
~
~EJC-j %!!~
CYLINDER HEAD
54
~A~ .I.~
Fig,025 INJECTION NOZZLE
*~(Q'ty)
J;IAII!!£ ·~~~ ...
"'T"
:a:
Ailfl~ .:!!!~Ill
l!.=
~

Tl Tl
s.c ICA Remarks
1 65.1 01 01-7055A .I.~~ .£C-j 3".~~ NOZZLE & HOLDER ASS'Y 6 -
- 65.101 01-7050A .I.~~ ~C-j 3".~~ NOZZLE & HOLDER ASS'Y - 6
2 65.1 01 02-6049A . .I.~ 3".~* · NOZZLE ASS'Y 1 - D
- 65.1 01 02-6026A . .I.~ 3".~* · NOZZLE ASS'Y - 1 D
3 65.1 01 09-0005 . L-j ~ ·NUT - 1
4 65.96501-0057 AI~ 'a RING; SEAL 6 6
55
~A~ li~O I .I.L
Fig.026 INJECTION PIPE(1)
56
~A~ :rr~OI~
Fig.026 INJECTION PIPE(1)
¥ ~ ~j,2 *~(Q'ty)
J:IAII!!.2: Aflll~ .2:@~ Ill .:i!
Key No. Part No.
1::1
"'T"
:a:
i5 ~ Description AD AD
086 136
i!.=
s.c ICA Remarks
Tl Tl
1 65.1 0301-6119 ~li ~Af lifO!~ 35.'EJ~ FUEL INJECTION PIPE ASS'Y 1 -
2 65.1 0301-6122 ~li ~Af lifO!~ 35_'EJ~ FUEL INJECTION PIPE ASS'Y 1 -
3 65.1 0322-0005 E~oj\§1 ~i9('23li ~Af) BLOCK ; TERMINAL(FUEL INJECTION) 1 -
4 65.96501-0097 0-'6 0-RING 6 -
5 65.98150-0052 ~£42- LfAf SCREW ; HOLLOW 6 -
6 06.08092-2402 ~2-j.::::J.LfAf SCREW; PLUG M1 Ox1.25 2 -
7 06.56180-0714 AI~ i5 RING ; SEAL A1 Ox15 13 -
8 65.96341-6001 A ""
1T -1:1 TUBE 1 -
9 06.78144-2402 ~£.lf-LfAf SCREW ; HOLLOW 2 -
10 65.12201-0001 ~ li 2.1 E! ~ 3. TANK ; FUEL RETURN 1 -
11 06.01913-3120 ~~ ~rs~ BOLT ASS'Y M8x45 2 -
12 65.27425-6006 ~li .!r~ ~~~' SWITCH ; FUEL LEAKAGE 1 -
13 06.56190-0732 AI~ i5 RING ; SEAL A30x36 1 -
14 65.98130-0143 ~'ElJE~ ADAPTER 1 -
57
~A~ IL~OI~
Fig,027 INJECTION PIPE(2)
~ 12-"-=--"
2
~('~\
~J
10
58
~A~ li~OI.u.
Fig,027 INJECTION PIPE(2)
,;I All!!£ *~(Q'ty)

¥~\:!::!£ Ill
Ailll~ .t!t~ ,j!
Key No. Part No.

t::l
"'T" ""
086 136
i! =
s.c ICA Remarks
Tl Tl
1 65.1 0301-6123 'C!li ~Af :U:fOIE. .3::.~~ FUEL INJECTION PIPE ASS'Y - 1
2 65.1 0301-6184 'C!li ~Af :U:fOIE. .3::.~~ FUEL INJECTION PIPE ASS'Y - 1
3 65.1 0322-0006 EiDI'§ -§~('C!li ~Af) BLOCK ; TERMINAL(FUEL INJECTION) - 1
4 65.96501-0097 0-~ 0-RING - 6
5 65.98150-0052 ~£..!f- LfAf SCREW ; HOLLOW - 6
6 06.08092-2402 ~2.-j.:::J. LfAf SCREW ; PLUG M1 Ox1.25 - 2
7 06.56180-0714 AI~~ RING ; SEAL A1 Ox15 - 13
8 65.96341-6001A E
TT
1:1
- TUBE - 1
9 06.78144-2402 ~£..!f- LfAf SCREW ; HOLLOW - 2
10 65.12201-0001 'C!li 2.1 E! ~ .3. TANK; FUEL RETURN - 1
11 06.01913-3120 ~~~iS~ BOLT ASS'Y M8x45 - 2
12 65.27425-6006 'C!li i'-~ ~~:i:l SWITCH ; FUEL LEAKAGE - 1
13 06.56190-0732 AI~~ RING ; SEAL A30x36 - 1
14 65.98130-0143 Qi'Elj Ei ADAPTER - 1
59
~A~~ IL
F1g.
. 028 INJECTION PUMP(1)
~71 DHLI~~
INTAKE MANIFOLD
60
-li!-A
I.!.. rL IL-4
cII -
Fig.028 INJECTION PUMP(1)
*~(Q'ty)
J:IAII!!£. ¥~~~ Ail! I~ .2!t~ Ill .:i!
Key No. Part No.
1::1
-r
:a:
086 136
.n
s.c
=ICA Remarks
Tl Tl
1 65.111 01-7 430A £1li ~Af l.!J~ ±EJ-fk FUEL INJECTION PUMP ASS'Y 1 -
2 06.29141-0215 t1'§!" 71 KEY ; WOODRUFF 6x22 1 -
3 06.01923-3228 -§-.§.~iS~ BOLT ASS'Y M10x85 3 -
4 65.90201-0178 ~.itiiOIA~ .g~ BOLT ; SPACER M1 Ox85 1 -
5 06.1501 0-2312 ~ .2.fA~ WASHER ; PLAIN 10. 5 1 -
6 65.05701-5356 2.~ :u:fol~ PIPE; OIL 1 -
7 06.01913-2910 -&::>f
.., .!2.E
E!- BOLT ; HEX. M6x1 2 1 -
8 65.98130-0029 ~'E!JE1 ADAPTER 1 -
9 65.98150-0028 ~.£~ LfAf SCREW ; HOLLOW 1 -
10 06.56180-0714 AI~ 'El RING ; SEAL A1Ox1 5 3 -
11 65.05701-5358 2.~ :u:fol~ PIPE; OIL 1 -
12 65.90420-0012A ~.£~ LfAf SCREW ; HOLLOW M16x2 1 -
13 06.56190-0708 AI~ 'a RING ; SEAL A16x22 2 -
14 65.08310-6002 ~71 .£.~±Elf§- AIR HOSE ASS'Y 1 -
15 65.98150-00538 ~.£~ LfAf SCREW ; HOLLOW 1 -
16 06.56180-0714 AI~ 'El RING ; SEAL A1Ox15 2 -
61
Fig,029 INJECTION PUMP(2)
16
17 ~~Ci ~~
CYLINDER BLOCK
62
~A L Ii:f
I.!... r c::u:
-
Fig,029 INJECTION PUMP(2)
*~(Q'ty)
~I All!!£: ¥~!!:!~ Ill
Ailfl~ :2!t~ ,j!
Key No. Part No.

1:01
-r
:a:
i5' ~ Description AD AD
086 136
li =
s.c ICA Remarks
Tl Tl
1 65.111 01-7371 A <ali ~Af JE:IE. ~'EJ~ FUEL INJECTION PUMP ASS'Y - 1
2 65.11401-0040 of~'S ~~XI ~'El~ MOUNTING FLANGE ASS'Y - 1
3 65.90201-0059 ~E1~ ~~ BOLT ; STUD M1 Ox35 - 4
4 06.16731-2108 ~E.~ .2.fA~ WASHER; SPRING A1 0 - 4
5 06.15010-2312 ~ .2.fA~ WASHER; PLAIN 10.5 - 4
6 06.11 063-821 5 ~Zj- L-j~ NUT; HEX. M1 0 - 4
7 65.111 06-001 0 <ali ~Af ~E. 7J-§~ COUPLING ; INJECTION PUMP - 1
8 65.11301-0063 <ali ~Af JE:IE T-% 7IOJ GEAR ; INJECTION PUMP DRIVE - 1
9 06.01913-3116 ~~~~~ BOLT ASS'Y M8x28 - 6
10 65.90710-0015 ~ .2.fA~ WASHER ; PLAIN - 6
11 65.11 902-0018A ~~X/7f~~ GASKET ; FLANGE - 1
12 06.22220-1110 ~E.~~ PIN; SPRING - 1
13 65.97 480-0233 ~ C-j HOLDER - 1
14 06.16731-2108 ~E.~ .2.fA~ WASHER ; SPRING A1 0 - 7
15 06.11 063-8215 ~Zj- L-j~ NUT ; HEX. M1 0 - 7
16 65.05701-5329 .2.~ ~.g .2.~ HOSE ; OIL DELIVERY -. 1
17 65.98130-0029 oj'ElJE1 ADAPTER - 1
18 65.98150-0028 ~£~ Lf.Af SCREW ; HOLLOW - 1
19 06.56180-0714 AI~~ RING ; SEAL A1Ox1 5 - 3
63
~A~~~ T--5 7101
Fig,030 INJECTION PUMP DRIVE GEAR
1
~
2-20
23
27
64
~A~ ¥:l.I.L T-~ 71 <>-!
Fig,030 INJECTION PUMP DRIVE GEAR
*~(Q'ty)
J;IAII!!~ ¥~~.2
...
I =
Ail:ll~ U!~lll
.n .:.
~

Tl Tl
s.c ICA Remarks
1 65.11301-7008D ~Af ~E. T--* .:::;_;s~ INJECTION PUMP DRIVE ASS'Y 1 -
2 65.11 309-0005C . 7-1 ~ ·COVER 1 -
3 06.32092-0307 · Ejjolnj ~2:j t!IIOi'a ·BEARING; TAPER ROLLER 2 -
4 65.01510-0039 . .2.~ AI~ ·SEAL; OIL 1 -
5 65.11 308-0056 ·'B ·SHIM 1 - R
6 65.11308-0002 'E ·SHIM 1 - R
7 65.11308-0003 ·'B ·SHIM 1 - R
8 65.11308-0004 ·'B ·SHIM 1 - R
9 65.11308-0058 ·'B ·SHIM 1 - R
10 65.11308-0060 ·'B ·SHIM 1 - R
11 65.11308-0061 ·'B ·SHIM 1 - R
12 65.11312-0006A · ~Af ~E. -T-* 7-j~ · COVER ; INJECTION PUMP DRIVE 1 -
13 06.01913-3114 . ~~ .:::;.;s~ ·BOLT ASS'Y M8x22 3 -
14 65.11302-001 OB . ~Af ~E. T~ ~ · SHAFT ; INJECTION PUMP DRIVE 1 -
15 06.29141-0215 . 't_f~71 · KEY ; WOODRUFF 6x22 1 -
16 65.11301-0009 . 't:lli ~Af ~E. T~ 7j0j · GEAR ; INJECTION PUMP DRIVE 1 -
17 06.11250-4329 · &:zf Li~ ·NUT; HEX. M24x1.5 1 -
18 06.16050-0316 · ~ .3. .2.fA1 · WASHER ; LOCK 1 -
19 65.98112-0027 . ~t!JA:I ·FLANGE 1 -
20 06.01913-2910 . &Zf ~~ · BOLT ; HEX. M6x12 2 -
21 65.11902-0018A ~t!JXI :;>f~~ GASKET ; FLANGE 1 -
22 06.22220-1110 ~E.'S ~ PIN; SPRING 1 -
23 65.97480-0233 ~ C-j HOLDER 1 -
24 06.1501 0-2312 %J .2.fA1 WASHER ; PLAIN 10. 5 7 -
25 06.16731-2108 ~E.'S .2.fA1 WASHER; SPRING A10 7 -
26 06.11063-8215 &Zf Li~ NUT ; HEX. M1 0 7 -
27 65.11219-6001 A ~Af ~E. T-~ 7-j tlj COVER ; INJECTION PUMP DRIVE 1 -
65
Nr n~
0
1!:'
1:::1
Fig,031 INJECTION PU
~~~M OUNTING(1)
c ::u:: MP
7,8,9,10
3,4,5,6
66
~AL.II.-l::U:: oi~EI
1..1... r c - rl.!.. o
Fig,031 INJECTION PUMP MOUNTING(1)
XI All!!~ *W(Q'ty) Ailll~ ~@~Ill

·~~.2 .:i!.
Key No. Part No.
1::1
"T"
:a:
086
Tl Tl
=ICA Remarks
136 .ns.c
1 65.11401-0046A -lE-Af -l!J E. Of~ 'a .!:!.2.f~ BRACKET ; INJECTION PUMP MOUNTING 1 -
2 06.22022-1112 ~~ B PIN ; PARALLEL 1OM6x20 2 -
3 65.11405-0001 'EI SHIM 1 - R
4 65.11405-0002 'EI SHIM 1 - R
5 65.11405-0003 'EI SHIM 1 - R
6 65.11405-0004 'EI SHIM 1 - R
7 65.11 405-0009 'EI SHIM 4 - R
8 65.11405-001 0 'EI SHIM 4 - R
9 65.11405-0013 'EI SHIM 4 - R
10 65.11405-0015 'EI SHIM 4 - R
11 06.01913-3234 ~§.~~~ BOLT ASS'Y M10x130 3 -
12 06.01013-9226 -l§f/f .!:!.E
--,2- BOLT ; HEX. M1 Ox11 0 1 -
13 06.16731-21 08 ~E. 'a £fA~ WASHER; SPRING A1 0 1 -
14 06.01913-3229 ~.§.~iS~ BOLT ASS'Y M10x90 1 -
67
~)..L oL~EI
I.!.. r II..f
~::~-
::U::
rL:...a
~Af~~
INJECTION PUMP
68
~AL .Ii.~
1.!... r c ::u:
- ol ~EI
rl.!..a
*;y(Q'ty)
AlAI I!!£. ¥~1:!::!.2 Ill
Ailll~ :2!t~ .:i!
Key No. Part No.
1::1
-r ~ ~ Description AD AD
086 136
~ =
s.c ICA Remarks
Tl Tl
1 65.11401-0034A -lE-Af -l!J ~ 2.1 Oj .!:!,2.f~ BRACKET ; INJENTION PUMP REAR - 1
2 06.1501 0-2312 ~ .2.fA9 WASHER ; PLAIN 10. 5 - 1
3 06.16731-21 08 ::::::0~'& .2.fA9 WASHER ; SPRING A10 - 1
4 06.11 063-9215 ~Z{ Li5. NUT ; HEX. M1 Ox1 .25 - 1
69
cw~ ~.§~
Fig,033 ENGINE CONTROL(1)
E.f-01~ 710i 7iiOI~

TIMING GEAR CASE 7
70
cw~ ~.§.~
Fig.033 ENGINE CONTROL(1)
J;IAII!!£. *~(Q'ty)
¥~1!:!.2 Ailll~ .2.!l~ Ill :il
,...
t:::l :a:
i5" ~ Description AD AD .n .:.
Tl Tl
s.c ICA Remarks
1 65.25900-601 OA .gCJI.I.OI~ ±%1~ SOLENOID ASS'Y 1 -
2 06.01913-2917 -§.§. ±%1~ BOLT ASS'Y M6x30 4 -
3 65.25909-0016 .gCJI.I.OI ~ .!::.2.f~ BRACKET ; SOLENOID 1 -
4 06.01913-3216 -§.§. ±%1~ BOLT ASS'Y M10x28 2 -
5 65.11610-7020 Z:j.§.~ 2.liji/XI ±%1~ CONTROL LINKAGE ASS'Y 1 -
6 60.91010-0011 ~ PIN 1 -
7 06.29030-21 08 2.1 RING 1 -
0
8 06.15010-2309 ~ 9.f.A1 WASHER ; PLAIN 6.4 1 -

9 65.32630-0020 .!::.2.f~ BRACKET 1 -
10 06.11063-8215 -9-=4 Li .§. NUT ; HEX. M1 0 1 -
11 06.16731-2108 ~~'a 9.f.A~ WASHER; SPRING A1 0 1 -
71
'W-E~ E~
Fig,034 ENGINE CONTROL(2)
J:EAf_ ~E.
INJECTION PUMP
72
<W~ zjE~
Fig.034 ENGINE CONTROL(2)
,;IAII!!.t *~(Q'ty)
·~~~ ,...
1=11
~ ~ Description AD AD .n
Ill
Ailll~ .t!l~
=ICA Remarks
~
Key No. Part No. 086 136 s.c

Tl Tl
1 65.25900-601 OA ~a!I::C.OIE. ~iEl* SOLENOID ASS'Y - 1
2 06.01913-2910 -9-Zj- .g §. BOLT ; HEX. M6x12 - 4
3 60.25909-5011 ~a!I::C.OIE. ~C.f~ BRACKET ; SOLENOID - 1
4 65.11610-7009 tj§.~ 1iiOI~ CABLE ; CONTROL - 1
5 60.91010-0011 :a PIN - 1
6 06.1501 0-2309 IM .2.fA~ WASHER ; PLAIN 6.4 - 1
7 06.29030-2108 2.1 RING - 1
0
8 06.01923-3228 g.§. ~iEl* BOLT ASS'Y M1 Ox85 - 2

9 65.91701-0188 ~il!IOIAi SPACER - 2
73
£1li IL~O I==.
Fig.035 FUEL PIPE(1)
~li Oj:i!.f/1
FUEL FILTER
!£-Af ~~
INJECTION PUMP
74
ec!.E IL~ oI .u.
Fig.035 FUEL PIPE(1)
*~(Q'ty)
;i;IAII!!.t ¥~~.2:
...
"'T" =
Ailll~ .i:!!~
:a = Ill ,j!
Key No. Part No. 086 136 s.c ICA Remarks

Tl Tl
1 65.12301-5330 ~li :u:foiE. ~~~ FUEL PIPE ASS'Y 1 -
2 65.12301-5331 ~li :u:foiE. ~~~ FUEL PIPE ASS'Y 1 -
3 06.78144-2204 ~,Sg,.!f LfAf SCREW ; HOLLOW 3 -
4 65.98150-0029 ~,Sg,.!f LfAf SCREW ; HOLLOW 1 -
5 06.56190-0706 AI~~ RING ; SEAL A14x20 8 -
6 65.12509-5002 !::!.2.1 Ci LfAf SCREW; BREATHER 1 -
7 65.96507-0003 AI~~ RING; SEAL 1 -
8 65.12301-5224A ~li :u:foiE. ~~~ FUEL PIPE ASS'Y 1 -
9 65.98150-0042A ~,Sg,.!f LfAf SCREW ; HOLLOW 7 -
10 06.56180-0712 AI~~ RING ; SEAL A8x14 14 -
11 65.12301-5226A ~li :U:fOIE. ~~~ FUEL PIPE ASS'Y 1 -
12 65.98101-0027 Ci~ 'til~ {TL..j'2:J UNION ; DOUBLE BANJO 1 -
13 65.97 401-6009 :U:fOIE. -§~ ~~~ PIPE CLIP ASS'Y 2 -
14 65.98130-0139A Oj~Ei ADAPTER 1 -
15 06.56190-0706 AI~~ RING ; SEAL A14x20 1 -
75
IL~ 0 I ==-
'21li
Fig,036 FUEL PIPE(2)
!EN -1!1~
INJECTION PUMP
5
~ 3
r-9
~1210
I
15 12
14
76
'2:! li IL~O I~
Fig,036 FUEL PIPE(2)
*~(Q'ty)
J;IAII!!£: ¥~~.§:
...
"'T" ~ ~ Description AD AD
Ailll~ £:!!~ Ill
=ICA Remarks
.ns.c
.:i!.
Tl Tl
1 65.12301-5332 \>:I.E :U:fOIE. ~~~ FUEL PIPE ASS'Y - 1
2 65.12301-5333 \>:I.E :u:foiE. ~'E)~ FUEL PIPE ASS'Y - 1
3 06.78144-2204 ~.£4!- L..fN SCREW ; HOLLOW - 3
4 65.98150-0029 ~.£4!- L..fAf SCREW ; HOLLOW - 1
5 06.56190-0706 AI~ 'a RING ; SEAL A14x20 - 8
6 65.12509-5002 -'=.2.1Ci L..fAf SCREW; BREATHER - 1
7 65.96507-0003 AI~ 'a RING; SEAL - 1
8 65.12301-5224A \>:I.E :U:fOIE. ~'EI~ FUEL PIPE ASS'Y - 1
9 65.98150-0042A ~.£4!- L..fAf SCREW ; HOLLOW - 7
10 06.56180-0712 AI~ 'a RING ; SEAL A8x14 - 14
11 65.12301-5225A \>:I.E :u:foiE. ~'EI~ FUEL PIPE ASS'Y - 1
12 65.98101-0027 C-j~ ~~ fft-1~ UNION ; DOUBLE BANJO - 1
13 65.97 401-6009 :U:fOIE. ~'E) ~'EI~ PIPE CLIP ASS'Y - 1
14 65.98130-0139A OjrJIE~ ADAPTER - 1
15 06.56190-0706 AI~ 'a RING ; SEAL A14x20 - 1
77
'21li 0:1 I!J-71
Fig,037 FUEL FILTER
78
[! l i 0:1 j].~ 71
Fig,037 FUEL FILTER
J:IAI\!!:2 ¥~~~ *EHa'ty) Ailll~

.2:!tM 111
.:il
Key No. Part No.
1:::1
I ~ ~ Description AD AD
086 136
.n =
s.c ICA Remarks
Tl Tl
1 65.12501-7034C \:!li Ofilf71 ~~~ FUEL FJLTER ASS'Y 1 1
2 06.01943-3318 ~~~~~ BOLT ASS'Y M12x1.5x35 2 2
79
~~71 D~~~
Fig.038 ALTERNATOR MOUNTING
9------,
'c!!Zf-? -l!lE.
WATER PUMP
80
~~71 D~-ff:~
Fig,038 ALTERNATOR MOUNTING
J;IAII!!£. *~(Q'ty)
¥~!:!!~ Ill
Ailll~ .t!t~ ,jl
Key No. Part No.

t::l
..,- :a:
086 136 =ICA Remarks
.ns.c
Tl Tl
1 65.1 91 02-0084A ~~:PI Dfff~ ~2.f~ BRACKET; ALTERNATOR MOUNTING 1 1
2 06.01914-3320 .g5_ ±iEJ~ BOLT ASS'Y M12x45 1 1
3 06.11063-9216 -&:zf Li 5. NUT; HEX. M12x1.5 1 1
4 06.1 501 0-4313 ~ .2.fA:j WASHER ; PLAIN 12 1 1
5 06.16731-2109 ~E.'a .2.fA:j WASHER ; SPRING A12 1 1
6 06.01914-3219 .g5. ±iEJ~ BOLT ASS'Y M1 Ox40 2 2
7 65. 90001-0002A -&7~ e E-
..., S!. BOLT ; HEX. M12x1.5x150 1 1
8 65.1 91 03-5045 ~~::!71 A-j3!_5_ SUPPORT; ALTERNATOR 1 1
9 65.1 91 03-6009C ofol .g5. ±iEJ~ EYE BOLT ASS'Y 1 1
10 06.01914-3320 .g§. ~iS~ BOLT ASS'Y M12x45 1 1
11 06.01913-3228 .g5. ±iEJ~ BOLT ASS'Y M1 Ox85 1 1
12 06.11063-9216 -&:zf Li 5. NUT ; HEX. M12x1.5 1 1
13 06.11 063-821 5 -&:zf Li 5. NUT ; HEX. M1 0 1 1
14 06.1501 0-2312 ~ .2.fA:j WASHER ; PLAIN 10.5 1 1
15 65.96801-0084 v-~5. V-BELT 1 1
81
~~71
Fig,039 ALTERNATOR
82
~~71
Fig,039 ALTERNATOR
*~(Q'ty)
:XI All!!£ ·~~~ AiHI~ :2!!~ HI ,j!
,...
t::t :a:
i5" ~ Description AD AD .n .:.
Tl Tl
s.c ICA Remarks
1 65.26101-7174 ~~:!71 ALTERNATOR 1 1
83
AI~ ~~71
Fig.040 STARTER
84
AI~ ~~71
Fig,040 STARTER
7;IAII!!~ *~(Q'ty) Ailll~ ~!!M

¥~\:!1.2 111 :il
,.. =
t:::l
=ICA Remarks
086 136 l!s.c
Key No. Part No.
Tl Tl
1 65.26201-7092 AI~ tj~71 STARTER 1 1
2 65.26214-0001 · of.:::IL:II '9 ~~ ~1 ::EEl~ · MAGNETIC SWITCH ASS'Y 1 1
3 06.01953-3318 -§ §. ::EEl~ BOLT ASS'Y M12x1.5x35 3 3
85
~~~~~
Fig,041 SPARE PARTS
5
7
f
8
~
6
86
~11::11~
Fig,041 SPARE PARTS
"i"~(Q'ty)
J:IAII!!.i ~~l!f~
...
"T" =
i5' ~ Description AD AD =.i!lM
Ailll~
.ns.c
111 :i!
Key No. Part No. 086 136 ICA Remarks
Tl Tl
1 65.05510-50228 7f~2.IXI ~~~ CARTRIDGE ASS'Y 3 3
2 65.12503-5025A '2H~.<J:I1lf71 '€11~1'2!!~ ELEMENT ; FUEL FILTER 6 6
3 65.96801-0084 v-~~ V-BELT 2 2
4 65.03901-0070A 1Mi:!Ci 511~ 7f~~ GASKET;CYUNDERHEAD 6 6
5 65.03905-0022 1Mi:!Ci 511~ 7~1::1j 7f~~ GASKET ; CYUNDER HEAD COVER 6 6
6 65.99710-0002 Ej'cJ Cll::lfOI~ DEVICE ; TURNING 1 1
7 65.98814-7012 '§!~IOI RELAY 1 1
8 65.25502-6011 · <>U~ "t>IEj ~~ · FUSE ; AIR HEATER 1 1
87
-¥-%lti~ ::<] -"] Jti ~ -¥-%Jti~ ::<] -"] Jti ~ -¥-%18~ ::<] -"] Jti ~
Part No. Fig. No. Key No. Part No. Fig. No. Key No. Part No. Fig. No. Key No.
04.27199-1803 023 18 06.01913-3122 Oll 13 06.08092-2404 014 9
04.27405-0904 014 17 06.01913-3215 002 28 06.08092-2405 014 ll
04.27405-1908A 014 14 06.01913-3216 033 4 019 9
06.01013-9107 017 9 06.01913-3217 019 8 019 27
06.01013-9114 017 19 019 17 06.08095-4604 015 20
06.01013-9l18 010 ll 020 8 015 22
06.01013-9l19 017 15 06.01913-3228 038 ll 016 12
06.01013-9120 017 20 06.01913-3229 031 14 06.08095-4606 015 24
06.01013-9127 018 3 06.01913-3234 031 11 016 14
06.01013-9215 010 18 06.01914-3126 009 48 06.l1053-9217 010 16
06.01013-9219 017 17 06.01914-3219 038 6 06.l1063-8212 002 23
06.01013-9221 009 31 06.01914-3320 038 2 06.11063-8214 001 23
06.01013-9226 031 12 038 10 002 7
06.01013-9227 019 12 06.01923-2914 002 15 004 7
020 3 06.01923-2918 002 19 019 32
06.01013-9517 002 26 06.01923-3112 012 18 06.11063-8215 020 19
06.01283-7114 013 16 06.01923-3113 005 3 021 5
06.01733-4309 019 24 013 30 022 23
020 15 024 2 023 3
06.01913-2910 028 7 06.01923-3l15 004 5 023 23
030 20 06.01923-3122 014 3 029 6
034 2 06.01923-3124 014 4 029 15
06.01913-2917 033 2 06.01923-3126 012 20 030 26
06.01913-311l 013 19 06.01923-3218 021 3 033 10
06.01913-3112 012 26 06.01923-3228 028 3 038 13
06.01913-3113 002 4 034 8 022 3
013 18 06.01924-3215 022 21 032 6
06.01913-3l14 001 20 023 21 06.11063-9216 003 7
015 14 024 6 038 3
019 20 06.01924-3225 012 22 038 12
020 ll 06.01943-3317 002 8 06.11064-9216 001 33
022 5 06.01943-3318 037 2 06.11250-4329 030 17
022 14 06.01943-3319 003 8 06.15010-2309 002 21
023 5 06.01953-3318 040 3 033 8
023 14 06.02090-0418 012 12 034 6
030 13 06.02090-0422 013 23 06.15010-2311 004 3
06.01913-3115 001 20 06.02106-0619 006 49 013 17
013 7 06.04201-8907 017 13 013 25
015 5 06.06225-0704 001 21 06.15010-2312 028 5
016 5 002 5 029 5
06.01913-3116 029 9 06.06225-0706 019 30 030 24
06.01913-3117 015 4 06.06225-0809 002 10 032 4
016 4 007 11 038 14
06.01913-3118 011 14 06.06225-0810 002 11 06.15010-4313 038 4
06.01913-3120 009 42 06.08092-2402 026 6 06.15030-0513 012 13
026 11 027 6 06.15030-0514 009 33
027 11 06.08092-2403 001 28 021 7
-¥-%~~ Aj J-] ~ ~ -¥-%~~ Aj J-] ~ ~ -¥-%~~ Aj J-] ~ ~
06.15091-0319 007 6 06.29020-0132 017 6 06.67020-0105 005 4
06.16050-0311 010 15 06.29030-2108 033 7 06.67020-0106 014 18
06.16050-0316 030 18 034 7 014 20
06.16110-0106 012 14 06.29141-0207 010 14 014 22
06.16731-2105 002 22 06.29141-0215 028 2 06.67020-0108 016 11
06.16731-2107 001 22 030 15 06.67020-0109 014 15
002 6 06.31420-0314 010 22 015 10
004 4 06.31641-0429 012 5 016 10
013 24 06.32092-0307 030 3 06.67020-0115 023 19
017 10 06.56180-0712 035 10 06.78144-2204 035 3
017 16 036 10 036 3
018 4 06.56180-0714 001 14 06.78144-2402 026 9
019 31 023 25 027 9
06.16731-2108 009 32 026 7 06.78144-2403 022 9
017 18 027 7 023 9
019 13 028 10 60.08101-5030D 020 1
020 4 028 16 60.25909-5011 034 3
020 18 029 19 60.91010-0011 033 6
021 6 06.56190-0704 001 17 034 5
022 2 001 29 65.01101-0040R 001 2
022 22 022 10 65.01101-6040N 001 1
023 2 023 10 65.01101-60461 001 1
023 22 06.56190-0705 015 21 65.01105-1156D 001 7
029 4 015 25 65.01105-1160F 001 6
029 14 016 15 65.01105-11728 001 5
030 25 06.56190-0706 014 10 65.01105-1173C 001 5
031 13 035 5 65.01105-1174C 001 7
032 5 035 15 65.01105-1175C 001 8
033 11 036 5 65.01105-1176C 001 6
06.16731-2109 001 32 036 15 65.01110-6120 006 4
003 6 06.56190-0708 028 13 65.01110-6351 006 4
038 5 06.56190-0709 001 25 65.01110-6352 006 5
06.16731-2110 006 28 014 12 65.01110-6353 006 6
06.22022-0907 002 13 019 10 65.01110-6354 006 7
010 17 019 28 65.01110-6355 006 8
06.22022-0909 007 8 06.56190-0712 015 23 65.01150-0015 006 9
010 5 016 13 65.01150-0016A 006 14
06.22022-0912 006 3 06.56190-0716 011 7 65.01150-0019 006 10
06.22022-1010 006 26 06.56190-0718 012 4 65.01150-0020 006 11
06.22022-1016 009 40 06.56190-0724 015 19 65.01150-0021 006 12
06.22022-1112 031 2 06.56190-0726 011 11 65.01150-0022 006 13
06.22220-1110 029 12 019 5 65.01150-0023A 006 15
030 22 06.56190-0728 012 9 65.01150-0024A 006 16
06.29010-0120 009 29 014 7 65.01150-0025A 006 17
06.29010-0125 010 25 06.56190-0732 013 33 65.01150-0026A 006 18
06.29020-0126 006 46 026 13 65.01201-0050 001 15
06.29020-0132 010 23 027 13 65.01304-0010N 002 1
-¥-%~~ .Al Al ~ ~ -¥-%~~ .Al Al ~ ~ -¥-%~~ .Al Al ~ ~
65.01305-5028C 002 14 65.03203-1028D 007 4 65.05104-5004 010 3
65.01307-5002 002 18 65.03203-1029G 007 5 65.05200-6034 010 20
65.01401-0274 003 1 65.03401-0021H 008 1 65.05201-0037 010 13
65.01510-0037 003 10 65.03401-0056A 008 2 65.05204-0036 010 21
65.01510-0039 030 4 65.03401-60448 008 3 65.05205-0018 010 24
65.01510-0157 002 16 65.03901-0070A 007 9 65.05405-6001 001 27
65.01601-6003C 001 26 041 4 65.05410-0025 010 8
65.01601-6005A 001 26 65.03905-0022 008 4 65.05501-70648 011 1
65.01705-00028 004 1 041 5 65.05503-5042 011 3
65.01801-5099C 005 1 65.03905-0023A 008 7 65.05510-50228 011 2
65.01810-5011 008 8 65.04101-0026 009 2 041 1
65.01903A0207 003 2 65.04101-0027 009 5 65.05518-0003 011 4
65.0190380029 002 17 65.04101-0037 009 3 65.05518-0006 011 8
65.0190380113 002 12 65.04101-0038 009 6 65.05601-71378 012 1
65.01903C0021 002 3 65.04101-0041 009 1 65.05604-5030 012 2
65.01907A0002 004 2 65.04101-0042 009 4 65.05605-0028A 012 15
65.02101-00568 006 1 65.04102-0007 009 11 65.05606-5020 012 10
65.02115-0040K 006 2 65.04102-0027 009 10 65.05611-0001 012 8
65.02201-7032 006 19 65.04102-0028 009 12 65.05701-5153 013 27
65.02201-7033 006 20 65.04102-6002 009 8 65.05701-5230 013 28
65.02201-7034 006 21 65.04102-6019 009 7 65.05701-5329 029 16
65.02301-0313 006 24 65.04102-6020 009 9 65.05701-5356 028 6
65.02301-5184 006 23 65.04103-0009 009 14 65.05701-5358 028 11
65.02310-0010A 006 25 65.04103-0013 009 13 65.05701-5488 023 6
65.02401-0005 006 30 65.04104-0006 009 15 65.05701-5735 023 11
65.02401-0030 006 30 65.04200-6025E 009 17 65.05701-5736 022 12
65.02401-60188 006 29 65.04201-0006K 009 19 023 12
65.02401-6101F 006 29 65.04201-5013E 009 18 65.05701-5737 022 11
65.02405-0010 006 32 65.04202-0017 A 009 26 65.05701-58098 013 13
65.02405-0015C 006 32 65.04203-0009A 009 24 65.05701-5997 022 6
65.02410-0010 006 34 65.04203-5009 009 23 65.05701-60238 013 12
65.02410-0011 006 35 65.04205-0003A 009 21 65.05715-5001 013 22
65.02410-0012 006 36 65.04301-0005 009 34 65.05740-0016 013 14
65.02410-0013 006 37 65.04302-5010 009 35 65.05801-5205A 013 1
65.02410-0014 006 38 65.04401-0014E 009 36 65.05805-5137A 013 11
65.02501-02148 006 39 65.04410-0017 001 4 65.05806-6052 013 10
65.02501-0507 006 39 65.04501-0057 009 41 65.05809-0012 013 2
65.02502-0010 006 44 65.04505-0005 009 44 65.05809-0013 013 3
65.02502-0106 006 45 65.04505-5008A 009 43 65.05809-0014 013 4
65.02502-0206 006 43 65.04506-0008 009 46 65.05809-0037 013 5
65.02503-0054 006 40 65.04507-0003A 009 45 65.05901A0052 011 12
65.02503-0115 006 42 65.04902-0013 009 16 65.05902-0008A 012 19
65.02503-0120 006 41 65.05100-6022 010 1 65.05902A0011 012 23
65.02601-0153 006 47 65.05102-0014 010 2 65.0590380003 013 21
65.03101-1087A 007 2 65.05103-5012 010 7 65.05904A0016 013 9
65.03101-60878 007 1 65.05103-5015 010 6 65.06301-0083 014 13
65.03201-1011A 007 3 65.05104-5003 010 4 65.06301-0134C 014 1
.!f-%Jtl§. .A] Aj Jtl §_ .!f-%Jtl§. .A] Aj Jtl §_ .!f-%Jtl§. .A] Aj Jtl §_
65.06301-0160 012 16 65.10101-7050A 025 1 65.12301-5225A 036 11
65.06301-0308 019 18 65.10101-7055A 025 1 65.12301-5226A 035 11
020 6 65.10102-6026A 025 2 65.12301-5330 035 1
65.06301-0309 019 15 65.10102-6049A 025 2 65.12301-5331 035 2
020 9 65.10109-0005 025 3 65.12301-5332 036 1
65.06301-5399 015 1 65.10301-6119 026 1 65.12301-5333 036 2
016 1 65.10301-6122 026 2 65.12501-7034C 037 1
65.06301-5400 014 16 65.10301-6123 027 1 65.12503-5025A 041 2
65.06301-5824 015 12 65.10301-6184 027 2 65.12509-5002 035 6
65.06401-6039 015 8 65.10322-0005 026 3 036 6
016 8 65.10322-0006 027 3 65.19102-0084A 038 1
65.06500-6214A 017 1 65.11101-7371A 029 1 65.19103-5045 038 8
65.06501-0075C 017 2 65.11101-7430A 028 1 65.19103-6009C 038 9
65.06503-0078 017 8 65.11106-0010 029 7 65.19202-0039 019 23
65.06504-0030A 017 7 65.11219-6001A 030 27 020 14
65.06506-0023 017 4 65.11301-0009 030 16 65.19202-5015 002 24
65.06512-0010 017 11 65.11301-0063 029 8 65.25502-6011 041 8
65.06520-6007 017 3 65.11301-7008D 030 1 65.25900-6010A 033 1
65.06601-5050 018 2 65.11302-0010B 030 14 034 1
65.06611-0158 018 1 65.11308-0002 030 6 65.25909-0016 033 3
65.06901A0019 017 12 65.11308-0003 030 7 65.26101-7174 039 1
65.06901A0020 017 21 65.11308-0004 030 8 65.26201-7092 040 1
65.06903A0011 014 2 65.11308-0056 030 5 65.26214-0001 040 2
65.06903A0014 015 2 65.11308-0058 030 9 65.27 425-6006 026 12
016 2 65.11308-0060 030 10 027 12
65.08101-0281A 019 2 65.11308-0061 030 11 65.32630-0020 033 9
65.08101-5015A 019 1 65.11309-0005C 030 2 65.41530-0199 001 35
65.08112-0027 020 20 65.11312-0006A 030 12 65.41530-0200 001 30
65.08112-5008A 019 26 65.11401-0034A 032 1 65.54903A0013 002 27
65.08201-5078 021 1 65.11401-0040 029 2 65.90001-0002A 038 7
65.08202-0275 023 17 65.11401-0046A 031 1 65.90001-0084 006 27
65.08202-0276 022 17 65.11405-0001 031 3 65.90001-0088 001 34
65.08220-0002A 024 7 65.11405-0002 031 4 001 36
65.08310-6002 028 14 65.11405-0003 031 5 65.90001-6003 009 39
65.08901-0055 019 11 65.11405-0004 031 6 65.90001-6005 013 6
020 2 65.11405-0009 031 7 65.90001-6006 013 8
65.08902A0024 021 2 65.11405-0010 031 8 013 29
65.09100-7090 022 1 65.11405-0013 031 9 65.90001-6011 012 21
65.09100-7149 023 1 65.11405-0015 031 10 65.90020-0006 019 14
65.09411-0201 024 4 65.11610-7009 034 4 020 5
65.09411-0202 024 4 65.11610-7020 033 5 65.90020-0009D 006 31
65.09501-7002 024 1 65.11902-0018A 029 11 65.90020-0035B 001 10
65.09901-0018A 020 16 030 21 65.90020-0056 009 30
65.09901-0022 019 33 65.12201-0001 026 10 65.90020-0062B 006 22
65.09901-0023 019 25 027 10 65.90020-0073 008 5
65.09904-0008 024 5 65.12301-5224A 035 8 65.90021-0007 007 10
65.09905-0006 024 3 036 8 65.90030-0009 010 26
-¥-%~~ 7-l Al ~ ~ -¥-%~~ 7-l Al ~ ~ -¥-%~~ 7-l Al ~ ~
65.90201-0006 001 31 65.91615-0020 019 6 65.96801-0084 041 3
65.90201-0037 001 21 65.91701-0188 034 9 65.97401-0207 019 19
65.90201-0048 002 9 65.91701-0273 002 25 020 10
65.90201-0049 003 4 65.91710-0016 003 9 65.97401-6009 035 13
65.90201-0059 029 3 65.91710-00358 001 9 036 13
65.90201-0072 020 17 65.93020-0032C 009 20 65.97440-0094 022 19
65.90201-0146 002 20 65.93410-0087 017 5 65.97440-0100 015 7
65.90201-0149 004 6 65.96002-0003 003 3 015 11
65.90201-0167 021 4 65.96002-0005 003 5 016 7
65.90201-0178 028 4 65.96301-0259A 014 21 019 22
65.90302-0012 009 25 65.96301-0276 005 5 020 13
65.90302-0050 019 3 65.96301-0281 015 15 65.97440-0103 015 16
65.90310-0003 012 7 65.96301-0315 022 18 022 16
65.90310-0033 023 24 65.96301-0327 A 022 15 023 16
65.90310-0048 001 13 023 15 65.97450-5003 024 8
65.90310-0057 011 6 65.96301-0376 019 21 65.97480-0232 015 3
65.90310-0065 011 10 020 12 016 3
65.90310-0091 001 16 65.96301-0579 015 6 65.97 480-0233 029 13
65.90310-0104 010 10 016 6 030 23
65.90310-0109 001 24 65.96301-0580 015 9 65.97480-0657 023 20
65.90310-0123 019 29 016 9 65.97480-0658 022 20
65.90310-0136A 012 3 65.96301-0589 014 19 65.97601-0004 012 6
65.90310-0145 015 18 65.96301-6003 024 7 65.97601-0055 009 27
65.90310-0148 013 34 65.96341-6001A 026 8 65.97601-0065 011 5
65.90310-0149A 019 4 027 8 65.97601-0075 011 9
65.90320-0019 014 5 65.96501-00338 005 2 65.97601-0110 010 9
65.90420-0012A 028 12 65.96501-0057 025 4 65.98101-0027 035 12
65.90501-0003 009 22 65.96501-0058 024 8 036 12
65.90510-0012 010 12 65.96501-0097 026 4 65.98103-0019 013 31
013 15 027 4 65.98112-0027 030 19
65.90701-0087 018 5 65.96507-0003 035 7 65.98112-0038 009 38
65.90701-0088 006 48 036 7 65.98115-0011 017 14
65.90701-0202 008 6 65.96601-0018A 012 11 65.98130-0029 028 8
65.90710-0015 029 10 65.96601-0029 012 17 029 17
65.90710-0039 009 28 65.96601-00468 022 4 65.98130-0130 022 8
65.90720-0019 009 47 023 4 023 8
65.90720-0099 009 37 65.96601-0050 013 26 65.98130-0139A 035 14
65.90801-0018 010 19 015 13 036 14
65.91001-0013A 001 11 65.96601-0056A 019 7 65.98130-0143 026 14
007 7 019 16 027 14
65.91010-0018 002 2 020 7 65.98130-0259 014 8
65.91020-0013 001 12 65.96601-0067 022 13 65.98131-0037 022 7
65.91301-0010 006 33 023 13 023 7
65.91605-0006B 001 19 65.96601-034 7 012 24 65.98131-0140 014 6
65.91605-0110 012 25 65.96601A0042 001 18 65.98150-0028 028 9
65.91605-5003 001 19 65.9660180019 013 20 029 18
65.91606-0037 001 3 65.96801-0084 038 15 65.98150-0029 035 4
lf-%Jt!.~ .A] ;..] Jt!. ~ -¥-%Jt!.~ .A] J..] Jt!. ~ -¥-%Jt!.~ .A] J..] Jt!. ~
65.98150-0029 036 4
65.98150-0042A 035 9
036 9
65.98150-0052 026 5
027 5
65.98150-00538 028 15
65.98150-0077 015 17
65.98150-0115 013 32
65.98814-7012 041 7
65.99710-0002 041 6
s..
(I)
c ·~
(I) ~~
(.) ~,;
~ ~1
·~ ~
Cl)';f
UJ
olS 'P'K
~ ~lo
~ ll~
• Applications for DOOSAN Engine
• Marine Propulsion Engines
D1146 133(181 )/2,500 DV11 309(420)/1 ,800 L034 51 (70)/3,000 V158TIM 397(540)/2, 100
D1146TI 158(215)/2,200 DL06S 199(270)/2,500 L034TIH 88(120)/3,000 V158TIL 500(680)/2,300
DEOBTIS 176(240)/2,300 DLOBS 250(340)/2,200 L034TIM 107(145)/3,300 V180TIH 441 (600)/1 ,800
DE12 169(230)/2,200 DV11 S 324(440)/1 ,900 LOB6TI 265(360)/2,500 V1BOTIM 478(650)/2, 100
For
DE12T 220(300)/2,200 DV15T 272(370)/2,300 L086TIH 210(285)/2,100 V180TIL 820(603)/2,300
Vehicle DE12TI 250(340)/2, 100 DV15TI 309(420)/2, 100 L086TIM 232(315)/2,300 V222TIH 530(720)11 ,800
DE12TIS 250(340)/2, 100 DV15TJS 309(420)/2, 100 L126TIH 265(360)/2,000 V222TIM 588(800)/2, 100
DL06 184(250)/2,500 GEOBTI 191 (260)/2,300 L126TIM 294(400)/2, 100 V222TIL 736(1 ,000)/2,300
DL08 235(320)/2,200 GE12TJ 250(340)/2, 100 L136 118(160)/2,200 4V158TIH 390(530)/1 ,800
L136T 147 (200)/2,200 4V158TIM 441 (600)/2, 100
DB33 53(72)/3,000 DB5BTIS 127(173)/2,000
L136Tl 169(230)/2,200 4V158TIL 588(800)/2,300
DB33A 46(63)/2,300 DEOBTIS 151 (205)11 ,900
L136TL 177(240)/2,500 4V222TIH 588(800)/1 ,800
DB 58 96(130)/2,800 DE12T 188(255)/2,000
MD196T 206(280)/2,000 4V222TIM 647(880)/2, 100
For DB5BS 75(1 02)/2,200 DE12TI 213(290)/2,000
MD196TI 235(320)/2,000 4V222TIL 883(1 ,200)/2,300
DB5BT 104(142)/2,500 DE12TJS 238(323)/2,000
Industrial DB5BTI 112(152)/2,200 DV15T 238(324)/2,300
V15BTIH 353(480)/1 ,800
D1146 115(156)/2,200 DL06 129(175)/1 ,900

D1146T 140(190)/2,200 DLOB 191 (260)/1 ,750
D1146TI 162(220)/2,200 DV11 245(333)11 ,BOO
• Generator Set Engines (G-Drive & G-Pac)
P034TI 60(82) 55(75) 48(65) 42(57) P15BLE·1 402(546) 366(498) 362(492) 327(444)
DB33 35(47) 32(43) 29(39) 26(35) P158LE·2 361(491) 329(447) 321(437) 293(399)
DB58 70(95) 64(87) 59(80) 54(73) P15BLE-S 481(654) 441(660) 441(600) 402(546)
D1146 105(143) 96(130) 85(116) 77(105) P180LE 540(734) 497(676) 496(674) 443(602)
D1146T 138(187) 125(170) 118(160) 107(145) PlBOLE-1 498(677) 454(617) 442(601) 403(548)
DE12T 199(270) 180(245) 166(226) 151(205) P180LE-S 567(771) 519(705) 496(674) 452(615)
P086TI 223(260) 205(237) 199(223) 177(203) P222LE 649(883) 591(803) 574(781) 532(723)
P086TI·1 191(303) 174(279) 164(270) 149(420) P222LE·1 625(850) 563(765) 552(750) 496(675)
P126TI 298(405) 278(378) 272(370) 241(328) P222LE-S 682(927) 625(850) 603(820) 552(750)
P126TI-1 288(392) 262(356) P158FE 492(669) 441(600) 441(600) 402(546)
P126TI·ll 342(465) P180FE 770(566) 675(496) 615(452)
P158LE 443(602) 402(547) 414(563) 363(494) P222FE 711(967) 659(896) 612(832) 569(774)
• Natural Gas Engines
GE08TI 165(224) 150(204) 141(192) 128(174) GV180TI 374(508) 340(462) 319(434) 290(394)
GE12TI 220(299) 200(272) 192(262) 175(238) GV222TI 451(613) 410(557) 385(523) 350(476)
GV158TI 297(404) 270(367) 253(344) 230(313)
• Marine Auxiliary Engines
AD034F 26(35) AD136TIF 121(165) AD034S 32(43) AD136TIS 143(195)

AD034TIF 42(57) AD158TIF 302(410) AD034TIS 55(75) AD158TIS 353(480)
AD086TIF 151(205) AD180TIF 357(485) AD086TIS 186(253) AD180TIS 441(600)
AD126TIF 206(280) AD196TF 155(210) AD126TIS 247(336) AD196TS 181(246)
AD136F 77(105) AD196TIF 173(235) AD136S 93(126) AD196TIS 199(270)
AD136TF 107(145) AD222TIF 446(606) AD136TS 125(170) AD222TIS 530(720)
PU034 50(68)/3,000
PU066 85(116)/2,800
PU086 116(158)/2,200
PU086T(EADPA) 151 (205)/2 ,200
PNM DB33 24/30 20/25 PU086T(EADPB) 151 (205)/2,300
PNB AD034TI 50/63 36/45 PU086TI 213(290)/2,200
PNJ AD136 80/100 68/85 PU126TI 294(400)/2, 100
PNK AD136T 104/130 96/120 PU158TI 397(540)/2, 100
PND AD136TI 1321165 108/135 PU180TI 478(650)/2,100
PNE AD086TI 1721215 136/170 PU222TI 588(800)/2, 100
PNL AD196TI 176/220 160/200
PNI AD126TI 224/280 192/240
PNZ AD158TI 3281410 276/345
PNS AD180TI 400/500 3321415
PNY AD222TI 500/625 408/510
• Fire Pump Engines
PU086 121 (165)/2,450

PU086T 173(235)/2,450
PU086TI 228(31 0)/2,450
PU126TI 294(400)/2,1 00
PU158TI 408(555)/2,350
PU180TI 511 (695)/2,350
PU222TI 625(850)/2,350
DOOSAN INFAACORE CO., LYD.
AROUND Tt-:~ WORLD
\).
Head Office Doosan lnfracore America Corporation Cleveland Office

Hwasu-Dong 7-11, Dong-Gu, lncheon, Korea. 4530 Renaissance Parkway, Warrensville Heights, OH 44128, U.S.A
Tel : +82-32-211-1114 Fax : +82-32-211-1231 Tel: +1-216-595-1212 Fax: +1-216-595-1214
Seoul Office Doosan lnfracore America Corporation N.J. Office
Doosan Tower 18-12, Euljiro-6Ga, 8 York Avenue, West Caldwell, N.J. 07006, U.S.A
Jung-Gu, Seoul, korea 100-730 Tel: +1-973-618-2500 Fax: +1-973-618-2501
Tel: +82-2-2167-3281 Fax: +82·2-3389-8117
EUROPE
ASIA & OCEANIA
Doosan lnfracore U.K., ltd.
Doosan lnfracore Machine Tools Yantai Co.,Ltd. Doosan House, Unit 6.3, Nantgarw Park, Cardiff
1, Dayu Road 1, ETDZ, Yantai, Shandong, China CF47QU, U.K.
Tel: +86-0535-693-5060, Fax: +86-0535-693-5619 Tel: +44-1443-84-2273 Fax: +44-1443-84-1933
Doosan lnfracore Liaoning Machinery Co.,Ltd. Doosan lnfracore Germany GmbH
No.32 DongLing Road, DongLing District, ShenYang,
Hans-Boeckler strasse 27-29, D-40764, Langenfeld-Fuhrkamp,
Liaoning, China
Germany I Tel: +49-2173-8509-20 Fax: +49-2173-8509-60
Tel: +86-24-8841-1407, Fax: +86-24-8841-1404
Doosan lnfracore Xinjiang Machinery Co.,Ltd. Doosan lnfracore Europe S.A. (Europe Head Office)
No. 178, Hetanbei Road, Wurumuqi, Xinjiang, China 1A, Rue Achille Degrace, 7080 Frameries, Belgium
Tel: +86-991-469-7217, Fax: +86-991-469-8641 Tel: +32-65-61-3231 Fax: +32-65-61-3238
Dajlan(Tianjln) Mechanical Construction Co., Ltd Doosan lnfracore France SARL

No.87 Gongxing Road, Tanggu, Tianjin, china (Doosan lnfracore Europe S.A. France Office)
Tel: +86-22-2521-0540 Fax : +86-22-2521-0714 2Eme Etage, 1/3 Avenue Pavlov, Z.A.I. Des Bruyeres, 78190 Trappes France
Tel: +33-1-3016-2140 Fax: +33-1-3016-2144
Doosan lnfracore (China) Co., Ltd.
#28, Wuzhishan Road, Eco. & Tech, Development Zone, Doosan lnfracore Europe S.A.Italy Office
Yantai, Shandong, China Via Monfalcone 41,20090 Cinisello B.mo (MI)
Tel : +86-535-638-2000 Fax : +86-535-638-2004 Tel: +39-2-612-0565 Fax: +39-2-612-6322
Doosan lnfracore Japan Corporation
3rd Floor, k-1 Bld.,19-4, Nishi-shinbashi 2-Chome, SOUTH AMERICA
Minato-Ku, Tokyo, Japan
Phone: +81-3-3434-2547 Fax: +81-3-3434-2548 Colombia Liaison Office
Doosan lnfracore Middle East Center(Dubai) Diagonal127 A No. 17-34 Oficina 302
183127, AI-Serkal Building, Air Port Road, Dubai, U.A.E Bogota, Colombia
Phone: +971-4-295-2781, 2782 Fax: +971-4-295-2783 Tel: +57-1-625-3470 Fax: 57-1 -625-3883
NORTH AMERICA
AFRICA
Doosan lnfracore America Corporation
2905 Shawnee Industrial Way, Suwanee, Doosan lnfracore South Africa (PTV)Ltd.
Georgia 30024, U. S. A 60C Electron Road, lsando 1600, Johannesburg, South Africa
Tel: +1-770-831-2200 Fax: +1-770-831-0480 Tel : +27-11-974-2095 Fax: +27-11 -974-2778
65.99897-SOSOA
lnfracore
Operation &
Maintenance Manual
:·.- -·,
FOREWORD
This manual is designed to serve as an instruction for the Operation & Maintenance of marine
propulsion engines (L 136/T!TI/086TI) and marine auxiliary engines (AD136/T/TI/086TI), combined in
one book.
The first half is explained for operation and the latter half is described for maintenance like
disassembling, inspecting and re-assembling etc in order to help an understanding for the
maintenance procedure more easily.
To keep the best performancE! and the durability of engine 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.
E3 Removal
lEI Adjustment
E3 Installation
riJ Cleaning
l·!·l Disassembly
w Pay close attention-Important
1·:·1 Reassembly
~ Tighten to specified torque
D Align the marks

tl Use special tools of manufatur's
El Directional Indication
8 Lubricate with oil
lL!I Inspection
Bl Lubricate with grease
~ Measurement
Some figures of thi$ manual may be different from the actual appearance of the engine
because of explaining them with the representative figure among these models.
If you have any question or recommendation in connection with this manual, please do not
hesitate to contact our head office, dealers or authorized service shops near by your location
for any services.
For the last, the content of this manual instruction may be changed without prior notice for
some quality improvement. Thank you.
Sep.2003
DOOSAN lnfracore Co., Ltd.
CONTENTS
Operation Parts
1. Specification ......................................................................................................................... 1
1 .1. Engine Specification 1.3. Engine Performance Curve
1 .2. Engine Aspects 1.4. Engine Model & Serial Number
2. Safety Regulations ·············································································································· 8

2.1. General Notes 2.4. Regulations Designed to Prevent Pollution
2.2. Regulations Designed to Prevent 2.5. Notes on Safety in Handling Used Engine Oil
Accidents with Injury to Persons
2.3. Regulations Designed to Prevent
Damage to Engine and Premature Wear
3. Commissioning and Operation ..................................................................................... 12

3.1. Inspections Before Operation 3.5. Check After Initial 50 Hours Operation
3.2. Starting 3.6. Operation in Winter Time
3.3. Engine Break-in 3.7. Tuning the Engine
3.4. Inspection After Starting
4. Maintenance and c;are ..................................................................................................... 21

4.1. General Instructions 4.6. Fuel System
4.2. Periodical Inspection & Maintenance 4.7. Electric System
4.3. Cooling System 4.8. Cylinder
4.4. Lubrication System 4.9. Engine Preservation Points for a Long Time
4.5. Intake & Exhaust System 4.1 0. Management for Sunken Engine
5. Main Accessory Parts ······································································································ 43

5.1. Reduction Gear 5.3. Propeller Selection
5.2. Front Power Take--Off (F.P.T.O) 5.4. Electric System
Maintenance Parts
6. Disassembly and Assembly of Major Components ................................................. 50
6.1. Disassembly 6.3. Engine Re-assembly
6.2. Inspection 6.4. Break-in After Maintenance
7. Main Parts Maintenance ................................................................................................ 105

7.1. Lubricating System 7.3. Fuel System
7.2. Cooling System 7.4. Turbocharger
8. Trouble Shooting ............................................................................................................. 166

9. Special Tool List················································································································ 172
10. Tightening Torque··········································································································· 174
11. Maintenance Specification Table for Major Parts .................................................. 176
• Part & After service center

• Applications for Doosan Engine
1. Specification
1.1. Engine Specification
1.1.1. L 136/T/TI
~ .
Units L136 L136T L136TL L136TI
4 cycle, in line,
4 cycle, in line,
direct- injection, 4 cycle, in line, direct- injection, direct- injection,
Engine type water cooled
water cooled water cooled with turbo charger with turbo charger
naturally aspirated & inter-cooler
Rating output (B.H.P) PS(kW)/rpm 160(118)/2,200 200(147)/2,200 240(177)/2,500 230(169)/2,200
Displacement cc 8,071
Cyl. No. - bore(¢) x stroke mm 6 - ¢111 X 139
Valve clearance at cold mm ln. : 0.3 , Ex. : 0.3

Low idling rpm rpm 725 ± 25
No load max. rpm rpm below 2,400 below 2,750 below 2,400
Mean effective press. (Initial ) kg/cm 2 8.07 10.14 10.71 11.66
Mean piston speed m/sec. 10.19 11.58 10.19
Compression ratio 17.6 16.7
Max. firing pressure of cylinder kg/cm 2 80 117 128 106

2
Comp. pressure (at 200 rpm) kg/cm 28 ( Initial condition)
Governor type of injection pump Mechanical all speed (R.S.V)
g/PS.h 165 155 172 162

Fuel consumption
liter/h 32 37 50 45
I I
Injection timing (B.T.D.C) deg. 18° ± 1 ° 14° ± 1°
2
lnj. nozzle opening pressure kg/cm 214 + 8
Starting system Electric Starting by starter motor
Starter motor capacity V-kW 24 v- 4.5

Alternator capacity V-A 24 v- 50
Battery V- Ah 24V- 150
Cooling system Indirect cooling by sea water with heat exchanger
Cooling water capacity lit Max. : 27 , Min. : 25
Fresh water pump type Centrifugal type, driven by V- belt
Sea water pump type Rubber impeller type driven by gear
Lub. Oil Pan capacity lit Max: 23, Min: 17 ( Engine total : 25)
(Engine) Pressure kg/cm 2
Full : 3.5, Idle 1.2
Direction of Crankshaft Counter clockwise viewed from stern side

revolution Propeller Clockwise viewed from stern side
Engine size Without M.G mm 1,182 X 770 X 925 1182 X 766 X 925 1,182 X 825 X 925
(L x Wx H) With M.G mm 1,546 X 770 X 937 1,541 X 766 X 963 1,552 X 825 X 1,027
Engine Without M.G kg 735 745 773

dry weight WithM.G kg 920 935 994
- 1 -
1.1.2. L086TI
~
LOSGTI
Units
. LOSGTIH LOSGTIM LOSGTIL
4 cycle, in line, direct- injection, water cooled

Engine type
with wet-turbo charger & inter-cooler
Rating output (B.H.P) PS(kW)/rpm 285(210)/2,100 300(221 )/2,300 360(265)/2,500

Cylinder No. - bore( ¢) x stroke mm 6 - ¢ 111 X 139
Valve clearance at cold mm ln. : 0.3, Ex. : 0.3
No load max. rpm rpm below 2,310 below 2,530 below 2,750
Mean effective press (Initial) kg/em' 15.14 14.55 16.06
Mean piston speed m/sec. 9.73 10.66 11.58
Max. firing pressure of cylinder kg/em' 130 130 135
Camp. pressure (at 200 rpm) kg/em' above 28 (Initial condition)
Governor type of
Mechanical all speed (R.S.V)
injection pump
g/PS.h 152 163 170

Fuel consumption
liter/h 52 62 74
Injection timing (B.T.D.C) deg. 15° ± 1°
lnj. nozzle opening pressure kg/em' 214 + 8
Battery V-Ah 24V- 150
Cooling system Indirect sea water cooling with heat exchanger
Cooling water capacity lit Max. : 25 , Min. : 23
Lub. Oil Pan capacity lit Max : 23, Min : 17 (Engine total : 25)
(Engine) Pressure kg/em' Full : 3.5, Idle: 1.2
Direction Crankshaft Counter clockwise viewed from stern side
of
revolution Propeller Clockwise viewed from stern side
Engine size Without M.G mm 1, 182 X 825 X 962

(l x W X H) With M.G mm 1,557 X 825 X 1,062
Engine Without M.G kg 790

dry weight With M.G kg 1,015
w Note : L086T/L model is not available right now but shows only the development target in
V future.
- 2 -
1.1.3. AD136/T/TI/086TI
~
. Units AD136
4 cycle, in line,
AD136T
4 cycle, in line,
AD136TI
4 cycle, in line,
AD086TI
4 cycle, in line,
direct- injection, direct- injection, direct- injection, direct- injection,
Engine type water cooled with water cooled with
water cooled water cooled with turbo charger & wet-turbo charger
naturally aspirated turbo charger inter-cooler & inter-cooler
105(77) /1 ,500 145(107)/1,500 157(115)/1,500 205(151 )/1 ,500
50 Hz
Rating output PS(kW) (AD136F) (l\D136TF) (AD136TIF) (AD086TIF)
(B.H.P) I rpm 126(93)/1 ,800 170(125) /1,800 188(138) /1,800 253(186)/1 ,800
60Hz
(AD136S) (AD136TS) (AD136TIS) (AD086TIS)
Cylinder No. - bore(¢) x stroke mm 6 - ¢ 111 X 139
Valve clearance at cold mm 0.3 I 0.3
No load max. rpm Mechanical governor: 1575 (52.5 Hz) /1890(63Hz),

rpm
(50Hz I 60Hz) Electric govt:lrnor : 1575 (52.5 Hz) /1890(63Hz),
Mean effective press. (Initial ) kg/em' 7.81 I 7.81 10.78/10.53 11.65/11.65 15.24 /15.67
Mean piston speed mise c. 6.95/8.34
Max. firing press. of cylinder kg/em' 74.4 179.5 11)5/117.3 109.1/127.5 109.1 I 127.5
Camp. Press. (at 200 rpm) kg/em' About 28 (Initial condition)
Governor type of inj. pump Electric Governor
g/PS.h 160 /160 '153/155 153 I 153 150 I 151

Fuel consumption
liter/h 20/24 27/32 29 I 34 37 I 46
Injection timing (B.T.D.C) deg. 18°±1° 14° ± 1° 15°±1°
lnj. nozzle opening press. kg/em' 224

Battery V-Ah 24V- 150
Cooling system Indirect copling by sea water with heat exchanger
Cooling water capacity lit Max. : 25, Min. : 23
Lub. Oil Pan capacity lit Max :23, Min: 17 (Engine total : 25)
(Engine) Pressure kg/em' Full : 3.5, Idle: 1.2
Revolution of Crankshaft Counter clockwise viewed from stern side
Engine only size (L x W x H) mm 1, 182x770x925 1,1 B2x766x925 1 , 182x825x925 1, 182x825x962
Engine only (Dry weight) kg 735 745 773 790
- 3 -
1.2. Engine Aspects
1.2.1. Engine Sectional Drawing
25 20 8
6
15
9
13 12 ~1 23 11 10 24
EC50M100
1. Cylinder block 11. Camshaft 21. Oil pump

2. Cylinder head 12. Vibration damper 22. Oil cooler
3. Cylinder head cover 1 3. Camshaft pulley 23. Oil pan
4. Cylinder liner 14. Piston 24. Oil suction pipe
5. Flywheel housing 15. Connecting rod 25. Water pump
6. Flywheel 16. Piston pin 26. Sea water pump
7. Rocker arm 17. Piston cooling spray nozzle 27. Exhaust manifold
8. Push rod 18. Turbocharger 28. Intake manifold
9. Tappet 19. Multi-hole injection nozzle
1 0. Crankshaft 20. Valve
-4 -
1.2.2. Engine Assembly
15
8 12 11 10
21 9 22 19
4 16 17 18
IL_____ _ _ _ _ _ _ _ _ _
EC50M099
_ j
1. Crank pulley 10. Oil pan 19. Thermostat housing

2. Expansion tank 11. Injection pump ass'y 20. Breather ass'y
3. Fuel filter 12. Oil guide tube & level gauge 21. Exhaust manifold
4. Oil cooler cover 1 3. Water pump 22. Oil filler cap
5. Intake manifold 14. Fresh water filler cap 23. Exhaust outlet pipe
6. Intercooler 1 5. Sea water pump 24. Turbocharger(wet)
7. Oil drain pump 16. Heat exchange ass'y 25. Clutch oil press. gauge
8. Flywheel housing 17. Starter 26. Marine ~Jear oil cooler
9. Oil filter 18. Marine gear ass'y 27. Sea water outlet pipe
- 5-
1.3. Engine Performance Curve
1.3.1. L 136 I L 136T I L 136TI IL 136TL
L136 L136T L136TI L136TL
en
a...
4oo en
a...
4oo en
a...
4oo en
a...
4oo
~ 300 ~ 300 ~ 300 ~ 300
::; ::; ::; Fun lo~d 1--7 ::; ~
200 200 a. 200 FuHlood
~
0. 200 0. 0.
8 F~ ::; ::;
1-- ~\?-'~""
6;:Y ::;
0 ~~
100
~PrOI)UitjQilCUrv~
0 100
~"'""
~}opuiJiOI'ICurvc
0 100
~Propul\ionCur~~
100
::::. ~roulJonCI.ir'o
-- H '"""""'"m••~ C- 170 1 - - RuclCllnaumptron -:+-t-- 170
160
:;;
~ 1 - -~ +- f-- 170
Fuel Con~ml)tro:
:;;
160 :1 1so
:c
a Fue1Con$umptlo~ - 170 :;;
160 ~
160 ~ 160 ~ 160 ~ 160~
1000 1600 2000 2600 1000 1600 2000 2600 1000 1600 2000 2600 1000 1600 2000 2600
Engine Speed (r.p.m) Engine Speed (r.p.m) Engine Speed (r.p.m) Engine Speed (r.p.m)
EC50M136
1.3.2. L086TI
Heavy Duty Medium Duty Light Duty
600 600 60 0
en 40o en 4oo en 400

e:. e:. e:.
::; 300
a. ~7
::; 300
8
a.
#
Fun load
::; 30 0
8
a. ·~ r-
~-~
8 200
~~
o"•
~
200
0~
~'1).\-r!' 200
v~
'b\.d'
100 100 100

/ rropuls ion Curv~ ..... \Propulsion Curve jropulsircurve
1
u Consumption 170 :c Fuel Consumption 170 :c ue Consum t1on ....... 170 :c

160 t 160 ~ 160 ~
160~ 160 ~ 160 ~
1000 1600 2000 2600 1000 1600 2000 2600 1000 1600 2000 2600
Engine Speed (r.p.m) Engine Speed (r.p.m) Engine Speed (r.p.m)
EC50M137
- 6 -
1.4. Engine Model & Serial Number
The engine serial number is inscribed on ,---------------------------------------.

the engine as illustrated. This number is
required when requesting warranty and
ordering parts. It is also referred to as
engine model and serial number because
of their location.
J
'U7 Note : The engine mQdel name Engine Plate
V (L 136/TITI/086TI) is described in EC50M138
the name plate on the cylinder
block.
• Engine serial No. (Example : L086TI)

EBPKM300001
I I se,;al No
Production Year(2003)
Engine Model Suffix
- 7-
2. Safety Regulations
2.1. General Notes
Day-to-day use of power engines and the service products necessary for running them presents
no problems if the persons occupied with their operation, maintenance and care are given
suitable training and think as they work.
This summary is a compilation of the most important regulations. These are broken down into
main sections which contain the information necessary for preventing injury to persons, damage
to property and pollution. In addition to these regulations those dictated by the type of engine
and its site are to be observed also.
"'\;! IMPORTANT : If, despite all precautions, an accident occurs, in particular through contact
V with caustic acids, fuel penetrating the skin, scalding from oil, antifreeze being
splashed in the eyes etc., consult a doctor immediately.
2.2. Regulations Designed to Prevent Accidents with Injury to Persons
2.2.1. During commissioning, starting and operation

Before putting the engine into operation for the first time, read the operating instructions
carefully and familiarize yourself with the "critical" points, If you are unsure, ask your
DAEWOO representative.
• For reasons of safety we recommend you attach a notice to the door of the engine room
prohibiting the access of unauthorized persons and that you draw the attention of the
operating personal to the fact that they are responsible for the safety of persons who enter
the engine room.
• The engine must be started and operated only by authorized personnel. Ensure that the
engine cannot be started by
unauthorized persons.
"'\;! • When the engine is running, do not ,---------------------------------,
V get too close to the rotating parts (All
pulleys, lnj. Pump drive & propeller
shafts, FPTO etc).
Wear the close-fitting clothing as
possible.
EC20M009
- 8 -
U7' • Do not touch the engine hot
V parts(Exh. Manifold & turbocharger
connection pipes, Inter cooler & heat
exchanger connection pipes .. etc) with
bare hands when it is warm from
operation risk of burns.
• Exhaust gases are toxic. Comply with
the installation instructions for the
installation of DAEWOO marine diesel EC20M010
engines which are to be operated in
enclosed spaces. Ensure that there is
adequate ventilation and air extraction.
• Keep vicinity of engine, ladders and stairways free of oil and grease.
Accidents caused by slipping can have serious consequences.
;2.2.2. During maintenance and care
• Always carry out maintenance work when the engine is switched off. If the engine has to be
maintained while it is running, e.g. changing the elements of change-over filters, remember
that there is a risk of scalding. Do not get too close to rotating parts.
• Change the oil when the engine is warm from operation.
w
V
CAUTION : There is a risk of burns and scalding. Do not touch oil drain plug or oil filter
with bare hands.
• Take into account the amount of oil in the sump. Use a vessel of sufficient size to ensure
that the oil will not overflow.
• Open the coolant circuit only when the
engine has cooled down.
U7' CAUTION : £:1{1.!ol .::.71~ITij ~li!DIAI.2.

V When remove the pressure of the filler NEVER REMOVE THE CAP
cap while the engine is still hot, cover WHEN ENGINE IS STILL HOT
the cap with a cloth, then turn it left

LhWARNING
slowly to release internal steam
pressure. This will prevent a person EC50M135
from scalding by hot steam spouted out.
• Neither tighten up nor open pipes and

hoses (lube oil circuit, coolant circuit and any additional hydraulic oil circuit) during the
operation. The fluid which flow out can cause injury.
• Fuel is inflammable. Do not smoke or use naked lights in its vicinity. The tank must be filled
only when the engine is switched off.
- 9-
• When using compressed air, e.g. for cleaning the heat exchanger, wear goggles.
• Keep service products (anti-freeze) only in containers which can not be confused with drinks
containers.
• Comply with the manufacturer's instructions when handling batteries.
w CAUTION :Accumulator acid is toxic and caustic. Battery gases are explosive.
2.2.3. When carrying out checking, setting and repair work

• Checking, setting and repair work must be carried out by authorized personnel only.
• Use only tools which are in satisfactory condition. Slip caused by the worn open-end wrenc
could lead to Injury.
• When the engine is hanging on a crane, no one must be allowed to stand or pass under
it.Keep lifting gear in good condition.
• When checking injectors, do not put your hands under the jet of fuel.
Do not inhale at atomized fuel.
• When working on the electrical system disconnect the battery earth cable first.
After repair engine parts, connect it up again last in prevent short circuits.
2.3. Regulations Designed to Prevent Damage to Engine and Premature Wear
(1) Never demand more of the engine than it was designed to yield for its intended purpose.
Detailed information on this can be found in the sales literature. The injection pump must not
be adjusted without prior written permission of DAEWOO.
(2) If faults occur, find the cause immediately and have it eliminate in order to prevent more
serious of damage.
(3) Use only genuine DAEWOO spare parts. DAEWOO will accept no responsibility for damage
resulting from the installation of other parts which are supposedly "just as good".
(4) In addition to the above, note the following points.
• Never let the engine run when dry, i.e. without lube oil, fuel or coolant. Use only
DAEWOO-approved service products. (engine oil, anti-freeze and anticorrosion agent)
• Pay attention to cleanliness. The diesel fuel must be free of water. See "4.6. Fuel System".
• Have the engine maintained at the specified intervals.
• Do not switch off the engine immediately when it is warm, but let it run without load for
about 5 minutes so that temperature equalization can take place.
• Never put cold coolant into an overheated engine.
• Do not add so much engine oil that the oil level rises above the max. marking on the
dipstick.
Do not exceed the maximum permissible tilt of the engine. Serious damage to the engine
may result if these instructions are not adhered to.
• Always ensure that the testing and monitoring equipment (for battery charge, oil pressure,
and coolant temperature) function satisfactorily.
• Do not let the sea water pump run dry. If there is a risk of frost, drain the water when the
engine switched off.
- 10-
2.4. Regulations Designed to Prevent Pollution
2.4.1. Engine oil, filter element, fuel filter

• Take old oil only to an oil collection point. Take strict precautions to ensure that oil does not
get into the drains or into the ground and sea.
• The drinking water supply may be contaminated.
• Oil and fuel filter cartridges are classed as dangerous waste and must be treated as such.
2.4.2. Coolant
• Treat undiluted anti-corrosion agent and I or antifreeze as dangerous waste.
• When disposing of spent coolant comply with the regulations of the relevant local authorities.
2.5. Notes on Safety in Handling Used Engine Oil
Prolonged or repeated contact between the skin and any kind of engine oil decreases the skin.
Drying, irritation or inflammation of the skin may therefore occur. Used engine oil also contains
dangerous substances which have caused skin cancer in animal experiments. If the basic rules
of hygiene and health and safety at work are observed, health risks are not to the expected as
a result of handling used engine oil.
Health precautions
• Avoid prolonged or repeated skin contact with used engine oil.
• Protect your skin by means of suitable agents (creams etc.) or wear protective gloves.
• Clean skin which has been in contact with engine oil.
-Wash thoroughly with soap and water. A nailbrush is an effective aid.
- Certain products make it easier to clean your hands.
- Do not use petrol, diesel fuel, gas oil, thinners or solvents as washing agents.
• After washing apply a fatty skin cream to the skin.
• Change oil-soaked clothing and shoes.
• Do not put oily rags into your pockets.
Ensure that used engine oil is disposed of properly.

- Engine oil can endanger the water supply -
For this reason do not let engine oil get into the ground, waterways, the drains or the sewers.
Violations are punishable. Collect and dispose of used engine oil carefully.
For information on collection points please contact the seller, the supplier or the local
authorities.
- 11 -
3. Commissioning and Operation
3.1. Inspections Before Operation
3.1.1. Lubricating oil

• The notches in dipstick must indicate
the oil level between max. and min.
permissible.
• The measurement of the oil level must
be done on a even water line and in
10 minutes after engine operating.
• Examining the viscosity and
thecontamination of the oil smeared at
the dipstick, replace the engine oil if
necessary.
Caution : If the installation angle of the engine exceeds 6 degrees, please remark the
maximum and minimum level of the oil dipstick by engraving on the lube oil
capacity of the engine. (Refer to 4.4. "Lubrication System")
3.1.2. Cooling water

Checking the level of th~ cooling water
in tank.
Check the opening pressure of the
pressure valve using cap tester.
Replace the filler cap assembly if the
measured valve does not reach the
specified limit.
(Opening pressure of valve 0.5 - 0.9
kg/cm 2
)
EA703004
NOTE : Because it is dangerous to

open the pressure cap quickly when coolant is hot, after covering the cap with a cloth
and then lower t,he inside pressure of the tank by opening slowly at first, open it up.
- 12-
3.1.3. Sea water pump
The rotating direction of the pump impeller determines the location of the pump's intake and
discharge ports.
OUT IN IN OUT
~ ~ ~ ~
EA703005
• Over-tightened belt or gear load will reduce the bearing life of the sea water pump.
• Do not run sea water pump at dry for more than 20 seconds.
• Make sure that all valves I cocks in the sea water circuit are opened before run.
• If there is a risk of freezing weather, drain the water by loosening bolts of end cover.
• Temperature range: 5 oc (41 °F)- 60 oc (140 oF)
3.1.4. Intake and Exhaust Line

Check the condition of intake and exhaust piping lines, and air filter element. If piping lines or
air filter is fouled or worn, clean or replace it.
3.1.5. Fuel Line

Check the leaking of fuel line by opening the fuel valve.
The contamination of fuel causes the clogging of the nozzle or the sticking of the components
of injection pump. Therefore the cleanness of the fuel system should be maintained at any
time.
3.1.6. Bottom of the Engine Room

The bottom of engine room would be as clean and dry as possible.
Check the bilge to prevent water accumulation.
If water accumulation is unavoidable, do not allow the bilge water to reach the bottom of the
engine. To install a bilge pump with an automatic control switch is a good solution.
w Caution : Excessive bilge water can cause engine damage like corrosion, rust and
V malfunction of engine parts.
- 13-
3.1.7. Gauge Panel
Check the all gauges of the panel whether the function is in normal or not.
• L 136
0 @) 0
8 0
~
~~ ®
@
:iA ~;\
~
00
0 0
0 0
~
EB1M3001
CD Case, Gauge ®Gauge, Water Temp ®Connector

® Panel, Gauge ® Key Switch Ass'y ®Button, Engine Stop
0 Meter, Tacho 0 Hour Meter @Fuse Holder
• L 136T/TI/086TI
11
EC50M007
CD Key Switch ® Engine Stop Button ®Oil Press. Warning Lamp

® Engine Oil Pressure Gauge ® Hour Meter @Over Speed Warning Lamp
0 Tacho-Meter 0 Battery Warning Lamp @Fuse
0 Water Temp. Gauge ®Water Temp. Warning Lamp
w Before operating your engine, familiarize yourself with the instruments supplied with your boat.
- 14-
3.1.8. Engine Stop & Waming Devices
L 136/T/TI/086TI gauge panel is equipped with warning lamps and an audible alarm to alert the
operator as follows.
1) Engine Stop Device (Stop solenoid)

Engine stop solenoid is operated with warning lamps and buzzer sound at the same time as
follows.
• When the engine oil pressure is less than 0.5 kg/cm 2
• When the engine water temperature is more than 100 °C.(212 °F)
2) Engine Warning Lamps

Engine warning lamp js turned on with buzzer sound at the same time as follows.
• When the engine oil pressure is less than 0.5 kg/cm 2
• When the engine water temperature is more than 100 °C.
• When the battery is not charged.
The alarm horn will sound when the ignition is turned on and continue to sound until the key
switch is shifted into "QFF" position or minimum oil pressure is obtained. This provides a
functional test of warning system.
~ Should engine coolant overheat occurs, the alarm horn will sound and the engine is stopped
V by stop solenoid at the same time automatically. Proceed as follows:
• First, quickly observe the water temperature gauge for engine coolant overheat and I or
needle oscillation indicating low coc1lant.
• If the temperature gauge indicates engine coolant overheat range, put the control lever back
to the idle speed position IMMEDI.ATEL Y and shift the reduction gear control lever into the
NETURAL position. Do not restart engine until the cause for the alarm has been found and
corrected. Refer to ·~overheating" in "8. Trouble Shooting" Chart.
• If the temperature gauge indicates high coolant temperature, check lack of coolant to fill
expansion tank or thermal sensor malfunction.
• If the cause for the alarm cannot be found, contact your DAEWOO dealer.
- 15-
3.2. Starting
3.2.1. C)peration 1
)\fter checking the warning lamps of the gauge panel and the NEUTRAL position of reduction
~)ear control lever, turn the key switch to the START position to crank the engine, at once.
Behavior- When the key switch is placed in the START position.
3.2.2. Operation 2
After the engine is cranked, convert the key switch to the ACC position quickly.
Behavior- As the engine is cranked, don't fix the key switch too long (over 5 seconds) in the
START position. If you do so, the starter may be malfunction.
"""\;~ If you fail the engine starting at first, restart the engine after waiting for 30 seconds at least to
V prevent the circuit malfunction of the starter.
3.3. Engine Break-in
All DAEWOO marine engines have been run for a short period of time as a final test at the
factory. During the first 20 hours of operation, you must follow the Engine Break-In procedure
to ensure maximum performance and long engine life.
"""\;~ Note : Failure to follow the Engine Break-in procedure may result in serious engine
V damage and wtll avotd the engme warranty.
During the break-in period, be particularly observe as follows :
• Check engine oil level frequently. Maintain oil level in the safe range, between the "min." and
"max." marks on dipstick.
• Watch the oil pressure warning lamp. If the lamp blinks whenever the boat attitude (i.e.
turning, climbing on plane, etc.) is changed, it may be the oil pick-up screen not to be
covered with oil. Check oil dipstick and if required, add oil to the oil pan. But do not fill over
maximum level.
w
V
Note : Oil pressure will rise as RPM increases, and fE!II as the engine RPM decreases. In
addition, cold oil will generally show higher oil pressure for any specific RPM than hot
oil. Both of these conditions reflect normal engine operation.
• Watch the engine water temperature gauge and be sure there is proper water circulation. The
water temperature gauge needle may fluctuate if water level in expansion tank is too low.
- 16-
,--------------·--··----------------
lnitional Break-In of DAEWOO Marine Engines
(Load)
100% -------------------------------------------- -------------------------- -------------------------.- ---------------- --------- ,--- -------------
75% ------- r- - ------------------------- -,--- - ---------1---r--, - - -- r-- - - -------
50%-------- ------ ------------------------- r-- ------ --------1--- ---- ------------------------- - ---------- ------------------
PS
Fast Idle 25 %- ------- I-- ------ --------1--- ------------ ---------------- -----------------------------
(1300rpm)
Idle -
Q 5 52 3min. 2 30 5 30min. 5 52 30 5 30 5 10 5 30min. 5 30 30 30 30 mir~.
L;-J I I
l ~~
Repeat again I L__
Up to 2 hours
Repeat again II Repeat again
I· Up to Next 8 hours I And then Next 10 hours
I. During 20 hours :. Last additional 30 hours

Total 50 hours Initial Break-In of DAEWOO marine Engines
Running Time ' t:>

EC50M126
3.3.1. Initial two hours of break-in

For the first five to ten minutes of operation, operate engine at a fast idle (below 1 ,500 rpm).
During the remaining first two hours of operation, accelerate to bring boat onto plane quickly and
bring throttle back to maintain a planing attitude. During this period, vary the engine speed
frequently by accelerating to approximately three-fourths throttle (1700 - 1800 rpm) for two to
three minutes, then back to minimum planing speed (700 - 750 rpm).
After the engine has reached operating temperature, momentarily reduce engine speed, then
increase engine speed, to assist the break-in of rings and bearings. Maintain planing boat attitude
to avoid excessive engine load.
w Note : Oo not run engine at any constant rpm for prolonged periods of time for this initial
V two hours of break-in.
3.3.2. Next 8 Hours

During the next 8 hours, continue to operate at approximately three-fourths throttle or less
(Minimum planning speed). Occasionally reduce throttle to idle speed for a cooling period. During
this 8 hours of operation, it is permissible to operate at full throttle for periods of less than two
minutes only 2 times.
w Note : Oo not run engine at a constant rpm for prolonged periods of time during the break-
V in period.
- 17 -
3.3.3. Final 10 hours
During the final 10 hours of break-in, it is permissible to operate at full throttle for five to ten
minutes at a time. After warming engine to operating temperature, momentarily reduce then
increase engine speed. Continue to operate at approximately three-fourths throttle. Occasionally
reduce engine speed to idle to provide cooling periods.
w Note Do not run engine at a constant rpm for prolonged periods of time during the break-
in period.
3.3.4. Operating after break-in 20 hours

When starting a cold engine, always allow the engine to warm up gradually. Never run the engine
at full throttle until the engine is thoroughly warmed up.
And you'd better run the engine at three-fourths throttle (about 1800 - 1900 rpm) until additional
30 hours (after finishing break-in 20 hours) as possible.
Be sure to check the oil level frequently during initial 50 hours of operation since the oil
consumption will be high until the piston rings are properly seate•;:l.
When the engine operation become to reach 50 hours in total including the break-in period 20
hours, replace the engine oil and oil filter to new ones. Refer to ' 14.4. Lubricating System".
W' NOTE : When engine is overheated, do not stop the engine immediately.
V Lower the engine load and run the engine to be a lovver rpm as possible.
- 18-
3.4. Inspection After Starting
During operation the oil pressure in the engine lubrication system must be monitored. If the
monitoring devices register a drop in the lube oil pressure, switch off the engine immediately.And
the charge warning lamp of the alternator should go out when the engine is running.
• Do not disconnect the battery or pole terminals or the cables.

• If, during operation, the battery charge lamp suddenly lights up, stop the engine immediately
and remedy the fault in the electrical system.
• Engine should be stopped if the color, the noise or the odor of exhaust gas is not normal.
• Confirm the following things through warning lamps and gau~e panel.
3.4.1. Pressure of lubricating oil

The normal pressure comes up to 1 kg/cm 2 (1.0 bar) at idling and 3 - 5 kg/cm 2 (3.0 - 4.9 bar) at
rated speed. If the pressure fluctuates at idling or does not reach up to the expected level at high
speed, shut down the engine immediately and check the oil level and the oil line leakage.
3.4.2. Temperature of cooling water

The cooling water temperature should be 71 - 85 oc in normal operating conditions. Abnormally
high cooling water temperature could cause the overheating of en~Jine and the sticking of cylinder
components. And excessively low cooling water temperature increases the fuel consumption,
accelerates the wears of cylinder liners and shortens the engine life-time.
3.5. Check After Initial 50 Hours Operation
To insure your continued boating enjoyment, you should check as follows:
• Change engine oil and oil filter cartridge.

• Change fuel filter cartridge.
• Check coolant level.
• Check the tension of all drive belts.
• Check engine mounting screws for tightness.
• Check for any deficiencies, malfunctions, signs of abuse, etc. Correction of any problems at
this time will prevent the worsening of a minor problem and help ensure a trouble free
boating season.
Note : This time is a good opportune to discuss with your dealer about your engine etc which
may have arisen after the first 50 hours of operation and establish a routine preventive
maintenance schedule like "4.2. Periodical Inspection & Maintenance".
- 19-
3.6. Operation in Winter Time
Pay special attention to the freezing of cooling water and the viscosity of lubricating oil.
3.6.1. Prevention against the freeze of cooling water

When not using anti-freeze, completely discharge the whole cooling water after engine running.
The freeze of cooling water causes the fatal damages of the engine. Because the anti-freeze is
used to prevent coolant from freeze and corrosion, it is always to be filled with the anti-freeze 35
- 40 % of the engine whole coolant.
3.6.2. Prevention against excessive cooling

Drop of thermal efficiency caused by excessive cooling increases fuel consumption. Therefore
prevent the engine from excessive cooling. If the temperature of coolant does not reach to normal
condition (71 - 85 °C) after continuous operation, examine the thermostat or the other cooling
lines.
3.6.3. Lubricating oil

As cold weather leads to the rise of oil viscosity, engine speed becomes unstable after starting.
Therefore the lubricating oil for winter (SAE 15W40 or 1 OW40) should be used to prevent this
unstableness. Refer to "4.4. Lubricating System".
3.7. Tuning the Engine
The purpose of an engine tune-up is to restore power and performance that's been lost through
wear, corrosion or deterioration of one or more parts or components. In the normal operation of
an engine, these changes can take place gradually at a number of points, so that it's seldom
advisable to attempt an improvement in performance by correction of one or two items only.
Time will be saved and more lasting results will be obtained by following definition and thorough
procedure of analysis and correction of all items affecting power and performance.
Economical, trouble-free operation can better be ensured if a complete tune-up is performed
once every year, preferably in spring. Components that affect power and performance to be
checked are:
• Components affecting fuel injection ;

Nozzle, delivery valve, fuel filter, fuel water separator, etc.
• Components affecting intake & exhaust ;
Air filter, inter-cooler, turbo-charger, silencer, good ventilation of engine room, etc.
• Components affecting lubrication & cooling ;
Air & oil filter, anti- freeze, heat exchanger, rubber impeller, sea water filter, kingston valve,
misalignment of propeller, stableness of bed frame, bent propeller blade, etc.
- 20-
4. Maintenance and Care
4.1. General Instructions
1. Before performing service operation, disconnect the grounding cable from the battery for
reducing the chance of cable damage and burning due to short-circuiting.
2. Use covers to prevent the disassembled parts and components from damage or pollution.
3. Engine oil and anti-freeze solution must be handled with care. They can cause damage for
painted parts.
4. The use of proper tools or specified special tools is important to perform the efficient and
reliable maintenance operation.
5. Use genuine DAEWOO parts necessarily.
6. Used cotter pins, gaskets, 0-rings, oil seals, lock washer and self-lock nuts should be
discarded. New ones should be used for re-assembled parts. If these are reused, normal
performance can not be maintained.
7. To facilitate reassembling, keep disassembled parts neatly in groups. Fixing bolts and nuts
for reassembled parts should be reused at the original position. They are varied in hardness
or length because they are designed depending on their application.
8. Clean the disassembled parts prior to inspection or re-assembly. By using compressed air,
make oil ports and etc. of them free from any foreign material.
9. Lubricate the surface of rotating and sliding parts with oil or grease before installation.
1 0. If necessary, use sealant onto gaskets to prevent leakage.
11. Carefully obey all specified torque to tighten bolts and nuts
12. When maintenance is completed, make a final check to be sure it has been done properly.
- 21 -
4.2. Periodical Inspection & Maintenance
In order to insure maximum, trouble-free engine performance at all times, regular inspection,
adjustment and maintenance are vital before occurring any problems.
• Daily inspections in below figure should be checked every day.
• The following maintenance details should be executed thoroughly at regular internals.
Every Every Every Every Every Every

Inspection Daily
50 hrs 100 hrs 250 hrs 500 hrs 600 hrs 1,000 hrs
Coolant level check and refill
•
Contamination of the coolant
1 Year
check and the quantity of the
anti-freeze
• change
Heat-exchanger and water

cooling line cleaning 1 ,200hr
Cooling (Change 0-Ring & Gasket)
System
2,000hrs
V-belt check <md adjustment • change
Check thermostat and clean

or exchange for excessive 1 years
corrosion
Impeller of sea water pump 2,000hr

check • change
Oil level check •
Lubrication oil exchange •
1st •
Lubrication
System Oil filter cartridge replacement •
1st •
Marine gear oil exchange •
1st •
Air filter element cleaning &
change •
Clean
•
Change
Inter-cooler cleaning
Turbocharger cleaning
•
2,000hrs
Intake Exhaust gas check
•
Exhaust Priming pump strainer cleaning
•
Fuel Fuel tank check & cleaning
•
System Water separator cleaning
•
Fuel filter exchange •
1st •
Fuel Injection timing check 1 year
Fuel Injection nozzle check 1 year
Electrical
Warning lamps check
•
System
Battery charging check
•
Wiring harness check
•
Cylinder compression
pressure check •
needed
Cylinder
ln./ Ex. valve clearance
adjustment •
- 22-
4.3. Cooling System
4.3.1. Coolant level check and refill

• Replenish the deficient coolant in the expansion tank every day before running. The coolant
must be changed at intervals of 1,200 hours operation or six months whichever comes first.
If the coolant is being fouled greatly, it will lead engine overheat or coolant blow off from the
expansion tank.
• Clean fresh water should be used for engine coolant.
• Additional agent (35 - 40% anti-freeze and 3 - 5% anti-corrosion agent) should be mixed
with fresh water for engine coolant to prevent the coolin£1 system problem like freezing,
corrosion and etc.
CAUTION : Suitable mixture of anti-freeze and anti-corrosion agent can protect the engine
corrosion from deteriorating and raises a boiling point, but by using unsuitable
mixture engine components like water pump impHIIer and water jacket of cylinder
block may be occurred a malfunction by any bad corrosion damage or cavitation.
(1) Coolant replenishment

Let the plug in the highest level of the water lines or the upper plug of wet turbocharger
open, and fill the coolant about three forth of the expansion tank slowly until the air bubbles
in water do not come out through the plug hole. Then reassemble the plug.
After filling the coolant, run the engine at the idle rpm for around 5 minutes and you will
find out the engine coolant level becomes lower than before cause of escaping the air
bubbles in water. Then stop the engine and replenish additional coolant properly.
(2) Coolant 1:::hange

• Open the pressure cap of
expansion to remove the air
pressure.
• Loosen two drain plugs. One is
J lower side of the oil cooler and
another is upper side of the
starter as figure.
• After drain reassemble the plug Drain plug
and replenish the coolant as same EC50M127
as "(1) Coolant replenishment".
CAUTION : When remove the pressure of the filler cap while the engine is still hot, cover the
cap with a cloth, then turn it left slowly to release internal steam pressure. This
will prevent a person from scalding by hot steam spouted out from the filler cap.
- 23-
4.3.2. Contamination check of the coolant and the quantity of the anti-freeze
V'Je recommend the engine coolant for D.A.EWOO marine engines should be mixture of fresh
water and additional agent (35 - 40% anti--freeze and 3 - 5% anti-corrosion agent).
Check the quantity of the anti-freeze every 600 hours. From time to time, refill the anti-freeze
as much as required.
You can check the quantity of anti-freeze and anti-corrosion agent by using a FLEETGUARD
test kit simply as follow. (Fieetguard CC2602M : DHI No. ; 60.99901-0038)
1) Contamination check
• How to use test kit (Striped pad)

(1) Collect half of a coolant sample cup from a drain plug at the lower side of the oil cooler
or cylinder block. Coolant must be between 1 ooc and 55oc when tested. Room
temperature is preferred.
Do not collect the coolant from the expansion tank or overflow system.
The collected sample is less contaminated, so it can not be substituted for the quality of
whole coolant.
(2) Shake the bottle filled with sample coolant to mix well and take out one strip from bottle
of the test kit. Then dip the strip in coolant sample for 3-5 seconds, take it out and shake
it briskly to remove excess liquid.
Do not touch the pads on the end of the strip. Discard the kit if unused strips have
turned brown for the nitrite test pad.
(3) Wait for 45 seconds after taking the strip out in the bottle of the sample coolant, then
compare the color of the pads with the standard color chart of the test kit label and record
the result as follows.
Caution : All three pad readings m4st be completed no later than 75 seconds after
dipping strip.
Do not touch the stripe with fingers.
• How to judge the strip
strip
c) b) a)
a) Compare FREEZEPOINT (end pad) to chart and record result.

b) Next compare MOLYDATE (middle pad) to chart and record result.
c) Finally compare NITRITE test to chart and record result.
-24-
(1) Compare the end pad "a)" color of the strip
with color blocks of a row at the upper part %GLYCOL I FREEZEPOINT (G) (End Pad)
25% 33% 40% 50% 60%
of the standard color chart (below of the
I I I I 'I 101 IE
letter "GL YCOL!FREEZE POINT'). Same -12" -15" -18" -21" -23" -29" -34" -43" -51"
color in the block of the row means the

SCA Units per Litre
•
content of anti-freeze in the coolant. --- -- .. -·· ··-- --·-
(Normal range is between 33% and 50%.) 0.0 0.4 0.7 0.9 1.0 1.1 1.3 1.5
RowS
--· - -- - ~-- -·-H ST-- --·--
(2) Compare the middle pad "b)" color of the 0.0 0.4 0.6 0.7 0.9 0.9 1.1 1.3
RowS
--····-- - ·--
strip with the color that the column block
D
Row4
0.0 0.4 0.5 0.5 0.6 0.7 1.0 1.2
color of MOLYDATE at the left side of the -··--·- - --:--···+
table intersects the row block color of

0.0 0.3 0.4 0.4 0.6 0.7 0.9 1.1
r-
NITRITE at the bottom (pad "c)" color of the 0.0 0.2 0.3 0.4 0.5 0.6 0.8 1.0
+--
strip) on the table "SCA Units per Litre".
0.0 0.2 0.2 0.2 0.4 0.5 0.7 0.9
(Normal range of "SCA Units per Litre" is +--P RE·C AR E
0.0 0.1 0.2 0.2 0.3 0.4 0.6 0.9
between 0.3 and 0.8 : "green color area")
·--
c_~2-
--
c 0
NITRITE
E
0 F G
• H
EA705013
During the comparison, if uncertain about color match, pick the lower numbered block.
(example: if the color of NITRITE pad is between standard color "0" and "F", then use column
E.)
(3) If the value of "SCA Units per Litre" is less than 0.3, refill the DCA4 liquid (anti-corrosion agent) a
little, But larger than 0.8, Drain some amount of engine coolant and replenish the fresh water
instead. The content of the anti-freeze and anti-corrosion agent can be regulated by this way.
Every year coolant must be replaced. It is essential the coolant should be mixture of
fresh water, proper anti-freeze and anti-corrosion agent.
- 25-
2) Quantity of anti-freeze
The anti-freeze, 35 - 40% of the whole coolant, is always to be used to prevent the cooling
system from the corrosion. And in winter the amount of anti-freeze shown in the following
table should be used in accordance with the ambient temperature.
As the individual freezing points corresponding to the proportions of antifreeze in the table
are subject to change slightly according to the kind of antifreeze, you must follow the
specifications provided by the antifreeze manufacturer.
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
Any coolant loss due to engine operation must be replenished. But adding fresh water for
coolant tends to lower the content of anti-freeze. Always replenish the coolant with a
mixture of antifreeze and water, and keep the proper content of antifreeze (35- 40%)
4.3.3, Heat exchanger and water cooling line cleaning

(1) Heat exchanger cleaning
If the heat exchanger tubes are clogged by small pieces or polluted by corrosion, the volume
of supplied sea water will be reduced gradually. This would be cause of engine overheating.
• Disassemble both left and right side covers of the heat exchanger.
• Remove the clogged small pieces and clean the heat-exchanger tubes.
When the heat-exchanger tubes do cleaning, clean outside and inner side of tubes by using
a small wire brush and pressurized water.
(2) Fresh water cooling line cleaning

If the cooling circuits are fouled with water scales or sludge particles, the cooling efficiency will
be lowered.
The poor condition of the cooling system might be normally due to use of unsuitable anti-
freezing agents so periodically clean the circuit interior with a cleaner.
w Cooling system cleaning interval : Every 1,200 hours
- 26-
4.3.4. V-belt check and adjustment
(1) Visual check
Check the belt for cracks, oil, overheating and wear.
(2) Tension check
By the finger-pressure, the belt is
presseo by 1 0 - 15mm between the
water pump pulley and the alternator
pulley in normal condition.
For the adjustment of the tension, Water pump
loosen the adjusting bolts which support

the alternator, adjust the tension and Alternator
tighten the bolts again.

(3) V-belt change
Change the belt if necessary after every
2,000 hours of operation.
EB103006
If, in tfle case of a multiple belt drive,
wear or differing tensions are found,
always; replace the complete set of the
belts.
w Note : Always apply to DAEWOO genuine parts every replacement.
4.3.5. Thermostat check

The thermostat maintains a constant
temperature of coolant (71 - 85 oc) and
improves thermal efficiency of the engine
by preventing heat loss.
Namely, vvhen the temperature of coolant is
lower than 85 °C, the thermostat valve is
closed to make the coolant bypass to
directly enter the water pump. When the
coolant ternperature rises to open wide the
thermosta.t valve, the bypass circuit is
closed and the water passage to the heat
exchanger is opened so that the coolant is
forced to tlow into the heat exchanger.
Item Specifications
Type Wax-pallet type
Open at 71 oc
Open wide at 85 oc
Valve lift 8 mm or more
- 27-
• Inspection
(1) Check the wax pallet and spring for
damage.
(2) Put the thermostat in a container of
water, then heat the water slowly
and check temperature with a Bar
Thermometer
thermometer. If the valve lift is 0.1
mm (starting to open) at
temperature of 71 oc and 8 mm or
more (opening wide) at temperature
of 85 oc, the thermostat is normal.
EFM20551
• Thermostat replacement
(1) Precautions for handling
The wax pallet type thermostat does not react as quickly as bellows type one to a
variation of temperature of coolant. Such relatively slow reaction is mainly due to the
large heat capacity of the wax pellet type thermostat. Therefore, to avoid a sharp rise of
coolant temperature, it is essential to idle the engine sufficiently before running it. In cold
weather, do not run the engine at overload or overspeed it immediately after starting off.
(2) When draining out or replenishing coolant, do it slowly so that air is bled sufficiently from
the entire cooling system.
(3) Replacing thermostat.
If the thermostat is detected defective, replace with a new one.
Check the thermostat and clean or exchange for excessive corrosion every 1 year.
4.3.6. Impeller of sea water pump check

The sea water pump is a rubber impeller type driven by gear. Every time the engine starts you
should always check whether the kingston valve on the bottom of boat is opened or not.
If the engine is run in a dry impeller condition for more than 20 seconds, the rubber impeller
is burned and cracked by high revolution of sea water pump.
- 28-
• Impeller disassembly
(1) Remove end cover screws, end cover
and a-ring.
(2) Grasp the hub of impeller with water
pump pliers and withdraw it by twisting to
the rotating direction of the sea water
pump body or remove it using two drivers
like upper figure.
(3) Detach the cam unscrewed a bolt and
clean the sealant of cam and body bore.
EB40401L
(4) Remove the wear-plate. ---------------------
EB40402L
• Impeller assembly
(1) Install wear-plate in body bore, aligning
slot in wear-plate with dowel pin in body.
(2) Apply a thin coat of sealant to cam screw
threads and top side of cam and install in
body with cam screw.
(3) Lubricate impeller bore and end surfaces
of impeller with light coat of water pump
grease and start the impeller in bore with
a rotary motion until shaft key engage,
then push it into the bore side by twisting
into rotating direction.
~ Caution : When you assemble the rubber impeller, do not use hammer to prevent
V the mechanical damage.
(4) Install 0-ring and end cover and secure with end cover screws.
(5) After assembled the impeller open the kingston valve and check the leakage of sea water
pump on running the engine.
- 29-
4.4. Lubrication System
4.4.1. Oil level check

• The notches in dipstick must indicate
the oil level between high and low
permissible when the vessel is in the
water and with its normal trim.
• The oil level should be checked with
the engine horizontal and only after it
has been shut down for about 1 0
minutes.
' ' @'"
©~MAX
• Examining the viscosity and the
~:::I MIN
@ . EA605001
contamination of the oil smeared at ·---· -·-------
the dipstick, replace the engine oil if
necessary.
CAUTION : Do not add so much engine

oil that the oil level rises _,.~--~-=-L_ _ ___,)
above the maximum
marking on the dipstick.
Over filling causes excessive
blow-by gas and will result in
damage to the engine.
EB007002
• How to re-mark the oil dipstick

Since the inclination angle of marine
engine may vary greatly as vessels,
the high and low oil levels on the
dipstick should be also changed when
the engine inclination angle is over 6
degree.
Dipstick should be re-marked by
engraving on the lube oil capacity of
each engine. Be sure to check and
EB007003
mark the oil levels between High and ····-·· -·---·-·------·----- - - - - - - - '
Low when the vessel is
commissioning at first. Please note
that stamping or notching will weaken the dipstick and the tip of the dipstick may break off
in the oil pan.
The capacity of lube oil can be referred to "1.1. Engine Specification".
- 30-
4.4.2. Lubrication oil exchange
Engine oil and the oil filter are important factors affecting engine life. They affect ease of starting,
fuel economy, combustion chamber deposits and engine wear.
The first engine oil change should be after 50 hours of operation and next exchange will be
performed every 250 hours. At the end of the break-in period (50 hours), change the engine oil
and replace the oil filter cartridge to new one.
(1) Oil drainage

• While the oil is still hot, discharge the
sump oil or marine gear sump oil by
rotating oil drain pump manually.
Oil drain pump
EC50M128
r--------------------------··-··-·
• Refill new engine oil to the oil filler
neck on the head cover in accordance
with the oil capacity of the engine. Be
careful about the mixing of dust or
contaminator during the supplement
of the engine oil.
Then confirm that the oil level gauge
indicates the vicinity of its maximum
level.
EA904002
• For a few minutes, operate the engine '------------------ ··-·-· ------------
at idling in order to circulate oil
through lubrication system.
• Thereafter shut down the engine. After waiting for about 10 minutes, measure the quantity
of oil and refill the additional oil if necessary.
• Recommendation for lubrication oil

Initial factory filling is high quality break-in oil (API Service CH-4 grade). During the break--in
period (50 hours), check the oil level frequently. Somewhat higher oil consumption is normal
until piston rings are seated. The oil level should be maintained in the safe range betwe~n
the Min. and Max. mark on the dipstick. To obtain the best engine performance and engipe
life, Engine oil is specified by API Service, letter designations and SAE viscosity numbers . If
the specified engine oil is not available, use a reputable brand of engine oil labeled for API
Service CH-4 and SAE viscosity 15W40 or 1 OW40.
Refer to oil identification symbol on the container.
- 31 -
Engine oil viscosity -ambient temperature
EA4M1008
··----------.. _ .._____
4.4.3. Oil filter cartridge replacement

Every time oil exchanges, replace the oil
filter cartridge.
• Drain engine oil by loosening the drain
plug on the filter head.
CAUTION : Don't forget tightening the

drain plug after having
drained engine oil.
• Remove the oil filter by turning it
EB105002
counter-clockwise with a filter wrench.
• Wipe, clean the fitting face of the body
contacting with the oil filter so that new
oil filter cartridge can be seated properly.
• Lightly oil the 0-ring and turn the oil filter until sealing face is fitted against the 0-ring And
then turn it in addition by 3/4 -1 turns further with hand or the filter wrench.
w NOTE : It is strongly advisable to use DAEWOO genuine oil filter cartridge for replacement.
4.4.4. Marine gear oil change

Always apply to API Service SAE #30 for reduction gear oil Change the reduction gear oil at
1 00 hours of operation at first and next exchange will be performed every 600 hours.
- 32-
4.4.5. Cylinder compression pressure
check
• Stop the engine after warming up, and
take out nozzle holder assembly.
• Install the special tool (compression
gauge adapter) at the nozzle holder
hole, and connect the compression
pressure gauge there.
Standard value 24 - 28kg/cm 2

Limit value 24kg/cm 2 or less
EB40403L
Difference between
Within± 10%
each cylinder
*Test Condition
Cooling water temperature 20°C, Engine rotation 200rpm (about 10 revolutions)
4.5. Intake & Exhaust System
4.5.1. Valve clearance adjustment

Usually should check the valve clearance of intake & exhaust every 1,000 hours after engine
operation. Refer to "6.3.24. Valve clearance adjustment" details.
The valve clearances are to be adjusted at the times of the following situations.
• After initial 50 hours operation.
• When the engine is overhauled and the cylinder heads are disassembled.
• When severe noise comes from valve train.
• When the engine is not normally operated, even though there is no trouble in the fuel
system.
- 33-
4.5.2. Air filter element cleaning &
change
The engine life and performance
depends on the intake air condition
greatly.
A fouled air filter element results
decreased intake air amount that leads
decreased engine output and finally
may cause an engine malfunction.
Further, a damaged air filer element
results wear on the cylinder component
or the valve mechanism etc. leading
increased engine oil consumption and
decreased engine output, finally leads to
shorten the engine life.
EA70~006
'-----------------
The air filter element should be cleaned

periodically as follow.
• Cleaning of the air filter element : Every 100 hours
• Exchange of the air filter element : Every 600 hours
Replace the air cleaner if deformed, broken or cracked.
(1) Air filter element cleaning

• Wash the polluted element in warm
water non-household detergent.
• Rinse the element with clean water
• Dry it thoroughly with natural air or
electric fan.
Don't use a flame or compressed air
for dry.
It makes damages to the element.
EA3M1024
(2) Air filter element check
• Confirm inside of the element clean
and dry.
• Replace the new element if tears, rips or damages are found.
-34-
4.5.3. Inter-cooler cleaning
Inter-cooler depends on the intake air
conditiongreatly. The fouled air pollutes
and clogs the air fins of the inter cooler.
As a result of this, theengine output is
decreased and the engine malfunction
may be occurred. Therefore
alwayscheck weather the intake air
systems like air filter element are worn
or polluted.
EC50M106
The inter-cooler has to be removed from
theengine for cleaning.
• How to inter-cooler cleaning

In order to maintain the heat transfer efficiency of the inter-cooler, it is necessary to clean it
at regular intervals. For this purpose, dismantle the inter-cooler. In almost all cases, it will
suffice to clean the individual parts in a hot alkaline solution, e.g. a 3 to 5% P3-FD solution.
If hard and firmly adhering scale deposits continue to exist, a second treatment should be
made with a descaling agent which will not corrode the cooler core. Use new gaskets when
reassembling the inter-cooler.
Be sure to clean the sealing surfaces carefully before installing the gaskets.
Observe the specified pressure when making the hydraulic test.
water side 400 kPa (4 bar)

Test gauge pressure
charge air side 300 kPa (3 bar)
w Cleaning of inter cooler : Every 1,000 hours.
4.5.4. Turbocharger cleaning

• Turbocharger should be cleaned every 2,000 hours. The only points to be observed are the
oil pipes which should be checked at every oil change for leakage and restrictions. Inspect
the condition of turbocharger like oil leaks, and unusual turbo sounds periodically.
• Air cleaner element should be checked and cleaned periodically to prevent foreign matters
from entering the inside of the engine.
• Should check and measure the pressure of intake air and exhaust gas periodically. If there
is air leakage, should repair the problem at once not to occur the engine power loss and over
heating.
• In case of operating in highly dust or oil-laden atmospheres, cleaning of the air
compressorimpeller may be necessary from time to time. To this end, remove compressor
casing (Caution: Do not skew it!) and clean in a non-acid solvent, if necessary use a plastic
scraper.
If the air compressor should be badly fouled, it is recommended that the wheel be allowed
to soak in a vessel with solvent and to clean it then with a stiff non-steel brush. In doing so,
- 35-
take care to see that only the compressor wheel is immersed and that the turbocharger is
supported on the bearing casing and not on the wheel.
4.5.5. Exhaust gas check

Exhaust gas depends on much or less of it shows whether combustion condition of the engine
is good or not. If exhaust gas is any abnormal condition like excessive smoke, white smoke,
black smoke, the engine should be serviced maintenance from specialist.
4.6. Fuel System

As fuel injection pumps and injection nozzles consist of very complicated and precise
components, the contamination of fuel causes the t::logging of the nozzle or the sticking of the
injection pump components. Therefore, the cleanness of the fuel system should be maintained
at any time.
If the engine is equipped with a fuel water separator, drain off any water that has accumulated.
Water in fuel can seriously affect engine performance and may cause engine damage.
4.6.1. Priming pump strainer cle~ming

----------···-· -- ... ------- - - - - - - - - · - - -
Clean the priming pump strainer every
100 hours operation. The strainer is
incorporated in the priming pump inlet
side joint bolt. Clean the strainer with the
compressed air and rinse it in the fuel
oil.
Strainer(lnner)
~112tV' EA705009
4.6.2. Fuel tank check & cleaning

Fill the tank with recommended fuel and should reduce water condensation of the fuel tank as
possible. Also it is important for the engine performance to keep the fuel cool.
w Make sure fuel supply valves (if used) are opened before run.
In marine environment, the mqst likely fuel contaminants are water and microbial growth
(black "slime"). Generally, this type of contamination is the result of poor fuel handling
practices.
Black "slime" requires water in the fuel to form and grow, so the best prevention is to keep
water condensation to a minimum in storage tanks.
If diesel fuel which contains motsture is used, injection system and cylinder liners, pistons will
be damaged. Drain moisture and accumulated sediment from drainage device of storage tank
regularly. You'd better change the element of the water separator or fuel filter cartridge several
times until fuel of the suction line is cleaned.
- 36-
NOTICE : A galvanized steel tank should never be used for fuel storage, because fuel oil
reacts chemically with the zinc coating to form powdery flakes which can quickly
clog the fuel filters and damage the fuel pump and injection nozzles.
• How to select fuel oil

Fuel quality is an important factor in obtaining satisfactory engine performance, long engine life,
and acceptable exhaust emission levels. DAEWOO engines are designed to operate on most
diesel fuels marketed today. In general, fuels meeting the properties of ASTM designation D975
(grades 1-D and 2-D) have provided satisfactory performance.
The ASTM 975 specification, however, does not in itself adequately define the fuel characteristics
needed for assurance of fuel quality.
The properties listed in the fuel oil selection chart below have provided optimum engine
performance. Grade 2-D fuel is normally available for marine service. Grade 1-D fuel should not be
used in pleasure craft engines, except in an emergency.
<Fuel Oil Selection Chart>
General Fuel ASTM No.1 No.2

DIN 51601
Classification Test ASTM 1-D ASTM 2-D
Gravity, oAPI #I
D 287 40-44 33-37 0.815 - 0.855
Flash Point
Min. oF ( 0 C) D 93 100 (38) 125 (52) 131 (55)
Viscosity, Kinematic
D 445 1.3- 2.4 1.9- 4.1 1.8- 10
CST 100 OF (40 oc)
Cloud Point oF •1 D 2500 See Note 1) See Note 1) See Note 1)
Sulfur Content
D 129 0.5 0.5 0.15
wt%, Max.
Carbon Residue
D 524 0.15 0.35 0.1
on 10%, wt%, Max.
Accelerated Stability
Total lnsolubles D 2274 1.5 1.5
mg/1 00 ml, Max. •>
Ash, wt%, Max. D 482 0.01 0.01
Cetane Number, Min. •) D 613 45 45 > 45
Distillation D 86
Temperature, oF(oC)
IMP, Typical•> 350(177) 375(191)
1 0% Typical•> 385(196) 430(221)
50% Typical•> 45(218) 51 0(256) 680(360)
90%•) 500 (260) Max. 625(329) Max.
End Point•> 550(288) Max.· 675(357) Max.
Water & Sediment
D 1796 0.05 0.05 0.05
%, Max.
•> Not specified In ASTM D 975 •I Differs from ASTM D 975
- 37-
Note : The cloud point should be 6 oc (10 OF) below the lowest expected fuel temperature to
prevent clogging of fuel filter by crystals.
4.6.3. Water separator cleaning

DAEWOO recommends the fuel water separator to install between fuel tank and fuel injection
pump strongly.
Condensation formed in a partially filled tank promotes the growth of microbial organisms that
can clog fuel filters and restrict fuel flow and cause the engine power decrease before.
Drain the accumulated moisture of the water separator every 100 hours to prevent engine
damage.
4.6.4. Fuel filter exchange

• Loosen the fuel filter by turning it
counter-clockwise with the filter
wrench. Discard the used filter a
designated place.
• Wipe the filter fitting face clean.
• Supply fuel to the new filter and apply
engine oil to the 0-ring face lightly.
• Turn the new filter until the filter 0-ring
is fitted against the sealing face.
EA705007
• And then turn the filter cartridge about
3/4 -1 turn with hands.
Fuel system bleeding

Whenever fuel filter is changed or the
engine is stopped by cause of the fuel
lack, the air of fuel line must be removed
as follows.
Bleed the fuel by manually operating the
priming pump with fuel filter outlet joint
bolt and injection pump bleeder screw
loosened.
• Press the feed pump cap repetitively
until the fuel without bubbles comes
out from the bleeding plug screw.
• After the whole air is pulled out, close
the plug screws of the filter and the pump.
• Confirm the resistance of fuel delivery by repetition pressing of the feed pump cap, Pressure
and turn the priming pump cap simultaneously to close it.
- 38-
4.6.5. Fuel injection timing check (by authorized specialist personnel)
Check the fuel injection timing every year. Refer to details in "6.3.27. Injection pump & timing "
Caution : • Check the fuel injection pump housing for cracks or breaks, and replace if
damaged.
• Check whether the lead seal for idling control and speed control levers have been
removed or not.
• No alterations must pe made to the injection pump. If the lead seal is damaged
the warranty on the engine will become null and void.
• We strongly recommend that any faults developing in the injection pump should
be taken care of by authorized specialist personnel.
4.6.6. Injection Nozzle check (by authorized speciali~t personnel)

Check the fuel injection nozzle every year or increasing the smoke excessively.
Refer to details in "7.3.3. Fuel injection nozzle".
4. 7. Electric System
4.7.1. Warning lamps check

Check the lamps of the gauge panel carefully whether the lamp is switch on or not while the
engine is running. The oil warning lamp should be switched on below 0.5 bar of the oil
pressure and the water temp warning lamp should be switched off under 95 o C of water
temperature (normal condition).
4.7.2. Battery charge check

Always check whether the battery capacity is sufficient or not before sailing far away from
harbor.
4.7.3. Wiring harness check

Check the engine wiring is loosened, shorted or worn every 600 hours.
- 39-
4.8. Cylinder

Usually should check the valve clearance of intake & exhaust every 1 ,000 hours after engine
operation. Refer to "6.3.26. Valve clearance adjustment" details.
w The valve clearances should be adjusted at the times of the following situations.
• After initial 50 hours operation.

• When the engine is overhauled and the cylinder heads are disassembled.
• When severe noise comes from valve train.
-When the engine is not normally operated, even though there is no trouble in the fuel
system.
4.8.2. Cylinder compression pressure

check
• Stop the engine after warming up, and
take out nozzle holder assembly.
• Install the special tool (compression
gauge adapter) at the nozzle holder
hole, and connect the compression
pressure gauge there.
Standard value 24 - 28kg/cm2

Limit value 24kg/cm 2 or less
EB40403L
Difference between
Within± 10%
each cylinder
* Test Condition
Cooling water temperature 20°C, Engine rotation 200rpm (about 10 revolutions)
-40-
4.9. Engine Preservation Points for a Long Time
Preserved engine for a long time should be prevented from corrosion or entering faulty matters.
Especially the external and internal major components of the engine are likely to corrode.
Please take care of the engine to maintain its good performance as follows.
• Drain the engine coolant completely and fill flesh water into the engine. Then run it sufficiently
until washing out the engine coolant line.
Finally drain the water, and refill new coolant (flesh water with 35- 40% anti-freeze).
• Run the engine until the temperature of engine coolant is reached to normal condition (71
85 °C), after then stop the engine.
• Drain engine oil by removing the drain plug of the oil pan or using the oil drain pump. Then
refill new engine oil up to "MAX" mark line and change oil filter cartridge to new one.
Prior to changing the oil, run the engine for 10 minutes. Drain engine oil while the engine is
still hot. It is helpful to drain the faulty matters attached in the bottom of the oil pan.
• Close the valve or the cock of the fuel tank securely. Then detach the fuel filter and the water
separator to clean them or replace with a new one.
• Run the engine about 5 minutes in order to circulate the new fuel through the all fuel lines
completely.
• Disassemble the air filter to clean. If the element is fouled or worn severely, replace it with a
new one.
• Drain the reduction gear oil completely, then clean the strainer that is assembled in the
reduction gear.
Refill the specified oil (SAE #30, above API CC grade) up to the "MAX" level.
• While the engine is running at idle rpm for 5 minutes, shift the control lever position of the
reduction gear in turn (eg. "Neutral" - "Forward"- "Neutral" - "Reverse") to circulate the oil
completely.
• Put the engine throttle lever at the idle position then reduction gear and FPTO lever at "switch
off' position (Neutral & OFF).
• Drain the engine coolant completely and let the drain plugs removed.
• Close the kingston valve of the sea water line tightly. To avoid damage cause of freezing,
drain the water of the heat exchanger, inter cooler, reduction gear oil cooler completely and
keep the plugs opened.
Finally don't forget to detach the sea water pump impeller and preserve it at a dark place.
• First of all, disconnect the battery wire (negative pole), then detach the other cables.
Clean battery and all cables. After that replenish the distilled water for battery. (for refill type)
DAEWOO battery is maintenance free type, so there is no need to refill the water.
To protect corrosion, apply the grease on the wire terminals of the battery.
• Loosen the V-belt(s) to release the pulley bearing from loaded tension and insert some pieces
of paper between V-belt(s) and the pulley grooves.
• At least run the engine at idle rpm or a little more for 10 minutes once 1 0 days in order to
lubricate all lubrication system and charge the batteries of the engine.
• The engine not used for a long time should be checked the condition regularly.
Apply the grease on the engine parts to keep from rust.
- 41 -
4.1 0. Management for Sunken Engine
If the engine is sunk in sea water, remove the moisture of all engine parts as soon as possible
and ask after service of your DAEWOO dealer at once.
All parts of the engine should be disassembled to remove the salty moisture. After this, engine
oil should be applied onto the parts at once. Finally check whether the components of the
engine are dried, eroded away or damaged especially components of the fuel system. These
actions must be finished quickly without delay. If not, engine fatal damage may result from
salty corrosion.
Be sure to install the auto bilge pump in the bottom of the engine room. It can be a good
solution to keep the water level below flywheel housing and to prevent overflowing with water.
-42-
5. Main Accessory Parts
5.1. Reduction Gear
Refer to "reduction gear manual" provided with engine separately for detail operation and
maintenance of reduction gear.
5.1.1. Construction and operation

The reduction gear is used for high-speed engine and consists of 4 major components such
as input shaft, gear shaft, output shaft, and housing.
The clutch for forward and reverse movements is composed of a hydraulic wet-type and multi-
plate type. The con;struction and power line is as follows;
EFM60061
<Power line>
Neutral : 1-2-5-4-B
Forward: 1-2-5-3··7-10
Reverse: 1-2-5-4·-8-9-6-7-10
1. Rubber block 6. Reverse pinion

2. Spider 7. Output shaft
3. Forward pinion 8. Reverse drive gear
4. Heverse drive gear 9. Gear shaft
5. Input shaft 10. Propeller shaft
-43-
5.1.2. Characteristics
The hydraulic-type clutch is composed of forward main body, reverse main body, output shaft,
and selector valve ..
The selector valve assembly installed on the external part is a device designed to control
forward, neutral, and reverse movements and also it can be remote-controlled. The oil
pumped up at the pump supplies hydraulic pressure for the clutch assembly, lubricating
portions on gear and bearings, and cooling system. But when assembling this hydraulic type
clutch, use care so that it is aligned with the engine correctly.
5.1.3. Operation
( 1 ) Before operation
• Check the tightening bolts and nuts on the components as a whole for looseness.
• Check the oil level with the oil level gauge.
(Run the engine at idle for a few minutes, then stop it before checking the oil level.)
• Place the control lever in the neutral position before starting the en!;Jine.
(2) Starting
• Run the engine at idle for about 10 minutes.
• Check for oil leaks, unusual sound, temperature, etc. during the en!;Jine idling.
• While checking the clutch pressure, increase the engine rpm.
(3) Driving and stopping

• Check to see that the specified pressure is obtained when engagin!;J the clutch.
The pressure may drop slightly at low engine rpm, but it does not affect the operation of
the engine.
• When attempting to change gears for forward or reverse movement, first put the engine
rpm at idle.
• The temperature of oil at operation must be 60 - 90°C.
• When attempting to stop the engine, be sure to place the control lever in the neutral
position.
-44-
(4) Emergency bolt
The emergency bolt is designed to couple the clutch mechanically when the clutch
indicates abnormal condition or slip at clutch coupling operation. The reverse clutch pack
has no emergency bolt. When using the emergency bolt, first loosen the tightening bolts to
remove the control block, tighten the 8mm wrench bolt on the forward disc pack using a
5mm L-shaped wrench, then reassemble the control block in the reverse order. Be sure to
use this emergency bolt literally in case of emergency.
Steel plate
Snap ring
--~ Sintered plate
Back plate
EE050091
5.2. Front Power Take-Off (F.P.T.O)
5.2.1. For maximum FPTO power

For front power take-off in line with
crankshaft, it is a standard procedure to
support driveshaft and V-pulley by two
pillow blocks by using flexile coupling
for connection to engine.
When the front PTO is installed, be sure
to take deflection reading. Radial run-
out should be no more than 0.02 mm.
Be sure to limit the front PTO output Crank pulley Pillow blocks EA40?00 1
within the maximum allowable
horsepower as specified for each
model. (Torque represents when there is no propeller load)
Model Load(kW) rpm Model Load(kW) rpm

L136 60 1,600 L 136TI 88 1,600
L136T 72 1,600 L086TI 105 1,600
-45-
5.2.2. For small cross drive power
~-----------------------------------,
The figure is applicable to the drive
arrangement (No supporting bearing on V-pulley, PTO
front side of PTO pulley) in which the NIAX. 170mm
Engine
distance between the end face of the (6.7 in) dia.
engine pulley and the centerline

through pulley groove is not greater
than 60mm. The distance is indicated
as L in the figure.
EA407002
Model Lmm Belt driven side load(kW) rpm

L136 35
L136T 40
60 1,600
L 136TI 50
L086TI 62
5.3. Propeller Selection
Your dealer has chosen a propeller

'5 Q; 100%
-@
designed to deliver top performance and
%~ 90%
economy under most conditions. To 0 a. 80%
obtain the maximum percentage of ® 70%

60%
available horsepower (A), the engine
50%
RPM at Full Throttle should be in the 40%
specified Full Throttle Operating Rage (B). 30%
Refer to Specifications in Performance

-RPM
Curve.
EB009001
If the engine's full throttle RPM on normal
load is below the specified on the low side
of the range (C), use a propeller with less pitch to increase the RPM. Should the engine's full
throttle RPM want to exceed the specified range (D), the engine RPM is limited by the governor.
Use a propeller of higher pitch to stop the limiting by the governor.
Note : Engine damage can result from incorrect propeller selection which:
• (C) Prevents engine RPM from attaining the specified "Full Throttle Operating Range".
Engine is laboring, install lower pitch propeller.
• (D) Allows engine RPM above the specified "Full Throttle Operating Range". Engine RPM is
limited by the governor, install a higher pitch propeller.
-46-
5.4. Electric System
5.4.1. Alternator
Terminal R Terminal L
EFM50011
The alternator is fitted with integral silicon

rectifiers. A transistorized regulator
mounted on the alternator limits the
alternator voltage evenly. The alternator
should be operated with the regulator and
battery connected in circuit to avoid the
damage of the rectifier and regulator.
The alternator is maintenance free, but it
must be protected against dust and above Circuit Diagram EA703008
all against moisture therefore it must be
mounted a cover for protector properly.
(1) Inspection Point (In case of abnormal charging)
• Voltage measurement between terminal and alternator body during operation.
<Voltage during operation> <Voltage during stop>
Measuring point Voltage Measuring point Voltage

Terminal B - Body about DC28V - 29V Terminal B- Body about DC24V
Terminal L- Body about DC28V - 29V Terminal L- Body about DC2V
Terminal R- Body about DC28V - 29V Terminal R - Body about DC24V
For the confirmation of wiring state, measurement of voltage should b.e carried out only at each
terminal during engine stop.
-47-
• Inspection points on the voltage regulator
<Resistance value between voltage regulator's terminals>
Resistance Value Resistance Value

Terminal Terminal
(K!) (K!)
+ - + -
L E about 2
R E about 53 E R 00
F E about 50
L F about 50
R L about 50 L R 00
R F about 168 F R 00
(2) Precautions in use

• Pay attention to dropping the battery voltage capacity when they are left for long time even
without use.
• In cold winter season, for the starting may not be done well sometime, do not try it to be
continuous immediately but try to start again after waiting about 30 seconds.
• Prior to operating the gauge panel, make sure of the polarity of battery once again (In
general, red side means"+" and black one is"-".)
• Disassembling the gauge panel may be accompanied with a risk of electrical shock, First
detach the cable from the connector at the rear side of the gauge panel without fail, then
disassemble it.
• If metallic foil is used for safety connector instead of the cut-off fuse, excessive current that
can make serious damage might flow into the electric parts of the engine. (Never do this!) If
cutting off of fuse is occurred, solve the problem, then replace it with a new fuse.
• Since battery has a danger of explosion by a heat, it must not be installed at the place where
there generates a lot of heat.
• When engine is in stop, always pull out the key. Then a hazard of fire or wound due to wrong
operation may not happen.
• In case of scrapping tl")e batteries, observe the followings.
NOTE : Do not throw it in the fire to scrap. It should not be thrown away into the places where
are liable to ca1.1se the environmental pollution such as stream, river and mountain.
Pack them as far as possible and dispose it as rubbish that is unable to use again.
• OAEWOO will not be responsible to the problems that might be raised by the disassembling
and structural change of this product without consultation.
-48-
5.4.2. Starter Motor
The starter motor is installed on the flywheel housing.
When the starter key switch is turned on, the starter motor pinion flies out and engages the ring
gear of the flywheel. Then the main contact is closed, current flows, and the engine is started.
After the engine starts, the pinion automatically returns to its initial position as soon as the starter
key switch is released.
Otherwise, the starter motor may be damaged or burned out.
In case of repairing the engine, dip the

pinion of the starter and ring gear into the
new fuel, then remove the dirty or corrosion
with a brush.
After that, apply the grease on them to
protect the corrosion.
Whenever you clean the starter, always
pay attention not to occur the electric short
due to entering the water.
Starter motor always should be

protected from humidity.
B w
Precaution : Before the maintenance
of the electric system,
be sure to detach the
Key S/W
battery wire (-) to avoid
the electric short. I
l
Circuit Diagram
E.A703009
L--------------------------------
-49-
6. Disassembly and Assembly of Major Components
6.1. Disassembly
6.1.1. General precautions

• Maintenance operation should be carried out in a bright and clean place.
• Before disassembly, provide racks for arrangement of various tools and disassembled parts.
• Arrange the disassembled parts in the disassembly sequence and use care to prevent any
damage to them.
6.1.2. Cooling water

• Remove the drain plug from the
cylinder block and under side of oil
cooler, then drain out the cooling
water into a container.
Drain plug EC50M129
6.1.3. Engine oil and drain pump

• Drain out the engine oil into a
container using oil drain pump.
• Remove the oil hose from oil pan and
reduction gear.
• Unscrew the oil drain pump fixing
bolts and disassemble the oil drain
pump.
EC50M108
6.1.4. V- belt
• Loosen the tension adjusting nut
installedon the alternator support, and
take off the V -belt.
EC50M130
-50-
6.1.5. Alternator
• Remove the electric wires and the
alternator fixing bolt and then
disassemble the cover and alternator.
• Remove the tension adjusting bolt and
bracket.
EC50M109
6.1.6. Fuel filter

• Remove fuel hoses connected to the
fuel injection pump, take off the filter
housing fixing bolts, then disassemble
the fuel filter.
EC50M110
6.1.7. Breather
• Loosen the clamp screw to remove
the rubber hose and the breather after
unscrew.
@ @
@
©@0
EB1M3006
6.1.8. Inter cool~r
• Remove the cooling water pipe from

inter cooler to marine gear oil cooler.
• Remove the air pipe connected to
intake manifold and turbocharger.
• Disassemble the intercooler after
unscrew the mounting bolts on the
heat exchanger.
EC50M111
-51 -
6.1.9. Air cleaner
• Remove the air filter element. --·--·-·--------------
• Loosen the clamp, then remove the air

cleaner.
EB1M3008
6.1.1 0. Tl~rbo charger

• Loosen the clamp screw of the rubber Turbo Charger
hose connected to the inter cooler,

and take off the intake pipes both
simultaneously.
• Unscrew the exhaust pipe flange
fixing bolts and the nuts installed on
theturbocharger, then take out the
e).:haust pipe.
EC50M131
• R~move the turbocharger after
removing the oil supply pipe and
return pipe including both inlet and
outlet cooling water pipes.
6.1.11. Ex;pansion tank

• Remove the reservoir tank and hoses
connected to the expansion tank.
• Loosen the expansion tank bracket
fi>dng bolts then remove the
e~:pansion tank.
EC50M113
-52-
6.1.12. Stop solenoid
• Remove the cable from the fuel stop
lever to the stop solenoid.
• Disassemble the stop solenoid.
EC50M114
6.1.13. Injection pipe

• Unscrew the hollow screws to
disassemble the fuel return pipe.
• Remove the nuts installed on the fuel
injection pump and the injection
nozzles, then disassemble the
injection pipe.
6.1.14. Intake manifold

• Remove the hoses connected to the
injection pump and fuel filter and
intake manifold.
• Loosen the intake manifold fixing
bolts, then disassemble the intake
manifold.
EC50M115
6.1.15. Thermostat
• Release the hose clamps connected
to the both portion of the heat
exchanger and cooling water pipe
• Remove the thermostat housing
assembly, and unscrew the mounting
bolts, then take off two thermostats.
EC50M116
-53-
6.1.16. Heat exchanger
• Loosen tile clamp on the rubber hoses
connected to the inter cooler and
cooling water pipe of the heat
exchanger, and remove the inter
cooler then take off tile rubber hoses.
• After remove the inter cooler, unscrew
the heat exchanger fixing bolts, then
detach the heat exchanger.
EC50M117
6.1.17. Exhaust manifold

• Remove the cooling water pipes on
the front and upper side and then
exhaust outlet pipe.
• Unscrew the exhaust manifold fixing
bolts, and then detach the exhaust
manifold and gaskets.
Caution : The exhaust manifold is
very heavy.
Be careful to handle it.
6.1.18. Starter
• Unscrew the starter fixing bolts, then
disassemble the starter.
EC50M119

• Release the clamp on the rubber hose
connected to the sea water pipe then
detach the rubber hose.
• Unscrew the sea water pump fixing
bolts, then remove the sea water
pump.
EC50M120
-54-
6.1.20. Water pump
• Remove the expansion tank and
rubber hose connected to the
expansion tank.
• Remove the water pipe and hoses
connected to the oil cooler.
• Unscrew the water pump fixing bolts
and remove the water pump.
EB1M3017
6.1.21. Injection pump

(A) L086TI
• Remove the oil supply pipe and the
return pipe connected to the fuel
injection pump.
• Unscrew the bolts connected the
coupling and drive shaft, disassemble
the injection pump mounting bqlts,
then detach the injection pump.
Note : After letting No.1 cylinder t.:o

the 'OT' position by turnin~
the crankshaft, disassembl.e

the injection pump.
• Unscrew the pump bracket fixing bolts

to detach the bracket from the cylinder
block.
Note : Do not mix the disassembled

shims. They should be
reassembled to the original
position.
-55-
(B) L 136/TITI
• Put the piston (No.1) of the engine to
O.T position, then remove the timing
gear case cover, and engrave a line
on the both flanges as the figure. (This
is only for no engraved line before.)
• Remove the injection pump,
EB40601L
To exchange the injection pump for new

one, put the piston (No. 1) of the engine
to 0. T position, then mark the line
temporary by using oil paint at the
geared point between injection pump
gear and idle gear separately.
This marking is used to assemble the
injection pump gear to reassemble the
new injection pump. (Refer to 6.3.27.
(b).)
6.1.22. Oil filter

• Detach the pipes connected to the
water pump and heat exchanger.
Remove the oil filter cartridge using a
filter wrench.
• Unscrew the oil filter fixing bolts and
detach the oil filter and cooler
assembly from the cylinder block.
EC50M132
6.1.23. Vibration damper

• Unscrew the pulley fixing bolts and
disassemble the pulley-vibration
damper assembly.
• Unscrew the vibration damper fixing
bolts and detach the damper from the
pulley.
-56-
6.1.24. Timing gear case cover
• Disassemble the oil seal using the
removing jig.
• Unscrew the cover fixing bolts and
disassemble the cover from the timing
gear case.
6.1.25. Idle gear

• Unscrew the idle gear fixing bolts and
disassemble the thrust washer and
idle gear.
• Disassemble the idle gear pin using a
rubber hammer to prevent them from
damaging.
6.1.26. Injection pump drive

• Unscrew the drive shaft bearing
housing fixing bolts and remove the
injection pump drive assembly like as
the shaft, gear, bearings, and housing
are put together.
6.1.27. Cylinder head cover

• Unscrew the head cover fixing bolts
and disassemble the cover.
• Keep the bolts in an assembly state so
that the packing and washers may not
be lost, and keep the cover packing as
assembled with the cover.
.. 57-
6.1.28. Rocker arm assembly
• Unscrew the rocker arm bracket bolts
and remove the rocker arm assembly.
• Take off the snap rings to remove the
washers and rocker arm, then
unscrew the bracket fixing bolts to
take off the bracket and springs.
• Take out the push rods.
6.1.29. Injection nozzle

• Take off the injection pipes between
the injection pump and injection
nozzles.
• Remove the nozzle holder assembly
using the nozzle removing jig.
Do not disassemble the injection
nozzle unless coolant or gas comes
out.
6.1.30. Cylinder head

• Unscrew the cylinder head fixing bolts
and take off the cylinder heads.
• Remove the cylinder head gaskets.
-58-
6.1.31. Valve & stem seal
• Compress the valve spring retainer
using a jig and take off the valve cotter
pins.
• Disassemble the valve springs and
retainers.
• Take off the valves.
• Remove and discard the used valve
stem seals in order not to be re-used.
EAOM4007
6.1.32. Oil cooler

• Unscrew the oil cooler cover fixing
bolts and disassemble the oil cooler
tube assembly from the oil cooler
housing.
EC50M132
6.1.33. Oil pan

• Stand the engine up the flywheel
housing end face towards the bottom
side.
• Release the oil pan fixing bolts, then
disassemble the oil pan.
EAMD0341
6.1.34. Oil pump & oil pipe

• Unscrew the oil suction pipe bracket
bolts, releasing the pipe fixing bolts,
then detach the oil suction pipe
assembly.
• Disassemble the oil pipes connected
the oil pump to the cylinder block.
• Unscrew the oil pump fixing bolts and
disassemble the oil pump.
-59-
6.1.35. Relief valve
• Unscrew the relief valve housing fixing
bolts
• Disassemble the relief valve from the
housing.
6.1.36. Piston and connecting rod

• Disassemble the pistons by two
cylinders while turning the crankshaft.
• Unscrew the connecting rod fixing
bolts and take off the pistons and
connecting rods in the direction of
If
piston upper side. Lc
[C
cc
• Remove the piston pin and snap rings,
then disconnect the connecting rod
from the piston.
• Disassemble the piston rings using a

ring pliers.
• Arrange the disassembled parts
carefully in order not to interchange
each other and keep them in the
sequence of cylinder number.
-60-
6.1.37. Cylinder liner
• Take off the cylinder liner.
EAMD0401
6.1.38. Flywheel
• First remove two fixing bolts of the
flywheel and install the two dowel pins
in the bolt hole.
• Unscrew the last flywheel fixing bolts,
and then detach the flywheel with
care.
EB1M3020
6.1.39. Oil seal

• Take off the rear oil seal using an oil
seal disassembling jig.
6.1.40. Flywheel housing

• Loosen the housing fixing bolts, then
disassemble the flywheel housing.
EB1M3021
- 61 -
6.1.41. Cam shaft and tappet
• Remove the camshaft gear and thrust
washer.
• Take out the camshaft with care not to
damage it and inner bearings.
• Take out the tappets by hand.
6.1.42. Crankshaft gear and oil pump idle gear

• Loosen the socket head bolts and
take out the oil pump idle gear.
• Use a puller of special tool to remove
the crankshaft gear.
EAMD045S
6.1.43. Timing gear case

• Unscrew the case fixing bolts and
dise1ssemble the timin!;r gear case.
6.1.44. Crankshaft and bearing cap

• Unscrew the main bearing cap fixing
bolts and remove the bearing caps.
• Take off the crankshaft.
• Detach the main bearings.
IU----..:.(1} EAMD047S
- 62-
6.1.45. Oil spray nozzle
• Unscrew the fixing bolt and remove
the oil spray nozzles.
-63-
6.2. Inspection
6.2.1. Cylinder block

1) Clean the cylinder block thoroughly and check a visual inspection for cracks or damage.
2) Replace if cracked or severely damaged, and correct if slightly damaged.
3) Check the oil and water passing lines for restriction or corrosion.
4) Make a hydraulic test to check for any cracks or air leaks.
Hydraulic test : Stop up each outlet port of water and oil passage;:; in the cylinder block,
apply air pressure of about 4 kg/em> against the inlet ports, then immerse
the cylinder block in water for about 1 minute to check any leaks. (Water
temperature: 70°C)

1) Inspection of cracks and damage
• Carefully remove carbon from the lower face 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
using a straight edge and a feeler
gauge at six positions as shown in the
right figure.
®
• If the measured value exceeds the
standard value, retrace the head with
grinding paper of fine grain size to
correct such defects.
~~~~~
• If the measured value exceeds the EA3M2031
maximum allowable limit, replace the
cylinder head.
<Lower face warp and height>
Standard Limit
Warp 0.2 mm or less 0.3 mm
Thickness : t
(reference) 109.9-110.1 mm 108.4 mm
EAOM4039
c.__ _ _ _ _ _ _ _ _ _ _ ._ _ _ _ _ _ _ ____J
-64-
3) Flatness
Measure the flatness of the intake and exhaust manifold face mounted on the cylinder head
using a straight edge and a feeler gauge.
Standard Limit
0.05 mm 0.2 mm
f'i'ii'l 4) Hydraulic test

~ Hydraulic test for the cylinder head is same as that for cylinder block.
6.2.3. Valve & valve guide

1) Valve
Clean the valves with clean diesel oil, then inspect them as follows :
• Valve stem outer diameter

Measure the valve stem outer diameter
at 3 positions (top, middle, and bottom).
If the amount of wear is beyond the
limit, replace the valve.
End of stem
~n
n
Standard Limit
Intake valve stem ¢8.95- ¢8.97 mm ¢8.93mm

ill IJ
EFM20361
Exhaust valve stem ¢ 8.935 - ¢ 8.955 mm ¢8.91 mm
• Valve seat contacting faces

Check the valve seat contacting face for scratch or wear, and correct the faces with fine
grinding paper as necessary. Replace if severely damaged.
• Valve head thickness

Measure the valve head thickness, and
replace the valve if the measured value
\
is beyond the limit.
D
~ Standard Limit
..........
~·-- - + - - - -
Intake valve 2.7 mm 1 mm or less
Exhaust valve 2.2 mm 1 mm or less
t EFM20371
-65-
2) Valve guide
• Install the valve into the valve guide r--------------------------------------,
and measure the clearance between
them by valve movement. If the
clearance is excessive, measure the
valve and replace either the valve or
the valve guide, whichever worn more.
I@] <Valve stem end play>
EAOM4052
Standard Limit
Intake valve 0.030 - 0.065 mm 0.15 mm
Ext"Jaust valve 0.045 - 0.080 mm 0.15 mm
• Install the valve into the cylinder head valve guide, then check and see if it is centered with
the valve seat using a special tool.
3) Valve seat
• Contacting face amount
Measure the contacting face between
the intake valve seat and exhaust valve
seat for valve seat wear, and replace if
the measured value exceeds the
specified limit.
~ EAOM4046
• Install the valve into the valve seat on

the cylinder head, and check the
amount of depression of the valve
from the lower portion of the cylinder
head using a dial gauge.
Valve Depression
Standard Limit
Intake &Exhaust 0-0.3 mm 0.55 mm
If the amount of depression is beyond the specified limit, replace the valve seat.
- 66-
• For removal of the valve seat, apply
----·-----------------
arc welding work to two points of valve

Valve seat
seat insert, and pull out the valve seat insert
insert with inner extractor.
Cylinder head
Welding bead
E,I\3M2032
• For assembling of a new valve seat, by putting it among the dry ices of an ice box pneviously
for about 2 hours for the cold shrinkage, and press it in the cylinder head by a special tool.
(bench press)
• Apply the valve lapping compound on the valve head seating face and lap the valve seat by
turning it until it is seated in its position, then wipe out the lapping compound.
Note : Clean the valve and cylinder head with light oil or equivalent after the valve seat
finishing is completed, and make sure that there are no grinding materials remained.
4) Valve spring
• Visual check
Visually check the exterior of the valve
springs for damage, and replace if
necessary.
• Valve Spring Free Length
Use a vernier caliper to measure the
valvespring free length.
If the measured value is less than the
specified limit, the valve spring must
be replaced.
Spring free Length Standard

Intake valve 64 mm
Exhaust Inner 60 mm
valve Outer 71 mm
-67-
• Valve Spring Inclination
Use a surface plate and a square to
measure the valve spring inclination.lf
the measured value exceeds the
specified limit, the valve spring must be
replaced.
Standard Limit
Valve spring
1.8 mm 2.7 mm
inclination
EJM20501
• Valve Spring Tension

Use a spring tester to measure the
valve spring tension if the measured
value is less than the specified limit, the
valve spring must be replaced.
Set Length Spring Limit

force
Intake Valve Spring
valve Tension at 41mm 70 kg ± 3kg
Set Length EAOM4056
Exhaust Inner 38 mm 28.6 kg ±6%
valve Outer 41mm 66 kg ±5%
6.2.4. Rocker arm shaft assembly

1) Rocker arm shaft
• Rocker arm shaft run-out
Place the rocker arm shaft on two V
blocks and inspect the shaft for
bending using a dial gauge.
If the amount of this run-out is small,
press the shaft with a bench press to
correct the run-out. Replace the shaft
if the measured value exceeds the
limit.
Limit 0.3 mm EDM20371
-68-
• Rocker arm shaft diameter
With an outside micrometer, measure ,------------------------------------.
the rocker arm shaft diameter at the

point where the rocker arms have
been installed.
Replace the rocker arm if the amount
of wear is beyond the specified limit.
Standard Limit
¢23.939- ¢23.96 mm ¢23.75 mm
EA8M3002
2) Rocker arm
• Visual check
Visually check the face of the rocker arm in contact with the valve stem end for scores and
step wear. If the wear is small, correct it with an oil stone or grinding paper of fine grain size.
Rocker arm with a considerable amount of step wear should be replaced.
• Diameter of the rocker arm bushing

Measure the inside diameter of the
rocker arm bushing with an inside
micrometer or vernier calipers, and
compare the measured values with
the rocker arm shaft diameter. If the
clearance exceeds the limit, replace
either bushing or shaft, whichever
worn more.
Standard Limit EAOM4059
0.020 - 0.093 mm 0.25 mm
3) Tappet and push rod

• Clearance
Measure the clearance of the tappet and tappet holes of the cylinder block. If the value is
beyond the specified limit, replace the tappet.
Standard Limit
0.035 - 0.077 mm 0.1 mm
- 69-
• Visual check of tappet
Visually check the face of the tappets
@G)
in contact with the cam for pitting,
scores or cracks, and replace if
. .
severely damaged. If the amount of
cracks or pitting is small, correct with unevenness Crack Normal
an oilstone or grinding paper.
abnormal
EA01'v14070
• Outside diameter
With an outside micrometer, measure
the tappet outside diameter. If the
measured value is beyond the limit,
replace tappets.
Standard I ¢ 19.944 - ¢ 19.965 mn~
Em.A20611
• Push rod run-out

Use a feeler gauge to measure the
push rod run-out.
Roll the push rod along a smooth flat
surface as shown in the figure.
~--L-im
__it--~~----o_.3__m_m
___
o_r_le_s_s____]
Feeler gauge
EAOM4073
- 70-
6.2.5. Camshaft
1) Cam
• Cam lobe height
r--------·-------------,
Use a micrometer to measure the cam
lobe height and journal diameter.
If the measured number is less than
the specified limit, the camshaft must
replaced.
Items Standard Limit
Cam lobe Intake 49.15 mm 48.85 mm

height (C) Exhaust 49.32 49.00 mm
EAOM4062
Cam journal 57.86-
57.52 mm
diameter (A, B) 57.88 mm
• Cam surface
Inspect the cam surface for scratch or damage.
Slight step wear or damage on the cam surface may be corrected with an oilstone or oiled
grinding paper. But, replace if severely damaged.
2) Camshaft
• Clearance between camshaft
journal and camshaft bush
- With an outside micrometer,
measure the camshaft journal
diameter.
- Measure the inside diameter of the
camshaft bush on the cylinder block
using a cylinder bore indicator, and
compare the measured value with
the camshaft outside diameter to
determine the clearance.
EAOM4063
<Clearance>
Standard Limit
0.12-0.17 mm 0.24 mm
Replace the bush if the measured value is beyond the specified limit.
- 71 -
• Run-out
Support the camshaft on two V blocks .-----------------------,
and check for run-out using a dial

indicator. Correct or replace the cam
shaft if the amount of run-out is
beyond the value indicating need for
servicing.
Standard Limit
0.05 mm 0.2 mm
EAOM4066
3) Camshaft end play

• Push the thrust plate toward the cam
gear.
• With a feeler gauge, measure the
clearance between the thrust plate
and camshaft journal.
• If the end play is excessive, replace
the thrust plate.
Standard Limit Feeler gauge

EAOM4067
0.28 - 0.43 mm 0.6 mm
6.2.6. Crank shaft

1) Defect check
• Visually check the crankshaft journal and crank pins for scores or cracks.
• Using a magnetic power and color check, inspect the crankshaft for cracks, and replace the
crankshaft which has cracks.
2) Wear measuring
• With an outside micrometer measure
the diameter of the crankshaft journals
and pins in the directions as shown,
and compare the measured values to
determine the amount of wear.
• If the amount of wear is beyond the
limit, polish the crankshaft and install
undersize bearings. However, if the
amount of wear is within the limit, you
can correct the wear using an oil
stone or oiled grinding paper of fine
grain size. (Be sure to use grinding paper which has been immersed in oil.)
- 72-
Standard Limit
Journal
83.966- 83.988 83.000 mm
diameter
0
Pin
70.971 - 70.990 70.000 mm
diameter D
I I )
:471
* Undersize bearings available

+ Standard
+ 0.25 (Inside diameter is 0.25 mm lesser than the standard size.)
Undersize bearings are available in 4 different sizes as indicated abov, · the
crankshaft can be reground to the above sizes.
Note : When regrinding the crankshaft

as described above, the fillet
section 'R' should be finished
correctly A void sharp corners or
insufficient fillet.
~
* Standard values of 'R'
(1) Crank Pin 'R' : 4.5 ·g2
®Crank journal 'R' : 4 0
·0.2
Normal Poor P. 481
3) Crankshaft run-out
• Support the crankshaft on V blocks.
• Turn the crankshaft with a dial
indicator placed on the surface plate
and measure the amount of
crankshaft run-out.
Standard Limit
0.05 mm 0.1 mm
- 73-
6.2.7. Crankshaft bearing and con- rod bearing
1) Visual check
Visually check the crankshaft bearing and the connecting rod bearing for scores, uneven
wear or damage.
2) Oil clearance between crankshaft and bearing.

• Main bearing clearance
Install the main bearing in the
cylinder block, tighten the bearing
cap to specified torque, then
measure the inside diameter.
Torque 30 kg·m
Crank journal
83.966-83.988 mm
Diameter
EAOM4019
Compare the two values obtained

through measurement of the main bearing inside diameter with the outside diameter of the
crankshaft journal to determine the oil clearance.
Standard Limit
0.052 - 0.122 mm 0.25 mm
• Connecting rod bearing clearance

(Method 1)
Install the connecting rod bearing in
the connecting rod bearing cap,
tighten the connecting rod cap bolts to
the specified torque, then measure
the inside diameter.
Torque 18 kg·m
lcranck pin Dia.l 70.971 - 70.990 mm I
- 74-
Compare the two values obtained -------------7·--
through measurement of connecting rod
bearing inside diameter with the outside
diameters of the crankshaft pins to
determine the oil clearance.
/
Standard I ___ L_i_m_i_t_--l
0.049 - 0.119 r~ 0.20 mm
EAMD0601
'U1 If the clearance deviates from the
V specified range, polish the crankshaft
journals and pins ground and install undersized bearings.
• Connecting rod bearing clearance (Method 2 : with plastic gauge )

Assemble the crankshaft on the cylinder block and put the plastic gauge on the journal and
pin of crankshaft and then after assembling bearing cap, tighten the bolts at the specific
torque. Again after disassembling the bearing cap by removing the bolts, take out the flatted
plastic gauge and measure the width of plastic gauge by means of plastic gauge measuring
scale. This is the oil clearance.
3) Bearing spread and crush

• Inspection
Check to see that the bearing requires
a considerable amount of finger
pressure at re-assembly operation.
( EDM2046S
oo Spread= ¢A- ¢ B
EDM20471
- 75-
• Crankshaft bearing crush
Install the bearing and cap in the
cylinder block, retighten the bolts to
specified torque, only unscrew out
one bolt completely, then measure the
clearance between the bearing cap
and cylinder block using a feeler
gauge.
Standard 0.19- 0.22 mm
• Connecting rod bearing crush

Install the bearing and cap in the
connecting rod big end, retighten the
bolts to specified torque, only unscrew
out one bolt completely, then measure
the clearance between the bearing
cap and the connecting rod big end
using a feeler gauge.
Standard 0.3-0.5 mm
EA6M0641
4) Crank shaft end play

• Assemble the crankshaft to the cylinder
block.
• With a dial gauge, measure crankshaft
end play.
Standard Limit
0.15-0.325 mm 0.5 mm
- 76-
6.2.8. Piston
1) Visual check
Visually check the pistons for cracks, scuff or wear, paying particular attention to the ring
groove.
2) Clearance between the piston and

cylinder liner
• With an outside micrometer, measure
the piston outside diameter at a point
13mm away from the lower end of
piston skirt at right angle against
direction of the piston pin hole.
Standard ¢110.801 - ¢ 110.959 mm I 13
EC50M133
• Using a cylinder bore gauge, measure

cylinder liner inside diameter at 3
points (Contacting face of the cylinder
1st, 2nd, and oil rings on B.D.C) in a
direction at an angle of 45•
separately. Take the mean value
except the largest and smallest
values.
EAMD0671
Standard Limit
111 - 111.022 mm 111.222 mm
• The clearance is computed by subtracting the piston outside diameter from the cylinder liner
inside diameter. Replace either piston or cylinder liner, whichever damaged more, if the
clearance is beyond the specified limit
<Clearance between piston and liner>
Standard 0.041 - 0.221mm
- 77-
6.2.9. Piston rings
1) Visual check
Replace the piston rings with new ones if detected worn or broken when the engine is
overhauled.
2) Piston ring gap
• Insert the piston ring into the upper portion of the cylinder liner bore and then it should be
positioned at a right angle against the cylinder liner wall surface.
• Measure the piston ring gap with a

feeler gauge.
Standard Limit
Top ring 0.40 - 0.65 mm 1.5 mm

2nd ring 0.40 - 0.65 mm 1.5 mm
Oil ring 0.30 - 0.60 mm 1.5 mm
Replace piston rings with new ones if

EAOM4033
the gap is beyond the limit
3) Piston ring side clearance

• Fit the compression rings and oil ring
in the piston ring grooves.
• With a feeler gauge, measure side
clearance of each ring, and replace
either the ring or piston if the
measured value is beyond the
specified limit.
Standard Limit
Top ring Tapered Type

2nd ring 0.07-0.102 mm 0.15 mm
Oil ring 0.05 - 0.085 mm 0.15 mm
4) Piston ring tension

With a tension tester, measure piston ring tension. Replace the piston ring if the measured
value is beyond the limit.
Standard
Top ring 2.58 - 3.88 kg

2nd ring 1.81 - 2.71 kg
Oil ring 3.57 - 5.03 kg
- 78-
6.2.1 0. Piston pin
1) Wear
Measure the amount of wear on the
piston pin at the points as shown. If
the measured values are beyond the
limit (0.005 mm or greater), replace
the pin.
I Standard Limit
~ 1.944 - 42.000 mm 41.940 mm or less
EAOM4031
2) Clearance
Measure the clearance between the
piston pin and connecting rod bush,
and replace either of them, whichever
damaged more, if the measured
Standard Limit
0.009 - 0.015 mm 0.08 mm

EA3M2047
3) Condition check
Check the insertion condition of the piston and piston pin. If it is possible to force the pin
into the piston heated by piston heater, the piston is normal.
w When replacing the piston, be sure to replace the piston pin together.
- 79-
6.2.11. ConnE;!cting rod
1) Distortion
Chec~: the connecting rod for distortion. As shown in the figure below, install the connecting
rod to the connecting rod tester, and check for distortion using a feeler gauge. If the
connecting rod is found distorted, never re-use it but replace with a new one.
2) Holes alignment (parallelism)

Measure the alignment of the
connecting rod small bushing hole
and ttw connecting rod big end hole.
At this time also, use both connecting
rod te:;;ter and feeler gauge.
8
~andard Limit
.05 mm 0.1 mm or less
EAOM4034
3) Wear
• Assemble the connecting rod to the crankshaft and measure connecting rod big end side
clearance using a feeler gauge.
• Assemble the connecting rod to the piston and measure connecting rod small end side
clearance.
• If the rneasured values are beyond the limit, replace the connecting rod.
L_L_i_m_i_t__._...J..._ _ _o_._s_m_m
___.....
- 80-
6.3. Engine Re-assembly
6.3.1. General precautions

• Clean all the disassembled parts, particularly oil and water ports, using compressed air,
then check that they are free from restrictions.!
• Arrange the general and special tools in order to engine assembly operation.
• To lubricate each sliding part, prepare the clean engine oil.
• Prepare maintenance materials such as sealant, gaskets, and etc.
• Discard used gaskets, seal rings, and consumable parts, and replace with new ones.
• Apply only the specified torque for bolts in the specified tightening order and avoid over-
tightening.
• Be sure to check that all the engine parts operate smoothly after being reassembled.
• Check the bolts for looseness after preliminary re-assembly.
• After completing the engine re-assembly operation, check if there is missing parts or short-
age of parts.
• Keep your hands clean during the maintenance.
6.3.2. Cylinder block

• Cover the floor of the workshop with wood plate or thick paper to prevent damage to the
cylinder head and place the head face of the cylinder block towards downward.
6.3.3. Oil spray nozzle
tJ• Tighten and assemble the oil spray

nozzle with fixing
spray nozzle jig.
bolts using the
EDM30531
6.3.4. Tappet and cam shaft
rm· Under cool a new bush with dry ice for about 2 hours and press it into position in the cylin-
der block using a bench press. After the pressing operation, measure the inside diameter of
the cam bush to check if it is not deformed.
- 81 -
Apply engine oil to the entire face of
the tappets and slide them into the
tappet holes on the cylinder block.
• Wet the cam bush inside diameter

and camshaft with oil, and carefully
assemble them while turning the
camshaft.
[!]. Check to see that the camshaft
rotates smoothly.
6.3.5. Crankshaft
• Install the main bearing machined
Key groove
with two holes in the cylinder block so
Oil port and passage
that the key is aligned with the key
groove, then apply oil to the bearing
surface.
EAOM4083
• Heat the crankshaft gear for at least

10 minutes to 120° C then apply
sealant (Loctite # 641) 'to the inside
wall of the heated crankshaft gear
evenly before inserting it to the end of
crankshaft.
EA8M3014
-82-
Semi-tighten a bolt at both sides of
the crankshaft, apply engine oil to
journals and pins, then assemble the
crankshaft with the cylinder block by
tightening the fixing bolts.
Install the oiled thrust washers with

the oil groove facing outward of the
bearing.
EAMD076S
Install the bearing and thrust washers

to the bearing cap and apply oil to the
bearing and thrust washers.
EAMD0771
Install the bearing cap by matching

the cylinder block number compare
with the bearing cap number.
- 83-
• Apply oil to the entire part of the bear-
ing cap bolts, then tighten in tighten-
ing sequence to specified torque.
Torque 30 kg·m
"W • After semi-tightening both bolts evenly, tighten them diagonally specified torque using a
V torque wrench as follows.
<Tightening order>
(1) First stage : Coat engine oil over the bolts.
(2) Second stage : Temporary assemble the bolts about 1 - 2 threads
(3) Third stage : With impact wrench, tighten up to about 15 kg·m
(4) Fourth stage :With torque wrench, tighten up to about 25 kg·m
(5) Fifth stage : By means of torque wrench, tighten finally in the specified torque. (30
kg·m).
• Tighten the bearing cap in the sequence of its number 4-3-5-2-6-1-7.

• Check to see that the assembled crankshaft turns smoothly.
6.3.6. Flywheel housing

• Temporarily install the guide bar on
the cylinder block.
• Apply gasket to the cylinder block.
• Using the dowel pin and guide bar,
install the flywheel housing and tight-
en the fixing bolts in a diagonal
sequence to specified torque.
Torque 8 kg·m
EB1M3021
- 84-
6.3. 7. Rear oil seal
Apply lubricating oil to the outside of
the oil seal and flywheel housing
inside diameter and fit them over the
crank shaft, then assemble the oil
seal using an oil seal fitting jig.
EA8M3003
6.3.8. Flywheel
Install a guide bar into a bolt hole on
the crank shaft, and lift the flywheel to
align the dowel pin with the pin hole
on the flywheel for temporary assem-
bly operation.
• Install bolts in the remaining holes,
ta~;e out the guide bar, then install a
bolt in the hole where the guide bar
had been inserted.
rm· Tighten the fixing bolts using a torque

wr~nch
sp~cified
in a diagonal sequence to
torque.
Torque 21.5 kg·m
6.3.9. Timing gear case

Mount the gasket using dowel pin on
the cylinder block.
• Install the timing gear case by align-
ing the dowel pin with the dowel pin
hole on the timing gear case.
- 85-
6.3.10. Injection pump drive gear
• Mount the gasket by aligning the bolt
holes with the pin holes on the bear-
ing housing.
• Tighten up the fixing bolts in the direc-
tion of fuel injection pump.
6.3.11. Timing gear

• Install the oil pump idle gear into the
No.7 bearing cap.
~·
Install a thrust washer over the
camshaft and assemble the cam flear
by aligning it with camshaft key
groove.
Torque 2.2 kg·m
• After the oil port on the idle gear pin

towards the cylinder block, install the
idle gear pin.
EA8M3004
Install the idle gear by coinciding the

marks impressed on the crank gear,
cam gear, fuel injection pump drive
gear, and idle gear each other.
Install a thrust washer on the idle fjear
~· and tighten to specified torque.
Torque 6.2 kg·m
EA8M3005
- 86-
• Check and adjust the amount of backlash between gears using a feeler gauge .
. .... Items Standard Limit
Cam gear & idle gear 0.16- 0.28 mm 0.35 mm

Crank gear & idle gear 0.16- 0.28 mm 0.35 mm
Injection pump &

0.16- 0.28 mm 0.35 mm
idle gear
6.3.12. Timing gear case cover

• Install the dowel pin on the timing
gear case.
• Mount a gasket by aligning the fixing
bolt holes with those on the gasket.
• Align the dowel pin with the cover pin
hole, then install the cover with light
tap.
• Tighten the fixing bolts beginning with
the oil pan fitting face.
6.3.13. Front oil seal

• Apply lubricating oil to the outside of
the oil seal and timing gear case
inside diameter and fit it over the
crankshaft, then assemble the oil seal
using an oil seal fitting jig.
6.3.14. Cylinder liner

• Stand the cylinder block so that the
flywheel faces downward.
f}J. Thoroughly clean the liner flange fit-

ting surface and bore inside with com-
pressed air to prevent the entry of for-
eign substances.
• After the cleaning operation, make
the cylinder liner dried up and push it
into the cylinder block by hand.
Wet the liner inside diameter with
engine oil.
- 87-
6.3.15. Piston and connecting rod
Use a piston heater to heat the piston
~- approximately 1 00 oC - 212 oF for 5
minutes.
• Align the piston pin hole with the con-

necting rod small end bush oiled and
press the piston pin (by lightly tapping
with a rubber hammer) to assemble
the connecting rod into the piston.
EAMD0881
Noticing the direction of the piston,

make the longer side (machined with
key groove on the bearing) of the con-
necting rod big end and the mark of
' ~~ ' impressed on the inside of the
piston face each other in opposite
directions. On the piston head sur-
face, the longer side of the connect-
ing rod big end is in opposite direction EAMD0891
from the valve seat surface.
• Install the snap rings and check to see that it is securely assembled.
~ • Install the piston ring in the piston using piston ring pliers.
- 88-
Identify the mark "Y" on the piston
ring end to prevent assembling the
bottom of the piston ring is being
interchanged with its top faced
marked "Y".
Note : Be sure to make the piston ring
enc} marked face("Y") upward.
"Y" marked from piston ring

manulacturing company
EAMD0901
tl. Adjust the angle among individual

piston ri,-,g gaps to goa and fit a piston
2nd ring gap
assembling jig onto the piston, Use (0.35-0.SOmm)
care no~ to match the ring gaps with

the pistcm pin direction.
90°
• Install the bearing by aligning it with
the connecting rod key groove and Piston pin
apply oil to the bearing and piston.
Piston
• Make a position the valve seating sur-

face toward the tappet hole and insert
the piston with hand.
Tappet hole
Use care not to damage the cylinder
liner and piston, and slightly lift and
insert the piston into the cylinder so
that the ring may not be damaged by
the fillet of the liner.
• Install the bearing in the connecting
rod cap and apply oil.
• Make sure that the manufacture serial

number impressed on the connecting
rod cap and the connecting rod big
end is identical, and install the con-
necting rod cap by aligning it with
dowel pin. Serial No.
• Wet the fixing bolts with oil, semi-tight-
en them by hand, tighten them to
specified torque using a torque
EAOM4092
wrench as follows.
- 89-
<Tightening order>
(1) First stage : Coat engine oil over bolts
(2) Second s,tage : Temporary screw the bolt about 1 - 2 threads
(3) Third sta9e : With torque wrench, tighten at about 10 kg·m
(4) Fourth stage : With torque wrench, tighten up to about 15 kg·m
(5) Fifth stage : Finally, tighten in the specified torque 18kg·m with torque wrench .
Torque 18 kg·m
[!]. Move the bearing cap with hand, and

release and reassemble it if no move-
ment is detected.
0
/ EAMD0941
6.3.16. Relief valve

• Assemble the relief valve.
6.3.17. Oil pump and oil pipe

Install a dowel pin in the No.7 bearing
~· cap, then assemble the oil pump with
specified torque.
Torque 4.4 kg·m
• Assemble the oil suction pipe with the

delivery pipe, then install the bracket
on the bearing cap.
- 90-
6.3.18. Oil pan
• Mount gasket and put the oil pan
thereon.
• Align the bolt holes with gasket holes
to prevent damage to the gasket and
tighten bolts to specified torque.
Torque 2.2 kg·m
EAMD0341
6.3.19. Vibration damper and pulley

• Assemble the vibration damper on the
Crankshaft pul,ey.
• Install the crankshaft pulley assembly
on the crankshaft, then tighten the
bolts and thrust washers.
Torque 13.4 kg·m

• Install the injection nozzle fixing stud
bolts and water pipe fixing stud bolts.
• Clean the head bolt holes on the cylin-
der block with compressed air to
remove foreign substances and thor-
oughly clean the gasket fitting face of
the cylinder biQck.
• Install head gasket, with 'TOP' mark
El facing upward, on the cylinder block

by aligning the holes with dowel pins.
- 91 -
• Check the inside of combustion cham-
ber for foreign substances, and care-
fully mount the cylinder head on the
cylinder block by aligning the dowel
pin in the pin hole. Be careful not to
damage the head gasket. If the dowel
pin is not in alignment, lift the cylinder
head again and then remount it.
• Coat the head bolts with engine oil,

then tighten them in proper sequence
to the specified torque according to
~
bolt tightening order. (refer to the fig- (® ®® ~(j) (®_ ...®.Q2_ ~(j) (®_ _ill®. """ff)
ure)
® G)@ ® ® <D0 ® ® G)@ ®
EDM20971
<Cylinder Head Bolts>
Type 1 Type 2
Specification
@ @
M14X1.5X146 M14X1.5X146
Torque 24.5 kg·m 6 kg.m +180'+150'
However, before tightening bolts, align the side face of 3 cylinder heads with parallel. They
should be adjusted in a straight line exactly.
<Tightening order of bolts by steps>

(1) First stagP. : Coat the bolts with engine oil.
(2) Second stage : Tighten 1 - 2 threads with hands.
(3) Third stage : Tighten at about 6 kg.m with a wrench.
(4) Fourth stage :Tighten at rotating angle method 180° with a wrench.
(5) Fifth stage : Finally, tighten at rotating angle method 150° with a torque wrench .
However, all bolts are tightened simultaneously by above steps as possible.
• Coat the push rod with engine oil and insert it into the push rod hole.
- 92-
6.3.21. Intake and exhaust valves
• Identify the marks of "IN" and "EX" /.
impressed on the valve head before

assembling the valve in the head.
• With a valve stem seal fitting jig,
assemble the valve guide and stem
seal.
EAMD096S
• After installing valve springs and

spring retainer, press the retainer with
a jig, then install cotter pin.
• Tap the valve stem lightly with a rub-
ber hammer to check that the valve is
assembled correctly.
EAOM4007
6.3.22. Rocker arm assembly

• Apply lubricating oil to the rocker arm
bush and shaft, and assemble the
intermediate bracket with the rocker
arm using fixing bolts.
LTorque 4.4 kg·m
EB1M3026
• Semi-install the valve clearance

adjusting bolts onto the rocker arm.
• lm;tall the spring, rocker arm, bracket,
El rocker arm, spring, washer, and snap

ring in the described sequence.
• Install the rocker arm and bracket in
the same direction.
EA8M3008
- 93-
6.3.23. Injection nozzle
• Install the dust seal with its round por-
E1 tion facing downward.

• Mount a seal ring on its position of the
cylinder head and then assemble the
nozzle holder.
Cylinder head
~~~ • Be sure to follow the specified torque.
EB1M3024
Torque 7.0 kg·m

• Cylinder l\lo. 1 begins from the rear side where the flywheel is mounted but cylinder No. 6
begins from the front side of the engine on the contrary.
Flywheel lntaek Valve Exhaust Valve Cylinder No. Crank Pulley
' /
' /
' /
'
t
I \ I \ I \
I 4 \I 5 \I 6 \
~ 0
EA7M2002
Step 1 :
• After letting the cylinder No.6 in the overlap TDC position by turning the crankshaft, adjust
the valves corresponding to" lJ" of following figure. At this time cylinder No. 1 should be at
the ignition TDC position.
Step 2:
• After adjusting upper valves turn the crank pulley 360° to adjust the other valve clearance
until the cylinder No. 1 comes to overlap TDC position.
At this time cylinder No. 6 should be at the ignition TDC position(O.T).
• Adjust the valve corresponding to " t " of upper figure.
After reconfirming the valve clearances, retighten it if necessary.
• Loosen the lock nuts of the rocker arm adjusting screws and push the specified feeler gauge
and adjusting the valve clearance with adjusting screw respectively.
ode I Intake Valve Exhaust Valve
T/TII086TI
0.3 mm 0.3 mm
.'IT/TI/086TI
- 94-
• Adjust valve clearance with a feeler
m3
5_
r.iit
~ gauge and tighten the fixing nuts to
specified torque.
6 I Torque 4.4 kg·m
6.3.25. Injection pipe

• Semi-assemble the nuts at both ends
of the fuel injection pipe and tighten
them up one by one to specified
torque.
Torque 2.9 - 3.2 kg·m
• Tighten the hollow screws to assem-

ble the fuel return pipe.
• Assemble the fuel return hose on the

fuel injection pump.
6.3.26. Cylinder head cover
• Assemble the new packing in the

cylinder head cover, install the cover
on the cylinder head, then tighten the
fixing bolts in sequence to specified
torque.
Torque 1.5 kg·m
• Assemble the breather hose and the

breather assembly.
• Assemble the oil filler cap in the cylin-

der head cover.
EA904002
-95-
6.3.27. Injection pump & injection timing
(1) Fuel injection pump
(A) L086TI, AD086TI
• Install the injection pump bracket in
the cylinder block.
• After measuring the amount of run-

out with an alignment setting jig,
disassemble the bracket, adjust the
shims, then reassemble it.
Run out 0.2 mm or less
• Mount the top/bottom adjusting

shims in the bracket and then
mount the fuel injection pump.
• Tighten the fixing bolts in a diagonal

sequence to specified torque.
Torque 4.4 kg·m
(B) L136/T/TI, AD136/T/TI

• Reassemble the injection pump by
using the engraved line as the fig-
ure.
-1-
1=
I
Engrave Line
~ EB40601L
To assemble the new injection pump,

align the center of the hexagonal
socket plug on the front side of the
injection pump with the upper bolt
hole of the injection pump flange.
Injection Pump
Flange
EB1M9090
- 96-
Then assemble the injection pump gear
by aligning with the oil paint marking
lines as figure.
(2) Injection timing

• Turn the crank shaft until cylinder No.
6 is placed in the overlap TDC and
then turn again the flywheel clockwise Timing
check hole
until the notch mark corresponding to
the injection timing degree its moclel is
aligned with hole center( • ) in the fly-
wheel as right figure.
<Fuel injection timing>

Refer to "1. Engine specification" for
each model. ~------------------------- --------·I
1 '
Flywheel Injection timing
ring gear notch mark
L-----------------------------------
EB1M3028
- 97-
(A) L086TI, AD086TI
• After letting the cylinder No. 6 at over-
lap TDC position, adjust the injection
timing degree of the engine.
• After that, turn the injection pump until
the notch mark of the pump indicator
plate mounted is aligned with the
notch mark of the drive shaft flange as
right figure.
• Tighten the coupling housing fixing
bolts and nuts to specified torque.
Torque 6.0 kg·m
• Tighten the coupling housing fixing

bolts and nuts to specified torque.
Torque 7.5 - 8.5 kg·m
• Install the oil delivery pipe and return

pipe.
• At the same time, install the oil deliv-
ery pipe which feeds oil to the sea
water pump.
(B) How to check the fuel injection timing exactiy

• To confirm the fuel injection pump
timing, put the cylinder No. 6 in the
overlap TDC position. And then ~Holde<
remove the seat, spring and delivery
valve from No. 1 plunger of the injec- @<? Seat
tion pump to check whether the fuel
ejection or not from the injection pipe A ~ Spring
[
visually. f.i>___.t-.. Delivery
• Assemble the holder and pipe except llf""--.r"' Valve
EA3M1017
seat, spring and delivery valve ("A"
parts).
Holder Torque 4-4.5 kg·m
- 98-
,-----------------------------
• Turn the crank pulley clockwise slowly
on pumping the priming pump to be
continues simultaneously and you can
see the point that fuel falls down by
one drop per every 5 or 6 seconds
from the fuel pipe No. 1. This point is
the very fuel injection timing degree.
• After confirming the fuel injection tim-

ing, reassemble the holder and inner
parts including seat, spring and deliv-
~Holdec
ery valve.
Seat
Holder Torque 1. 4 - 4.5 kg·m
Spring
Delivery
• Connect the No. 1 fuel injection pipe
Valve
EA3M1017
and tighten as specifie•.::l torque.
IFuel pipe nut Torque 13 - 3.5 kg·m I

Caution : Oo not too tighten the delivery valve holder to prevent the rack mal function of the
In case of exchanging the injection pump, be sure to fill the engine oil in the gover-
nor before engine starting.
<Oil capacity of injection pump>
L 136/T/TI L086TI
AD136/T/TI AD086TI
0.5 Lit. 0.7 Lit.
6.3.28. Oil cooler & oil filter

• After assembling the oil cooler onto
the oil cooler housing, tighten the
mounting bolts of the oil cooler
assembly in the cylinder block insert-
ing a new gasket. Oil filter
• Lightly oil the 0-ring and turn the oil fil-
ter cartridge until its O··ring is contact-
ed against the sealing face of the oil
filter head. And then turn the oil filter · EC50M134
cartridge 3/4-1 turn more with hands
or a filter wrench.
- 99-
• Connect the cooling water pipes to the water pump and the heat exchanger.
6.3.29. Water pump

• Mount a new gasket.
• Install the water pump on the cylinder
block and tighten the assembling bolts
with specified torque.
Torque 2.2 kg·m
• Connect cooling water pipe and the

expansion tank each other. EB1M3017

• Mount a new gasket.
• Install the sea water pump on the tim-
ing gear case cover and tighten the
assembling bolts with specified
torque.
Torque 4.4 kg·m
EC50M120
6.3.31. Heat exchanger

• Install the heat exchanger on the fly-
wheel housing, and tighten the fixing
bolts with specified torque.
Torque 4.4 kg·m
EC50M117
- 100-
6.3.32. Thermostat
• Install the thermostat.
• Fit the new gasket on the thermostat
housing, then assemble the thermo-
stat housing with mounting bolts.
• Assemble the hose clamps in both
sides of the heat exchanger and cool-
ing water pipe
EC50M116
6.3.33 Exhaust manifold

• Assemble the exhaust manifold with
steel gasket in order to be installed in
the small hole between two holes of
the gasket upward and be sure to
check the squared port of the gasket
whether the square port of the cylinder
head is aligned before assembling.
• Tighten the fixing bolts with specified
torque. EC50M125
M10 (Upper row) 4.4 kg.m

Torque
M12 Lower row) 8.0 kg.m
6.3.34. Intake manifold

• Assemble the intake manifold includ-
ing the gasket.
• Connect the air hose to the boost
compensator of the fuel injection
pump.
EC50M115
- 101 -
6.3.35. Stop solenoid (L086TI)
• Assemble the brackets on the injec-
tion pump body.
• Install the stop solenoid and tighten
the fixing bolts.
• Connect the tie rod to fuel feed pump
and stop solenoid.
EC50M114
6.3,36. Injection pipe

• Semi-assemble nuts at both ends of
the fuel high pressure pipe and tighten
them up one by one to specified
torque.
Torque 3.0 kg·m
• Tighten the hollow screws to assem-

ble the fuel return pipe.
• Assemble the fuel return hose to the
6.3.,37. Starter
• Assemble the starter in position on the
flywheel housing.
Torque 8.0 kg·m
EC50M119
6.3 . 38. Intercooler

• After sub-assembling the air inlet &
outlet pipe and sea water inlet & out-
let cooling water pipe in the heat
exchanger separately assemble the
intercooler assembly on the bracket of
the heat exchanger
• Insert the hoses each pipe and clamp
the hoses separately.
EC50M111
- 102-
6.3.39. Turbocharger
• Insert a new gasket on the exhaust
outlet pipe and mount the turbocharg-
er.
• Install the oil supply & return pipe.
• Clamp the rubber hose connected to
the air inlet pipe of the inter cooler,
and assemble the cooling water inlet
& outlet pipe.
EC50M130
6.3.40. Air cleaner

• Assemble the air cleaner and tighten
the bolt and nut of clamp properly
• Finally install the air filter element.
EB1M3008
6.3.41. Expansion tank and Reservoir

tank
• Assemble the expansion tank and
rubber hose for by-pass pipe, and
then tighten the clamp.
• Finally assemble the reservoir tank
using holder and connect the hose
between the expansion tank and
reservoir tank.
EC50M113
6.3.42. Fuel filter

• Assemble the fuel filter on the right of
intake manifold as figure.
• Assemble the fuel feed hose accord-
ing to the direction of the arrow
impressed on the fuel filter head so
that fuel can be fed in the sequence of
FUE:L FEED PUMP R FUEL FILTER
R FUEL INJECTION PUMP.
EC50M110
- 103-
6.3.43. Alternator
• Install the alternator mounting bracket.
• Assemble the alternator and protector.
EC50M109
6.3.44. V - Belt
• Install the V-belt on the crank pulley
and alternator.
• Adjust the V-belt tension using the
tension adjusting bolt.
EB1M3003
6.4. Break-in After Maintenance
Because the sliding parts of a new or an overhauled engine are not lapped enough, the oil film
can be destroyed easily by overload or over-speed and the engine life time may be shorten.
Therefore the operator must follow the things of "3.3 Engine Break-in" by all means.
- 104-
7. Main Parts Maintenance
7.1. Lubricating System

Lubricating oil pumped by the gear oil pump in the oil pan is filtrated in the oil filter through oil
cooler.
This filtrated oil passed on the main oil gallery of the cylinder block where is distributed to
lubricate the various sliding parts, fuel injection pump, and turbo-charger etc also in order to
ensure normal engine performance.
7.1.1. Specifications
Item Specifications
Lubricating system Forced pressure circulation
Oil pump type Gear type
Relief valve opening pressure 1 0 ± 1 .5 kg/cm 2
Bypass for oil cooler Opening pressure 5+1 kg/cm2
Adjusting valve for spray nozzle Opening pressure 1.5 - 1.8 kg/cm 2
Oil filter type Full flow
Bypass for filter element Cartridge Type
Valve opening pressure 1.8 - 2.3 kg/cm 2
Bypass for entire oil filter Valve opening pressure 4.0 - 4.8 kg/cm 2
7.1.2. Oil pump
1·:·1 • Disassembly
(1) Disassembly of oil pump drive gear
a) Unscrew the screw and
disassemble the oil relief valve.
b) Unfold the washer for the oil
pump drive gear fixing nut and
remove the nut.
c) Disassemble the drive gear.
EAMC0041
- 105-
(2) Remove the oil pump cover fixing ,----------------------------------,
nuts and disassemble the oil
pump cover.
The oil pump cover is fixed with
the two dowel pins.
(3) Disassemble the drive and driven

gear,.
EAMC0051
• Inspection and correction

(1) With steel ruler and feeler gauge,
measure the axial end play of the
oil pump gear. Replace if the
mea~ured value is beyond the
limit.
~.-im_it_...~...._o_._o_2_s_-_o_._o_a_9_m_m____.
(2) With a feeler gauge, measure the

amo1Jnt of backlash between the
oil pump drive gear and driven
gear. Replace if the measured
~·.-im_it_ _,__o_.o_s_o_-_o_.6_4_m_m
_ _.
(3) Mea:suring clearance between

drive shaft and bushing
a. Measure the outside diameter of
the drive shaft and driven shaft, and replace if the measured values are less than the
limit.
[umit 16.95 mm
b. Measure the inside diameter of the pump body bushing to determine the clearance
between the bushing and shaft, and compare the measured value with the standard
value to determine whether to replace or not.
<Clearance between oil pump shaft and bush>
L: Standard 0.032 - 0.077 mm
- 106-
83. Re-assembly
(1) For re-assembly, reverse the disassembly sequence.
7 .2. Cooling System
7.2.1. Cooling water pump

• Loosen the bolt (8) and remove the pulley (12).
• Unscrew the socket bolt (7) and detach the housing cover (5).
• After heating on the impeller (3) a little remove the impeller using a special jig.
• Detach the mechanical seal (4).
• Heat on the hub (9) little by little and then remove the hub using a removing jig.
• After detach the snap ring (11) remove the unit bearing shaft.
• Follow the re-assembly on contrary to order of disassembly.
• Exchange the oil seal (4) to a new one.
• If the used impeller is re-assembled, keep the clearance between the pump housing and
impeller not to be more than 0.35 mm.
<Water pump assembly>
12
EB1M4005
1. Water Pump Housing 5. Housing Cover 9. Spring Wash~r
2. Unit bearing & Shaft 6. Gasket 10. Hub

3. Impeller 7. Socket Bolt 11. Snap Ring
4. Mechanical Seal 8. Hex Bolt 12. Pulley
- 107-
7 .3. Fuel System
7.3.1. Injection pump

The components relating to the injection pump should be serviced at regular intervals as the
plunger and delivery valve may be worn after a given length of time for use and cause the
deterioration of the engine.
Make sure that servicing should be performed at the professional maintenance shop as
authorized by Bosch or Zexel Company.
For adjustment of fuel injection volume, refer to the 'Specifications of fuel injection pump'
described on the following pages.
1) L 136, AD136
(1) Main Specification
Fuel Injection Pump : 65.111 01-7269A
Governor Type : RSV
Model Type : PES6AD
Cam Lift : 11 mm
Fuel Feed Pump : 105210-4830
Injection Timing : BTDC 18°±1°
Injection Order : 1-5-3-6-2-4
Rotating Direction : Clockwise (Viewed at driving gear side)
(2) Calibration Data
(A) Test condition Nozzle & Holder Ass'y 105780-8140 Opening pressure : 175kg/cm 2
for injection pump Injection pipe(ID ,OD ,L) - ¢8.0 x ¢2.0- 600 mm
Test oil IS04113 Temperature :40 ± 5 ·c
(B) Engine standard 65.10101-7050 Nozzle (5 x ¢ 0.36)
Nozzle & holder Ass'y
parts - 214 + 8 kg/cm 2
Injection pipe (ID, OD, L) - ¢6 x ¢2.2-650 mm
Rack diagram and setting valve at each point
Refer to (3) Rack Diagram Injection Q'ty on RIG
Rack Pump
Check (mm' I 1 ,OOOst) Press.
position speed
point (A) Test condition Max. Var. (mmHg)
(mm) (rpm)
for inj. Pump Bet. Cyl. (%)
A 10.5 1100 88.5 ± 2 ± 2.5 Full
B 7.7 370 11.5 ± 2 ± 25 Idle
c - 100 (135) - -
Balance Weight 740g Lever ratio (min/max) 1 : 1.2
Governor spring k = 7.2 kg/mm Plunger ¢9.5, 20 + 45 lead
Idle spring k = 1.9 kg/mm Delivery valve retraction volume 70 mm'/st, t=0.11
Idle sub spring k = 3.0 kg/mm Delivery valve opening pressure 23.1 kg/cm 2
Start spring k = 0.01 kg/mm Delivery valve spring k = 1 .63 kg/mm
1 0521 0-5280
Max. discharge pressure k = 3.4 kg/mm 2 Feed pump
(KP-FP/KE-ADS)
- 108-
(3) Rack Diagram
Idling serve spring
c /rStroke ~t~rt
14 ~------- -· - · -
/
or more than 14
/
/ :Governor spring set
////
10.5 '--+---=:::::r----___.., /
··- - - - Pump speed (RPM)

EB707015
- 109-
2) L136T, AD136T
Fuel Injection Pump: 65.11101-7271A
Model Type : PES6AD
Governor Type : RSV
Fuel Feed Pump : 10521 0-4830
Cam Lift : 11 mm
Injection Timing : BTDC 18° ±1 o
(A) Test condition Nozzle & Holder Ass'y 105780-8140 Opening pressure : 175kg/cm 2
for injection pump Injection pipe(ID ,OD ,L) - ¢8.0x ¢2.0-600mm
parts - 214 + 8 kg/cm 2
Injection pipe (ID, OD, L) - ¢6 x ¢2.2-650 mm
Refer to (3) Rack Diagram Injection Q'ty on RIG
Rack Pump
Check (mm 3 I 1 ,OOOst) Press.
position speed
point (A) Test condition Max. Var. (mmHg)
(mm) (rpm)
A 10.5 '1100 113.5 ± 2 ± 2.5 Full
B 7.9 370 11.5 ± 2 ± 25 Idle
c :::: 100 - - -
Idle spring k = 1.9 kg/mm Deliv~ry valve retraction volume 70 mm 3 /st, t=0.11
Start spring k = 0.01 kg/mm Delivery valve spring k = 1.63 kg/mm
105210-5280
Max. discharge pressure k = 3.4 kg/mm 2
Feed pump
(KP-FP/KE-ADS)
- 110-
(3) Rae:k Diagram
c
1~
Booster compensating start : 1.0', omm
or more than 14
Governor spring setting

11.L ±:.
~
:2 10.5 c \. / ; g serve s;.i~~- setting
.~========~~=================d~\~~~~
.~
~~ 3~~~
c (7.7)
0
'+='
'iii = 17±1
0
0. 1~2 (7 0) /
-"'
() Rt - ()' 1
Ill
0:::
t
I
0
370
,_,_, ___ .,.. Pump speed (RPM)

EB707016
- 111 -
3) L 136TI, AD136TI
Fuel Injection Pump: 65.11101-7341
Nlodel Type : PES6AD
Governor Type : RSV
Cam Lift : 12 mm
Injection Timing : BTDC 14°±1 o
(A) Test condition Nozzle & Holder Ass'y 105160-4370 Opening pressure : 175kg/cm2
for injection pump Injection pipe(ID ,OD ,L) - ¢8.0 x ¢2.0-600 mm
Test oil Calibration oil Temperature :40 ± 5 "C
(B) Engine standard 105160-4370 Nozzle (5 x ¢ 0.36)
parts Calibration oil 214 + 8 kg/cm 2
Injection pipe (ID, OD, L) ¢6 x ¢2.0-650 mm ¢6 x ¢2.0- 650 mm
Refer to (3) Rack Diagram Injection Q"ty on RIG
Rack Pump Boost
Check (mm 3 I 1 ,OOOst)
position speed Press.
point (A) Test condition Max. Var.
(mm) (rpm) (mmHg)
A 12.5 1100 121 ± 2 - More
B (12.5) 750 (123.5) - 500
R,=12.5 c :::: 7.8 370 10 ± 1.5 - -
D R,-1.5 600 (89.5) - -
E more 14 100 (155) - -
Idle spring k = 1.9 kg/mm Delivery valve retraction volume 70 mm 3 /st
Max. discharge pressure k = 3.4 kg/mm 2
Feed pump 1 05210-5610
- 112 -
(3) Rack Diagram
--------------------------------------------------------------------------
E
or more than 14 r---t
'
'
c
''
\
.--- Booster compensating stroke : 1.5 •0 'mm
\
1:-J.1 ±II. I
B A
"' \ --------
I
12.5 ----+------·-
D I
I
I
]()_()±II I I Idle serve, spring set
7.tl \c 1\
\/
1\ \_ _
r fi.25±<11 \
6.()Q±IU \
IlL
()
~400'~ ~~c:,)
"" -1
1180
1140
------ Pump speed (RPM)
EB707018
- 113 -
4) L086TIH, AD086TI
Fuel Injection Pump: 65.11101-7311
Model Type : PE6P120/720RS3S
Governor Type : RSV 200/1300
Plunger : 134153-1420
Delivery Valve : 13411 0-1420
Cam Lift : 12 mm
Injection Timing : BTDC 15° ± 1 o
(2) Calibration data
Test oil IS04113 Temperature :40 ± 5 OC
parts LRC6703709 214 + 8 kg/cm 2
65.1 030 1-6049A
Injection pipe (ID, OD, L) ¢6.35 x ¢2.2- 650 mm
65.1 030 1-6052A
Refer to (3) Rack Diagram Injection Q"ty on RIG Press.
Rack Pump
Check (mm 3 I 1 ,OOOst) (mmHg)
position speed
point (A) Test condition (B) Engine
(mm) (rpm)
for inj. pump standard parts
A 12.2 1050 169.5 ± 2.0 ±2 98~
B (6.7) 315 10.0 ± 1.3 ± 15 -
c 12.2 500 (177) - 980$
D 10.0 500 (1 03) ± 3 - -
- -
-
Boost pressure dependent full - load stop (boost compensator spring operation point)
Refer to (4) Boost pressure Injection Q'ty on RIG Press.
Rack Pump
Check (mm I 1 ,OOOst)
3
(mmHg)
point position speed (A) Test condition (B) Engine
(mm) (rpm) for inj. pump standard parts
P1 10.0 500 177 - 150
P2 12.2 500 103 - 880
- - - - - -
Weight Weight = 7 40kg Lever ratio(min/max) Min. speed 1 : 1.2
Max. speed 1 : 1 .2
Governor spring k = 7.2 kg/mm Plunger ¢12, 30 lead
Idle spring k = 1.9 kg/mm Delivery valve retraction volume 100 mm 3 /st, t=0.09
Idle sub spring k = 1.2 kg/mm Delivery opening pressure 18.5 kg/cm 2
105237-5470
Boost compensator spring k = 1.0 kg/mm Feed pump
(NP-FP/KD-PS)
- 114-
(3) Rack diagram
14
c A
12
E 10
E D
z
0 8
E
CJ)
0
c.. 6
~
0
~ 4
INJECTION PUMP SPEED, rpm

EB1M4001
(4) Boost compensator pressure
13.0
P2
E 12.0
E
z-
0
E
CJ) 11.0
0
c..
~
0 P1
<(
0:: 10.0
9.0
0 200 400 600 800 1000
BOOST PRESSURE, mmHg

EB1M4002
- 115 -
5) L086TIM
Fuel Injection Pump : 65.11101-7311
Model Type : PE6P120/720RS3S
Governor Type : RSV 200/1300
Plunger : 134153-1420
Delivery Valve : 13411 0-1420
Cam Lift : 12 mm
I njec:tion Timing : BTDC 1 5°± 1 o
(2) Calibration data
parts LRC6703709 214 + 8 kg/cm 2
65.1 0301-6049A
Injection pipe (ID, OD, L) ¢6.35 x ¢2.2- 650 mm
65.1 0301-6052A
Refer to (3) Rack Diagram Injection Q'ty on RIG Press.
Rack Pump
Check (mm I 1 ,OOOst)3
(mmHg)
position speed
point (A) Test condition (B) Engine
(mm) (rpm)
for inj. pump standard parts
A 12.4 1150 178.7 ± 5.0 Max. Power -
B 8.1 700 19.1 ± 1.0 - -
c 12.4 500 182.2 ± 3.0 - -
D 10.0 500 99.5 ± 3.0 - -
E W/Cap 100 225.3 ± 3.0 - -
Boost pressure dependent full - load stop (boost compensator spring operation point)
Refer to (4) Boost pressure Injection Q'ty on RIG Press.
Rack Pump (mm 3 I 1 ,OOOst)
Check (mmHg)
point position speed (A) Test condition (B) Engine
(mm) (rpm) for inj. pump standard parts
P1 12.4 500 178.7±5.0 - 1,020
P2 10.0 500 99.5 ± 3.0 - 150
- - - - - -
Weight Weight= 740kg Lever ratio(min/max) Min. speed 1 : 1.2
Max. speed 1 : 1.2
Governor spring k = 7.2 kg/mm Plunger ¢12, 30 lead
Idle spring k = 1.9 kg/mm Delivery valve retraction volume 100 mm'/st, t=0.09
Start spri11g k = 0.01 kg/mm Delivery valve spring k = 0.87 kg/mm
105237-5470
Boost compensator spring k = 1.0 kg/mm Feed pump
(NP-FP/KD-PS)
- 116 -
(3) Rack diagram
E
14
A
12
E 10
.sz
0 8
E
en
0 6
a..
~
0
<( 4
a::
0 200 400 600 800 1000 1200 1400
PUMP SPEED (rpm)

EB104001
(4) Boost compensator pressure
-
14
P1
12
E
.sz
0 P2
i=
U5 10
0
a..
~
0
<(
a::
8
6
0 200 400 600 800 11)00 1200
BOOST PRESSURE (mmHg)

EB104002
- 117 -
7.3.2. EIE~ctric governor system
1) AD136/T/TI
Governor system for fuel injection pump consists of "Integral Actuator" and " Speed Control
Unit".
(1) ACAD176 Series Electric Actuator

• Introduction
The ACD176 SERIES electric actuator is designed to mount directly on a Bosch "A" size
fuel injection pump, with a left hand rack, in place of the mechanical governor. When the
ACE176 is installed on the fuel pump, an optimum performance, long life fuel control
system results. An external fuel shut off lever is available to manually override the
actuator's control. Also provided is an adjustable internal maximum fuel limit
The ACD176 can control fuel pumps of up to 6 cylinders.

The actuator was designed with two isolated chambers. The upper chamber is wet with
oil and contains the connection to the fuel rack and an optional manual shut off
mechanism.
The sealed lower chamber contains the electromagnetic components.
This design eliminates the possibility of magnetic pa other oil contaminants interfering
with the operation eletric actuator. Unreliable devices such as bell sliding seals are not
used so that no maintenance is The designed ieft of the actuator is typically longer of the
engine.
Available actuator models : ACD176-12 (12V w/o manual shutoff)

ACD176-24 (24V w/o manual shutoff)
ACD176A-12 (12V w/ manual shutoff)
ACD176A-24 (24V w/ manual shutoff)
The 176 SERIES actuator can also be supplied with tion sensor that allows the actuator
to be used in a agement system. Contact GAG for assistance.
• Specifications
Performance
Force ........... (see Figure 1) ............................................................ 6.2 lb. (27.5 N)
Operating Stroke ............................................................................ 0.80 in. (21 mm)
Response Time (1 0 - 90 %, 2- 19 mm) .................................................. 35 msec.
Electrical Power Input
Operating Voltage ............................................................................. 12 or 24V DC
Nominal Operating Curren ........... 12V DC version ......................................... 4.0 A
24V DC version ......................................... 2.0 A
Maximum Current ........................ 12V DC version ......................................... 5.8 A
24V DC version ......................................... 3.1 A
- 118 -
Environmental
Operating Temperature ....................................................... -40 to +95 oc (-40 to +200 oF)
Relative Humidity ............................................................................................. up to 100 %
Vibration .................................................................................................. 20 g, 20 - 500 Hz
Shock ....................................................................................................... 20 g@ 11 msec.
Physical
Dimensions .................................. , ................................................................... See Figure 2
Weight ....................................................................................................... 4.75 lb. (1.9 kg.)
Mounting ........... , ........................................................ Requires camshaft bearing retainer it
BOSCH P/N 1415522036
• Installation
Perparing the fuel injection pump

If the fuel injection pump is equipped 1111ith a mechanical governor, it must be removed. GAC
recommends that this mpdicication be performed by a qualified fuel injection service facility. The
following procedure lists the general steps required to remove the mechanical governor.
'U7 Note:
V Be prepared to collect the oil that will be released from the mechanical governor.
1. Remove the rear housing from the mechanical governor and disconnect the governor linkage
from the fuel rack. Rem'?ve the flyweight assembly. A specical tool is required.
2. Remove the intermediate governor housing. This leaves only the rack and camshaft protruding
from the pump.
3. Install the camshaft bearing retainer plate to provide support to the bearing formerly held by the
governor housing.
This plate must have countersunk holes for the mounting screws.
Installing the actuator

All hardware needed to attach the actuator to the pump is located in kit KT288 supplied with the
actuator.
1. The mounting surface on the pump must be clean. Attach the link(1) to the left-hand side of the
fuel rack with a M5 X ·1 0 mm screw(2) that includes a patch of locking C!dgesive.
Tighten the screw to 3- 4 NM so that the pump and torque to 5-6 NM.
2. Remove the two lower screws of the be<:!ring retainer plate and replace them with the retainers(3).
Attach the retainers with their shorter end threaded into the pump and torque to 5 - 6 NM.
3. Temporarily place the actuator over the rack and retainers and onto the pump face. Check that
the actuator contacts both the pump face and shoulders of the retainers. If necessary, use M6
spring washers to shim the retainers. The upper and lower mounting points of the actuator must
be equally supported. F~emove the actuator from the pump.
- 119 -
4. Remove both of the actuator covers. DO NOT remove or loosen the lever(16) from the actuator
shaft. Place the o-ring sea1(4) into the groove on the mounting face of the actuator. Apply a small
amount of grease to the o-ring to hold it in place.
5. Swing the armature out of the actuator so that the lever(16) is out of the way. Guide the actuator
over the rack and onto the lower mounting retainer studs. Attach the top of the actuator to the
pump with the M8 X 16 mm socket head screw(5), lock washer(6), and flat washer(?). Use M6
hex nuts(8) and spring washers(9) to secure the portion of the actuator. Torque the screw to 6 -
8 NM and nuts to 5- 6 NM.
6. Pull on the rack so that it is as far out of the pump as possible. Check that it moves freely. Place
the return spring(1 0) over the rack. Place the spring retainer I shut off plate assembly(11, 12) and
the M1 0 locking nut(13) over the threads on the rack link(1 ). The flats on the shut off plate(12)
must engage the flats on the link(1 ). Tighten the nut to 6 - 8 NM and insure that the shut off plate
is vertical and secure.
7. Test the engagement of the shut off mechanism with the rack linkage. Swing the lever back into
the actuator. Push on the armature to insure that the rack linkage operates smoothly and returns
immediately when released. Reattach the lower actuator cover(23) and tighten the screws(20) to
4-6 NM.
8. Loosen the fixation screw(17) so that the bearing(18) can be adjusted in its slot. Adjust the
bearing so that it pushes the rack0.5- 0.7 mm away from its stop position. Hold the bearing in this
position and tighten the screw(17) to 4 - ? NM. The rack is now adjusted so that premature wear
of the gear segments is avoided. Confirm that the operating lever screw(19) is tightened to 12 -
13 NM. Inspect the assembly to make sure all screws are tight.
9. Ther lever has a maximum fuel adjustment set screw(14). This screw is used to restrict the fuel
rack from 1 to 14.5 mm.
Caution:
Setting fuel levels above 14.5 mm can cause the screw to hit the back cover, which can
restrict minimum fuel. This can lead to a dangerous condition. Do not operate the engine this
way. Fuel levels above 14.5 mm require a shorter stop screw, M6 X 25mm.
With the fuel pump operating on the engine, the maximum fuel setting can be set to prvide specific
horsepower. Once this setting is made tighten the lock nut(15) on the stop screw to 5- 6 NM.
10. Move the manual shut off lever to the stop position and insure that the fuel is completely shutoff
and the engie stops.
11. With the engine shut down, install the upper chamber cover with the four scew(20, 21) and lock
washers. Note that when installed, the cover must not hit the internal lever or its stop screw.
Tighten the screws to 2 - 3 NM. Check for any oil leaks. Lock wire the screws for tamper
resistance.
Caution:
The engine should be equipped with an independent shut down device to prevent overspeed
whic can cause equipment damage or personal injury.
- 120-
Caution:
Adjusting the fuel pump is an essential part for performance and endurance of engine,
therefore operation and maintenance should be performed only by specialized engineer.
Figure 1 ACD176 Fuel Rack Force vs. Stroke

WIRNING 35
The ACD176 actuator is pre-wired for 12 or 24V 30

DC operation. Use the included cable harness to
25
connect the actuator to the speed control unit. Force (N)
The cable may be lengthened as necessary to fit 20

the specific application. Use the comparable 15
size wire to extend the cable harness. DO NOT
10
use an ACD176 on a 32V system, contact the
factory for assistance. 5
0 5 10 15 20 25
Angle of Actuator
Figure 2 ACTUATOR OUTLINE 0 5 10 15 21
Stroke (mm)
7.72 we-
, c
\1 A~ 1\\1
~
(196.1) ~\ OM.\
ELECTRIC ACTUATOR
MODEL: ACD176
SIN:
oiMCIIIII~Mittl.lA
4.20---------t
(106.7)
!OOA409001
- 121 -
----------------------------------------------------------------------------------
3.67 ----------~
(93.2)
SHUT OFF
LEVER
i - - - - - - - - - - - 4.31 --------------~
( 109. 5) PACKARD CONNECTOR 15300002
WITH TERMINALS 12048159
MATING CONNECTOR 15300027

WITH TERMINALS 12077411
(NOT INCLUDED)
EA409101
- 122-
2) AD086TI
Governor system for fuel injection pump consists of "Integral Actuator" and "Speed Control Unit".
(1) Integral Actuator
Adjust linkage length so that

Emergency . . when fastened to the operating
mechanjcalstop ..: .. ) ... ;, lever the fuel rack is approx.
~-·:.~,- ---~ l. . . . ·_ . 0.5~1.0mm away from its extreme
stop position
En~:e~i~~~~~~ed Y=1('1rr~~~~~~n- 'i

0 5-1.0mm
t--- •.
Linkage length L -- --;--
-1, ,_i~--~~~~;1&_:_
-----~ ·-- ··---------: I___ Extreme stop position
~-~G:j- ---- ~~-: --- - -
/,1:-=-J-·:~rli:c :~ :c~.cjl
:}of fuel rack
.JI-~~
Electromechanical chamber i
Completety enclosed, and 1
I~ ~=-· --
y,:;,: -
-u :
j.__ ___ : :
:.~.1~:::1 Fuel rack
;
~ '[ lf'.,L ~ ~~;:: ~< tJ
;;::.:~--'1{ ~-:,_ :_~ •,,
---Operating lever
:f..~
seated ~ i~d-· ., ', · -:·~;::-::!, /lbd2z3))7~ }·,'-. Max. fuel
~ --- -1----I{ _____: _!_.:.-:.--------- I
-~~- :<--c
:-· ---;-
/
I \"
/Operating lever'\ stop screw
The G.AC actuator concept
Fastest responsotime U 1 Fuel Stop nut Foxatron screw
Maintenance free stopplate
Linear EA6M4001 EA6M4002
<Side View> <Top View>
• Functions of Actuator's component

1. Emergency stop lever
It is emergency stop lever operated by manual at emergency.
2. Upper control chamber
The cover for controlling the inside is installed.
3. Electro control chamber
Operating lever is started by the electric signal generated in it.
4. Adjusting screw
As it is a part of controlling the max. fuel amount if the length which comes outside is long
the torque decreases or if the length is short the torque increases.
5. Fuel stop plate
It is the plate which prevents fuel from increasing by stopping the proceeding of adjusting
screw.
6. Operating lever
It is a connecting lever for operating the fuel rack.
7. Fuel lever
It is connected with link lever, controls fuel amount of the fuel injection pump.
Caution:
Adjusting the fuel pump is an essential part for performance and endurance of engine,
therefore operation and maintenance should be performed only by specialized engineer.
- 123-
EA6M4003
No. Description Q'ty Remark No. Description Q'ty Remark

1 Stop lever(emergency) 1 20 actuator spring 1
2 pump gasket 1 21 gasket,lower cover 1
3 washer 4 22 lower cover 1
4 allen screw 4 7-9 N.m 23 washer 8
5 ball link 2 * 24 allen screw 6 2.0 ± 3.0 N.m
6 stop nut 2 3.5-4.0 N.m 25 receptacle 1
7 operating lever 1 26 sealing screw 2 3.5 ± 4.5 N.m
8 oil seal 1 27 gasket, upper cover 1
9 counter nut 1 4.5-6.0 N.m 28 flat washer 2
10 stop screw 1 29 screw, ball link 2 *
11 connector screw 4 30 connecting rod 1 *
12 mounting bar 1 31 nut 2 *
13 flat washer 2 32 stop plate 1 *
14 lock washer 2 33 top cover 1
manual stop
15 nut 2 17- 21 N.m 34 device complete 1
linkage complete
16 flat washer 2 * comprise pas. 1
5,6,28,29,30,31 ,32
17 lock washer 2 35 fixing screw 1 12.5±13.0N.m
18 nut 2 7-9 N.m 36 stop nut 1 12.5±13.0 N.m
threaded bolt
19 (part of bearing kit) 2
- 124-
(2) Speed control unit for governor system (All)
a) Introduction
Series speed control unit is an all electronic device designed to control engine speed with
fast and precise response to transient load changes. This closed loop control, when
connected to a proportional electric actuator and supplied with a magnetic speed sensor
signal, will control a wide variety of engines in an isochronous or droop mode.
The speed control unit are the engine STARTING FUEL and SPEED RAMPING
adjustments. The use of these features will minimize engine exhaust smoke experienced
prior to attaining engine operating speed.
Other features include adjustable droop and idle operation, inputs for accessories used in
multi-engine or special applications, protection against reverse battery voltage, transient
voltages, accidental short circuit of the actuator and fail safe design in the event of loss of
speed sensor signal or battery supply.
AD136/T/TI AD086TI
GAG actuator model ACD 176A-24 ACE 175
Speed control unit model DWC-2000 ESD55500
b) Description
Engine speed information for the speed control unit is usually received from a magnetic pick-
up sensor Any other signal generating device may be used provided the generated
frequency is proportional to engine speed and meets the voltage input and frequency range
specification. The speed sensor is typically mounted in close proximity to an engine driven
ferrous gear, usually the engine ring gear. As the teeth of the gear pass the magnetic sensor,
a signal is generated which is proportional to engine speed.
Signal strength must be within the range of the input amplifier. An amplitude of 0.5 to 120 volts
RMS is required to allow the unit to function within its design specifications. The speed signal
is applied to Terminals C and D of the speed control unit. Between these terminals there is
an input impedance of over 33,000 ohms. Terminal D is internally connected to Terminal E,
battery negative. Only one end of the cable should be connected.
When a speed sensor signal is received by the controller, the signal is amplified and shaped
by an internal circuit to provide an analog speed signal. If the speed sensor monitor does not
detect a speed sensor signal, the output circuit of the speed control unit will turn off all current
to the actuator.
A summing circuit receives the speed sensor signal along with the speed adjust set point
input. The speed range has a ratio of 8:1 and is adjusted with a 25 turn potentiometer. The
output from the summing circuit is the input to the dynamic control section of the speed control
unit. The dynamic control circuit, of which the gain and stability adjustments are part, has a
control function that will provide isochronous and stable performance for most engine types
and fuel systems.
The speed control unit circuit is influenced by the gain and stability performance adjustments.
The governor system sensitivity is increased with clockwise rotation of the gain adjustment.
The gain adjustment has a range of 33:1.
- 125-
The stability adjustment, when advanced clockwise, increases the time rate of response of the
governor system to match the various time constants of a wide variety of engines. The speed
control unit is a PID device, the "D", derivative portion can be varied when required. (See
Instability section.)
During the engine cranking cycle, STARTING FUEL can be adjusted from an almost closed,
to a nearly full fuel position.
Once the engine has started, the speed control point is determined, first by the IDLE speed
set point and the SPEED RAMPING circuit. After engine speed ramping has been completed,
the engine will t•e at its governed operating speed.
At the desired governed engine speed, the actuator will be energized with sufficient current to
maintain the desired engine speed, independent of load (isochronous operation).
The output circuit provides switching current at a frequency of about 500Hz to drive the
actuator Since the switching frequency is well beyond the natural frequency of the actuator,
there is no visible motion of the actuator output shaft.
Switching the output transistors reduces its internal power dissipation for efficient power
control. The output circuit can provide current of unto 1 Oamps continuous at 25?C for 12 and
24VDC battery systems. The actuator responds to the average current to position the engine
fuel control lever.
In standard operation, the speed control unit performance is isochronous. Droop governing
can be selected by connecting terminals K and L and the percent of droop governing can be
varied with the droop adjustment control . The droop range can be increased by connecting
Terminals G and H.
The speed control unit has several performance and protection features which enhance the
governor system. A speed anticipation circuit minimizes speed overshoot on engine start-up
or when large increments of load are applied to the engine.
Engine idle speed can be remotely selected and is adjustable. Accessory inputs to achieve
variable speed operation and multi-engine control can be accepted by the speed control unit
from GAG load :sharing modules, automatic synchronizers.
- 126-
c) Specification
PERFORMANCE
Isochronous Operation/steady State Stability ± 0.25% or better
Speed Range/Governor 1 K ± 7.5 KHz continuous
Speed Drift with Temperature ± 1% Maximum
Idle Adjust CW 60% of set speed
Idle Adjust CCW Less than 1 ,200 Hz.
Droop Range 1 ± 5 % regulation*
Droop Adj. Max. (K-L Jumpered) 400Hz± 75Hz per 1.0 A change
Droop Adj. Min. (K-L Jumpered) 15 Hz ± 6 Hz. per 1 .0 A change
Speed Trim Range ±200HZ
Remote Variable Speed Range 500 ± 7.5 Hz or any part thereof
Terminal Sensitivity J 100 Hz ± 15 HzNolt @ 5.0 K Impedance
L 735 Hz ± 60 HzNolt @ 65 K Impedance
N 148Hz± 10 HzNo1t@ 1 Meg. Impedance
p 1 0 VDC Supply @ 20 ma Max.
Speed switch adjustment range 1,000- 10,000 Hz
ENVIRONMENTAL
Ambient Operating Temperature Range -40° to 180°F (- 40° to+ 85°C)
Relative Humidity up to 95%
All Surface Finishes Fungus Proof and Corrosion Resistant
INPUT POWER
Supply 1 2 or 24 VDC Battery Systems
(Transient and Reverse Voltage Protected)**
Polarity Negative Ground (Case Isolated)
Power Consumption 50 mA continuous plus actuator current
Actuator Current Range @ 77 ?F (25 ?C) - Min.2.5 Amps/ Max. 10 Amps continuous ***
(Inductive Load)
Speed Sensor Signal 0.5 - 120 Volts RMS
Speed switch relay contacts (N.O. and N.C.) 10 Amps
RELIABILITY
Vibration 1 G @ 20 - 1 00 Hz
Testing 100% Functionally Tested
PHYSICAL
Dimensions See Outline
Weight 1.8 lbs (820 grams)
Mounting Any Position, Vertical Preferred
Note:
* Droop is based on a speed sensor frequency of 4, 000 Hz and an actuator current.
Change of 1 amp from no load to full load. Applications with higher speed sensor signals will
experience less percentage of droop. Applications with more actuator current change will
experience higher percentages of droop. See droop description for specific details on
operation of droop ranges.
** Protected against reverse voltage by a series diode. A 15 Amp. fuse must be Installed in the
positive battery lead.
*** Protected against short circuit to actuator (shuts off current to actuator), unit automatically
turns back on when shorts is removed.
- 127-
d-1) Wiring Diagram and Outline (AD034TI, AD136/T/TI)
154
9.5
15
••
Over
Speed
1 2 3 4 5 6 7 8 9 Run
0
L~ L~ L~ 0 Crank
Reset
Overspeed Run Crank

0
Speed Test
(€ GOVERNOR CONTROLLER
MODEL : OWC-2000
0 D1
Gain
INPUT : OC2W ON [gO OFF Stability

PARTS No. : !J5.11:.!20·700fl
m SERIAL No :
Starting
"' Fuel
Speed
D2
0 ON [gO OFF
Ramping
(€ Idle Idle
~
Droop
Actuator Pick-Up ~atte7

,---, ,---, ,---, AUX 10V
A B C D E F G H J K L M N p
32
ADD JUMPER FOR 12V

BATIERY ORACTUATOR
CURRENTS ABOVE SA
• CLOSE FOR IDLE
OPTIONALACTUATOR
CABLE SHIELDING TO
MEET CE DIRECTIVE
- 128-
d-2) Wiring Diagram and Outline (AID086TI)
6.00 (152)
5.25 (133)
0 0.27 (7)
C1 OFF ~~ ON C1
0 0 SOFTCOUf•LING
0 0 LF.AD CIRCUIT
ON OFF 0
OVERSPEED
0 0
\G OVFHNORS
AMF.RICA
~ 1 2 3 RESET TEST
CoRP L'-JN OVERSPEED
- - - -'
SPEED CONTROL UNIT
w r~::
MODEL: ESD5550
SIN
MAOt:INAfiAWAM,MA U.S.A
in'
~
,,.,
0
.,0
N'
c"'
0
0
.,0
0 STARTING
FUEL
_ft SPEED
RAMPING
CAUTION
ENGINE SPEED CONTROl
0 OMPONENT WHEN INS TAl liNG

OR SfRVICING REFER TO
I'ROOUCT PUBI.!CATION 0
~
PICK-UP -
AC~R n BAHERY
ABCDEF G H J
0
0
OPTIONAL ACTUATOR ACCESSORY POWER 1.03 (26)
CABLE SHELDING TO SUPPLY
MEET CE DIRECTIVE
ACTUATOR
FUSE \5A
Note:
• If wire leads are longer than 3 meters (10 ft), a shielded cable should be used. Ground
shield at one end only.
• The speed control unit is rugged enough to be placed in a control cabinet or engine
mounted enclosure with other dedicated control equipment. If water, mist, or condensation
may come in contact with the controller, it should be mounted vertically. This will allow the
fluid to drain away from the speed control unit.
• Extremely heat should be avoided.
- 129-
Caution:
An overspeed shutdown device, independent of the governor system, should be provided to
prevent loss of engine control which may cause personal injury or equipment damage. Do not
rely exclusively on the governor system electric actuator to prevent overspeed. A secondary
shutoff device, such as a fuel solenoid must be used.
e) Functions of the Control unit

1. STARTING FUEL :When starting engine at first, it controls the amount of starting fuel. If you
turn it clockwise, the amount of fuel increases.
2. SPEED RAMPING : It controls time to be taken for the max. speed. If you turn it counter
clockwise, the time to be reached the rating speed is reduced.
3.1DLE : Adjust the idle speed of the engine. If the engine rotates clockwise, the
speed of the engine increases.
4. GAIN : It makes fluctuant rate of speed which generated from engine stable.
5. STABILITY : It makes fluctuant rate of speed according to the engine mounting stable.
6. SPEED : Adjust the engine speed. If engine rotates clockwise, engine speed
increases.
7. OVER SPEED : Adjust engine over speed. If engine rotates clockwise, engine speed
increases.
8. DROOP SPEED : It is used in parallel operation of generator.
9. RESET : It is used for initializing the over speed controller.
10. TEST : It is used for confirming and setting the over speed.
11. A, B TERMINAL : They are connected with actuator of the injection pump.
12. C, D TERMINAL : They are connected with magnetic pickup sensor, shield wire should be
used. Don't use magnetic pickup sensor connected with them for other
purpose.
13. E, F TERMINAL : They are connected with battery (E --..- polar, F-.. + polar)
14. G,M TERMINAL :They are terminals for maintaining the idle speed.
15. K, L TERMINAL :They are terminals for droop.
16. H, J, N, P TERMINAL: They are subsidiary terminals.
f) Wiring
Basic electrical connections are illustrated above. Actuator and battery connections to Terminals A,
B, E, and F should be #16AWG (1.3 mm 2 ) or larger.
Long cables require an increased wire size to minimize voltage drops.
The battery positive(+) input, Terminal F, should be fused for 15 amps as illustrated.
Magnetic speed sensor connections to Terminals C and D MUST BE TWISTED AND/OR
SHIELDED for their entire length. The speed sensor cable shield should only be connected to
terminal D. The shield should be insulated to insure no other part of the shield comes in contact
with engine ground, otherwise stray speed signals may be introduced to the speed control unit. With
the engine stopped,
adjust the gap between the magnetic speed sensor and the ring gear teeth. The gap should not be
any smaller than 0.020 in, (0.45 mm). Usually, backing out the speed sensor 3/4 turn after touching
the ring gear tooth will achieve a satisfactory air gap. The magnetic speed sensor voltage should
be at least 1 VAC RMS during cranking.
- 130-
g) Adjustments (Used new controller)
1. Be1fore Starting Engine
G) The GAIN and STABILITY adjustments are set to mid position.
(3) STARTING FUEL: FULL CW (Maximum Fuel)
0 SPEED RAMPING: FULL CCW (Fastest)
0 IDLE: FULL CW (Idle speed increase position)
® Place the engine in idle by connecting Terminals M & G.
2. After Starting Engine

When starting engine at first, actuator activates forward "maximum fuel" position. After starting
engine, adjust to maintain idle speed. The speed control unit governed speed setting is factory
set at approximately engine idle speed. (1 000 Hz, speed sensor signal)
G) Adjust STARTING FUEL and SPEED RAMPING depending on engine running status.
® If the engine is unstable after starting, turn the GAIN and STABILITY adjustments
counterclockwise until the engine is stable.
0 After disconnecting Terminals M & G, turn SPEED to adjust maximum engine speed.
0 After connecting Terminals turn IDLE to set idle speed at 750 rpm. Then disconnect Terminal
M & G, to recheck and readjust maximum engine speed.
3. Governor Speeding Setting

The governed speed set point is increased by clockwise rotation of the SPEED adjustment
control. Remote speed adjustment can be obtained with an optional 5K D. Speed Trim Control
4. Governor Performance
Once the engine is at operating speed and at no load, the following governor performance
adjustment can be made.
G) Rotate the GAIN adjustment clockwise until instability develops.
Gradually move the adjustment counterclockwise until stability returns.
Move the adjustment one division further counterclockwise to insure
stable performance.
® Rotate the STABILITY adjustment clockwise until instability develops.
Gradually move the adjustment counterclockwise until stability returns.
Move the adjustment one division further to insure stable performance.
0 Gain and stability adjustments may require minor changes after engine load is applied.
Normally, adjustments made at no load achieve satisfactory performance. A strip chart
recorder can be used to further optimize the adjustments.
Note:
If instability cannot be corrected or further performance improvements are required, refer to
the section on SYSTEM TROUBLESHOOTING.
- 131 -
5. Starting Fuel Adjustment
The engine's exhaust smoke at start-up can be minimized by completing the
following adjustments.
CD Place the engine in idle by connecting Terminals M & G.
® Adjust the IDLE speed for as low a speed setting as the application allows.
®Adjust the STARTING FUEL CCW until the engine speed begins to fall, Increase the
STARTING FUEL slightly so that the idle speed is returned to the desired level.
0 Stop the engine.
One of two methods of operation for the ESD5550 may now be selected.
Method 1) : Start the engine and accelerate directly to the operating speed (Generator Sets, etc.)
CD Remove the connection between Terminals M & G. Start the engine and adjust the
SPEED RAMPING for the least smoke on acceleration from idle to rated speed.
® If the starting smoke is excessive, the STARTING FUEL may need to be adjusted
slightly CCW. If the starting time is too long, the STARTING FUEL may need to be
adjusted slightly CW.
Method 2) : Start the engine and control at an idle speed for a p~riod of time prior to accelerating
to the operating speed. This method separates the starting process so that each may
be optimized for the lowest smoke emissions.
CD Replace the connection between Terminals M & G with a switch, usually an oil
pressure switch. Start the engine. If the stC~rting smoke is excessive, the
STARTING FUEL may need to be adjusted slightly CCW. If the starting time is too
long, the STARTING FUEL may need to be adjusted slightly CW.
® When the switch opens, adjust the SPEED RAMPING for the least amount of
smoke when accelerating from idle speed to rated speed.
6. Idle Speed Setting

If the IDLE speed setting was not adjusted as detailed in "Starting Fuel Adjustment" section, then
place the optional external selector switch in the IDLE position. The idle speed set point is
increased by clockwise rotation of the IDLE adjustment control. When the engine is at idle speed,
the speed control unit applies droop to the governor system to insure stable operation.
7. Speed Droop Operation

Droop is typically used for the paralleling of engine driven generators.
Place the optional external selector switch in the DROOP position, DROOP is increased by
clockwise rotation of the DROOP adjustment control. When in droop operation, the engine speed
will decrease as engine load increases.
The percentage of droop is based on the actuator current change from engine no load to full load.
A wide range of droop is available with the internal control. Droop level requirements above 10%
are unusual.
If droop levels experienced are higher or lower than those required, contact the factory for
assistance.
After the droop level has been adjusted, the rated engine speed setting may need to be reset.
Check the engine speed and adjust the speed setting accordingly.
- 132-
8. Accessory input
The Auxiliary Terminal N accepts input signals from load sharing units, auto synchronizers, and
other governor system accessories, accessories are directly connected to this terminal It is
recommended that this connection from accessories be shielded as it is a sensitive input terminal.
If the auto synchronizer is used alone, not in conjunction with a load sharing module, a 3M ohm
resistor should be connected between Terminals N and P This is required to match the voltage
levels between the speed control unit and the synchronizer.
When an accessory is connected to Terminal N, the speed will decrease and the speed
adjustment must be reset.
When operating in the upper end of the control unit frequency range, a jumper wire or frequency
trim control may be required between Terminals G and J. This increases the frequency range of
the speed control to over 7000 Hz.
9. Accessory Supply
The +1 0 volt regulated supply, Terminal P, can be utilized to J:.•rovide power to g..::>Vernor system
accessories. Up to 20mA of current can be drawn from this supply. Ground reference is Terminal
G. A short circuit on this terminal can damage the speed control unit.
10. Wide Range Remote Variable Speed Operation

A single remote speed adjustment potentiometer can be used to adjust the engine speed
continuously over a specific speed range. Select the desired speed range and the; corresponding
potentiometer value. (Refer to "Speed Range Potentiometer Value") If the exact range cannot be
found, select the next higher range potentiometer. An additional fixed resistor rnay be placed
across the potentiometer to obtain the exact desired rapge. Connect the speed range
potentiometer as shown in the next diagram.
<Speed Range Potentiometer Value>
Speed Range Potentiometer Value G J K L
t
900Hz. 1K
2,400 Hz. 5K
3,000 Hz. 10K
3,500 Hz. 25K
3,700 Hz. 50K
* Select Proper Potentiometer Value
Caution:
To maintain engine stability at the
minimum speed setting, a small amount
+-cw
EA6M4005
of droop can be added using the

DROOP adjustment. At the maximum speed setting the governor performance will be near
isochronous, regardless of the droop adjustment setting.
Contact the factory for assistance if difficulty is experienced in obtaining the desired variable
speed governing performance.
- 133-
h) System Trouble shooting
1. System Inoperative
If the engine governing system does not function, the fault may be determined by performing the
voltage tests described in Steps 1, 2, 3, and 4.Be careful of the meter polarities measuring.
Should normal values be indicated as a result of following the trouble shooting steps, the fault
may be with the actuator or the wiring to the actuator See the actuator publication for testing
details.
STEP TERMINALS NORMAL READING PROBABLE CAUSE OF ABNORMAL READING

1 F(+) & E(-) Battery supply voltage 1. DC battery power not connected. Check for blown
(12 or 24 VDC) fuse
2. Low battery voltage.
3. Wiring error.
2 C&D 1.0 VAG RMS min., 1. Gap between speed sensor and gear teeth too great.
while cranking Check gap.
2. Improper or defective wiring to the speed sensor.
Resistance between terminals C and D should be
30 to 1 ,200 ohms.
3. Defective speed sensor.
3 P(+) & G(-) 10 VDC, 1. Short on terminal P (This will cause a defective unit.)
Internal Supply 2. Defective Speed Control.
4 F(+) & A(-) 1.0-2.0 VDC 1. SPEED adjustment set too low
while cranking 2. Short/open in actuator wiring.
3. Defective speed control.
4. Defective actuator.
- 134-
2. Unsatisfactory Performance
If the governing system functions poorly, perform the following tests.
SYMPTOM TEST PROBABLE FAULT

1. Actuator goes to full fuel. Then, disconnect speed
1. Do not crank.
sensor at Terminals C & D.
Apply DC power to
Engine overspeeds If actuator still at full fuel speed control unit
the governor
defective. If actuator at minimum fuel position -
system.
erroneous speed signal. Check speed sensor
data.
2. Manually hold the 1. If the voltage reading is 1.0 to 2.0 VDC.

engine at the a) SPEED adjustment set above desired speed.
desired running b) Defective speed control unit.
speed. Measure
the DC voltage 2. If the voltage reading is above 2.0 VDC, a)
between Terminals Actuator or linkage binding.
A(-) & F(+) on the
speed control unit. 3. If the voltage reading is below 1.0 VDC, a)
Defective speed control unit.
4. Gain set too low.
1. Measure the
1. If the voltage is less than 7V for a 12V system,
voltage at the
or14V for a 24V system, replace the battery if it is
Actuator does not battery while
weak or undersized.
energize fully. cranl<ing.
2. M o m e n t a r i I y 1. Actuator or battery wiring in error.

connect Terminals
A and F The 2. Actuator or linkage binding.
actuator should
move to the full 3. Defective actuator.
fuel position.
4. Fuse opens. Check for short in actuator or
actuator wiring harness.
1. Measure the 1. If voltage measurement is within approximately 2

actuator output. volts of the battery supply voltage, then fuel
Engine remains below
Terminals A & B, control restricted from reaching full fuel position.
desired governed
while running under Possibly due to interference from the mechanical
speed.
governor control. governor, carburetor spring or linkage alignment.
2. Speed setting too low.
3. Insufficient Magnetic speed Sensor Signal

P.. strong magnetic speed sensor signal will eliminate the possibility of missed or extra pulses. The
speed control unit will govern well with O.Svolts RMS speed sensor signal. A speed sensor signal
of 3volts RMS or greater at governed speed is recommended. Measurement of the signal is made
at Terminals C and D.
- '135-
4. Electromagnetic Compatibility (EMC)
The governor system can be adversely affected by large interfering signals that are conducted
through the cabling or through direct radiation into the control circuits.
All speed control units contain filters and shielding designed to protect the units sensitive circuits
from moderate external interfering sources.
Although it is difficult to predict levels of interference, applications that include magnetos, solid
state ignition systems, radio transmitters, voltage regulators or battery chargers should be
considered suspect as possible interfering sort traces.
If it is suspected that external fields, either those that are radiated or conducted, are or will affect
the governor systems operation, it is recommended to use shielded cable for all external
connections.
Be sure that only one end of the shields, including the speed sensor shield, Is connected to a single
point on the case of the speed control unit. Mount the speed control unit to a grounded metal back
plate or place it in a sealed metal box.
Radiation is when the interfering signal is radiated directly through space to the governing system
To isolate the governor system electronics from this type of interference sort roe, a metal shield or
a solid metal container is usually effective.
Conduction is when the interfering signal is conducted through the interconnecting wiring to the
governor system electronics. Shielded cables and installing filters are common remedies.
As an aid to help reduce the levels of EMI of a conductive nature, a battery line filter and shielded
cables are conveniently supplied by KT130. To reduce the levels of EMI of a radiated nature, a
shielded container P/N CA114 can be sourced from GAC and its distributors.
In severe high energy interference locations such as when the governor system is directly iq the
field of a powerful transmitting source, the shielding may require to be a special EMI class
shielding. For these conditions, contact GAC application engineering for specific
recommendations.
- 136-
5. Instability
Instability in a closed loop speed control system can be categorized into two general types.
CD PERIODIC appears to be sinusoidal and at a regular rate.
0 NON-PERIODIC is a random wandering or an occasional deviation from a steady state band
for no apparent reason
Switch C1 controls the "Lead Circuit" found. The normal position is "ON " Move the switch to the
"OFF" position if there is fast instability in the system.
Switch C2 controls an additional circuit added is designed to eliminate fast erratic governor
behavior, caused by very soft or worn couplings in the drive train between the engine and
generator.
The normal position is "OFF". Move to the "ON" position if fast erratic engine behavior due to a soft
coupling is experienced.
The PERIODIC type can be further classified as fast or slow instability. Fast instability is a 3Hz. or
faster irregularity of the speed and is usually a jitter Slow periodic instability is below 3Hz., can be
very slow, and is sometimes violent.
If fast instability occurs, this is typically the governor responding to engine firings.
Raising the engine speed increases the frequency of Instability and vice versa.
In this case, placing switch C1 in the "OFF" position will reduce the speed control unit's sensitivity
to high frequency signals.
Readjust the GAIN and STABILITY for optimum control Should instability still be present, the
removal of E1 to E2 jumper may help stabilize the engine. Post locations are illustrated. Again,
readjust the GAIN and STABILITY for optimum control. Interference from powerful electrical
signals can also be the cause. Turn off the battery chargers or other electrical equipment to see if
the system disappears.
Slow instability can have many causes. Adjustment of the GAIN and STABILITY usually cures
most situations by matching the speed control unit dynamics. If this is unsuccessful, the dead time
compensation can be modified. Add a capacitor from posts E2 to E3 (negative on E2). Post
locations are illustrated. Start with 1 Omfds. and increase until instability is eliminated. The control
system can also
be optimized for best performance by following this procedure.
If slow instability is unaffected by this procedure, evaluate the fuel system and engine
performance. Check the fuel system linkage for binding, high friction, or poor linkage. Be sure to
check linkage during engine operation. Also look at the
engine fuel system. Irregularities with carburetion or fuel injection systems can change engine
power with a constant throttle setting Th is can result in speed deviations beyond the control of the
governor system. Adding a small amount of droop can help stabilize the system for
troubleshooting.
NON-PERIODIC instability should respond to the GAIN control. If increasing the gain reduces the
instability, then the problem is probably with the engine. Higher gain allows the governor to
respond faster and correct for disturbance. Look for engine misfirings, an erratic fuel system, or
load changes on the engine generator set voltage regulator If the throttle is slightly erratic, but
performance is fast, move switch C1 to the "OFF" position. This will tend to steady the system.
If unsuccessful in solving Instability, contact the factory for assistance.
- 137-
7.3.3. Fuel feed pump
1) General descriptions and construction
The P-type injection pump is mounted with NP-FP or KD-PS type feed pump. These pumps
have the same basic construction and operation, and the general descriptions of the KD
type pump are given below:
The figures show its construction (right figure) and operation (below figure). The piston in
the fuel feed pump is driven by the push rod and tappet via the camshaft of injection pump
and performs reciprocating operation to control the suction and delivery of fuel. When the
cam reaches the Bottom Dead Center as shown in the figure, the fuel is drawn in through
the check valve on the inlet side.
The fuel pressurized as the cam rotates on flows through the check valve on the outlet side
as shown in (B). If the feeding pressure increases abnormally, the spring is compressed,
resulting in interrupting further delivery of fuel as shown in (C).
Priming pump
Check valve
Check valve
Outlet
Inlet
side
side
Tappet
Piston
Cam shaft
EQM40191
- 138-
(A) (B) (C)
Inlet side Outlet side Interruption
EQM40201
This feed pump is mounted with a priming pump designed to permit manual feeding of fuel from the
fuel tank with the injection pump mounted in the engine. During the manual feeding operation, air
must be bled from the fuel lines.
When using the priming pump, fix it securely to prevent the possible entry of moisture or other foreign
substances in the inside of feed pump.
In addition, a strainer is fitted into joint bolt on

the inlet side of the fuel feed pump to filtrate
any foreign substances possibly mixed in fuel.
EB1M4003
- 139-
2) disassembly
42
~f
31
6
32
7
EQM4021S
• Clamp the feed pump with a vise and disassemble the plugs (30, 32), strainer (31) and gaskets
(35, 36).
• Take off the priming pump (25), plug (16), both gaskets (18), spring (15), and check valve (14).
• Take off the plug (7), gasket (8), spring (6), and piston (5) on the piston side.
• Pull out the snap ring (20) holding the tappet (1 0).
• Disassemble the snap ring, then take off the tappet (10) and push rod (1).
3) Inspection
• If the check valve is d;:tmaged or scored on its seat face, replace it with a new one.
• Inspect the piston and tappet for damage.
• Replace the push rod if excessively worn, and replace together with the purnp housing if
requireq. The inspection for wear should be performed in the same procedure ;as for suction
pressure test describE?<d below.
4) Re-asserr1bly
• Re-assembly operation is performed in reverse order of disassembly. All the gaskets must be
replaced with new ones at re-assembly.
- 140-
5) Testing
(1) Suction capacity test
Connect one end of a hose to the inlet
side of the feed pump and immerse the Outlet hose
other end of it into the fuel tank as
illustrated. Feed pump
Hold the feed pump in position about 1 m
above the level of fuel in the fuel tank.
Operate the tappet at the rate of 1 00 rpm
and check to see if fuel is drawn in and Inlet hose
delivered for 40 seconds or so.
EQM40221
(2) Delivery test

Make a test with tj-le feed pump mounted
on a pump tester as illustrated. Operate
the pump at the rate of 1 ,000 rpm and
check to see if the pump delivery is more
than 405 cc/15 seconds.
(3) Sealing test

Plug up the delivery port on the feed
Compressed Mass cylinder
pump and apply compressed air of 2 air 2kg I cm 2
kg/cm 2 into the inlet side. <==C>==~
Submerge the fee!d pump in a container
of diesel fuel and check for air leak.
EQM40231
- 141 -
7.3.4. Fuel injection nozzle
The injection nozzle assembly consists of the nozzle body and needle valve assembly.
Pressurized fuel delivered from the fuel injection pump is sprayed into the combustion
chamber past the injection nozzle at proper spray pressure and spray angle, then burnt
completely to achieve effective engine performance.
The fuel injected should necessarily be ignited immediately and combusted in a short period
of time as too long a combustion period will prevent the high speed operation of the engine
and can cause serious engine knocking.
(1) At valve closed (2) At valve opened
EQM40241
1) Construction
1. Nozzle holder
2. Union nut
3. Shim
1 4. Coil spring
5. Guide bush
2
6. Intermediate washer
3
7. Nozzle nut
4
8. Nozzle
5
6
7
8
EFM20541
2) Maintenance
Exercise extreme care when handling the injection nozzle assembly, particularly nozzle body
and needle valve as these parts are ultra precisely finished.
Wash clean the injection nozzle and remove it from the engine prior to disassembling.
- 142-
(1) Disassembly
r:t:'l • Clamp the nozzle holder in a vise and remove the cap nut.
I:!:J • Loosen the adjust screw lock nut and remove the adjust screw then detach the spring and
push-rod
• Clamp the nozzle holder body with the nozzle side up in a vise.
• With a wrench remove the nozzle nut using care not to drop the nozzle. Remove the nozzle
carefully not to drop the needle valve.
1. Nozzle Holder
2. Guide bush
3. Coil spring
4. Shim
5. Union nut
-8 6. Intermediate washer
7. Nozzle
8. Seal ring
EB1M4004
• Visual inspection
After washing, check the injection nozzles against the following:
(1) Needle valves
Check the valve seats, guide shafts and injection shaft for damage.
(2) Nozzle body
Check the valve seats for carbon deposit and damage. Also check the injection orifices
for uneven wear.
Replace both of the parts by using assembly even if either of the needle valve or the nozzle
body is found to be defective.
• Sliding test
A sliding test should be made on the entire injection nozzle often visual inspection.
Hold the nozzle body vertically Gjnd pull the needle valve upward about 1/3 of its entire
length and release it and see if it lowers onto its seat by its own weight.
If lowering of the needle valve is not smooth, check for presence of foreign matter and
repeat the test. If the trouble persists, replace the entire nozzle assembly with a new one.
- 143-
(2) Adjustment
• Remove the cap nut and assemble a
nozzle to a nozzle tester.
• With the adjusting screw loosened,
operate the nozzle 2 - 3 times to bleed it.
• Operate the nozzle tester lever at the
specified rate.
• Adjust the injection pressure to the
standard pressure using the adjusting
screw.
• After adjusting the injection pressure,

tighten the cap nut to specified torque.
• Re-check the injection pressure and see
if the spray pattern is normal. Spray
pattern should be uniform and free of
spattering.
Normal Abnormal Abnormal
EFM20571
(3) Testing
With the nozzle assembled to a nozzle tester and specified pressure applied, check the nozzle for
fuel leakage .
-
.
Modell L 136/T/TI/OSSTI
Opening pressure 214 + 8 kg/em>
If the joints are free from leaks and the

needle valvt:> is working normally, the
operation of the nozzle will be accompanied
by whistling sound.
Adjust the standard pressure by means of
the spring adjusting screw.
EAMC0221
- 144-
•
(4) Re-assembly
After removing carbon deposit, submerge the nozzle in diesel oil and clean it .
E3
••• • Replace all the gaskets with new ones.
• Assemble the parts and tighten them to specified torque.
Items Torque (kg·m)
Nozzle holder cap nut 7
Nozzle cap nut 6-8

Injection pipe cap nut 2.9 - 3.2
Injection pump delivery valve holder 2.5 - 3.0
7 .4. Turbocharger
The turbocharger is a system designed to make use of the engine exhaust gas energy to
charge high-density compressed air into the cylinders, thereby to increase the engine output.
As explained, the compressing of air to supply into the cylinders is called "Supercharging" and
the making use of the energy of exhaust gas dis,charged from the combustion chamber to
charge the compressed air into the cylinders is called "Turbocharging".
7.4.1. Specification
1) Main data and specifications
Sepecification L. 136T/TI L086TIH L086TIM
Turbocharger Model T04E55 HX35

At maximum Air pressure at compressor About 1.2 kg/em' About 1.24 kg/em' About 1.44 kg/em'
output
Air suction volume About 19.0 m'/min About 15.4 m'/min About 18.6 m'/min
Speed of turbine revolution Abo~t 100,000 rpm About 83,000 rpm About 83,000 rpm
Maximum allowable speed 130,000 rpm 130,000 rpm
Max. allowable temperature of

750°C 700°C
exhaust gas at turbine inlet
Lubricating system ~ External oil supply
Weight 10 kg 21 kg
- 145-
7.4.2. Turbo charger assembly
1) L 136T I Tl : T04E55
EB707017
1. Turbine Shaft 10. Bolt 19. Heat Plate

2. Thrust Bush 11. Clamp 20. Compressor Housing
3. Oil Shut Off 12. Bearin~J Housing 21. Clamp
4. Lock Nut 13. Retainer Ring 22. Bolt
5. Seal Ring 14. Seal Plate 23. Liquid Gasket
6. Seal Ring 15. Thrust Bearing 24. Loctite
7. Seal Ring 16. Journal Bearing 25. Liquid Anti-Burn Agent
8. Compressor Seal 17. Screw
9. Turbine Housing 18. Screw
- 146-
2) L086TI (HX35)
38
//]
I
36
58
I ('
32
I
I 13
I
~,,<>''
'
I /
1//
EA7M4003
2. Center housing rotating assembly 31. Oil slinger 57. Bolt, turbine housing
4. Bearing Housing 32. 0 ring seal, bearing housing 58. Screw thrust bearing
5. Turbine housing 33. Oil baffle 59. Bolt compressor cover
6. Assembly turbine wheel 36. Thrust collar 61. Lock nut,
7. Compressor wheel 38. Heat shield compressor wheel
8. Compressor housing 40. Lock plate compressor 62. V-band lock nut
11. Journal bearing 41. 0 ring seal, compressor 64. Ring retainer bearing
12. Thrust bearing 43. Oil seal plate 66. Insert, retaining ring
13. Piston ring seal, turbine 44. Thrust bearing spacer 77. Flat retaining ring
16. Piston ring seal, compressor 51. Clamp plate, compressor cover 78. Washer, compressor
29. V-band clamp 54. Lock washer, compressor 88. Clamp plate, turbine
- 147-
7.4.3. Inspection
As the condition of turbocharger depends greatly on how well the engine is serviced, it is very
important to maintain the engine in accordance with the specified maintenance procedure and
pay particular attention to checking oil & air leaks, unusual sound on running.
1) Checking of the rotor for rotating condition

The inspection of the rotor assembly for rotating condition should be performed by the
degree of unusual sound on running. If a sound detecting bar is used, install its tip on the
turbocharger housing and increase the engine revolutions slowly. If a high-pitch sound is
heard every 2-3 seconds or continuously , it means that the rotor assembly is not normal.
In this case, as the metal bearing and rotor are likely to be in abnormal conditions, the
turbocharger should be replaced or repaired.
2) Checking of the rotor end play

The radial and axial clearances of the rotor should check after every 2,000 hours operation.
This precaution will enable measuring for any wear of axial clearance bearings to be
detected in good time before serious damage is caused to the rotor and bearings.
Disassemble the turbocharger from the engine, then check the rotor axial play and radial
play.
(1) When disassembling the turbocharger, be sure to plug the oil inlet and outlet ports
(2) If the measured axial and radial plays are beyond the limit of wear, replace or repair the
turbocharger.
• Measuring rotor axial clearance

Turbine wheel chamber
Radial clearance 0.12 mm
• Measuring radial clearance
Radial clearance 0.58 mm shaft in axial

direction
EA705011
Dial gauge
EA705012
- 148-
3) Precautions for reassembling the turbocharger onto the engine
For re-assembly of the turbocharger or handling it after re-assembly operation, be sure to
observe the following precautions : Especially, pay attention to prevent foreign matters
from entering the inside of the turbocharger.
(1) Lubricating system

• Before reassembling the turbocharger onto the engine, inject new oil in the oil inlet port
and lubricate the journal and thrust bearings by rotating them with hand.
• Clean not only the pipes installed between the engine and oil inlet port but also the oil
outlet pipe and check them for damage or foreign matters.
• Assemble each joint on oil pipes securely to prevent oil leaks.
(2) Intake system

• Check the inside of the intake system for foreign matters.
• Assemble each joint on the intake duct and air cleaner securely to prevent air leaks.
(3) Exhaust system

• Check the inside of the exhaust system for foreign matters.
• Be sure to use heat resisting steel bolts and nuts. Do not interchange them with ordinary
steel bolts and nuts when performing re-assembly operation. Apply anti-seizure coating
to the bolts and nuts.
• Assemble each joint on the exhaust pipes securely to prevent gas leaks.
7 .4.4. Maintenance
1) Component identification
• Turbocharge identification
A dateplate is fitted to the
compressor housing (8). The
3SXXXXX
information on this dateplate must H01XXXX
be quoted for service and parts H2BIC/D/EIS

0
support.
EA7M4004
- 149-
• Center housing rotating assembly
(H20)
• Watercooled bearing housing (5)

This can have additional water feed drain
plug fittings. Special attention should be
made to the position of these fittings as
this may be specific ·for each application.
5
EA7M4006
2) Disassembly
• Before disassembling the turbocharger,
scribe the parts listed below to help in
alignment during assembly.
EA7M4007
• Secure the turbine h.ousing (5) in a vice.

Loosen and remove the 8 bolts (59) lock
washers (54) clamp plates (51).
Loosen and remove the compressor side
V-band lock nut (62).
EA7M4008
- 150-
• Gently remove the compressor cover (8),
and fitted, remove the 0 ring seal (41).
Caution : The compressor wheel blades

can be easily damaged when t
the compressor housing is
removed.
• Loosen and remove the 6 bolts (57) and

clamp plates (88).
Caution : The turbine blades can be

easily damaged when the
turbine housing is removed.
EA7M4011
• Locate the Center Housing Rotating

Assembly (CHRA) onto a 19mm socket
clamped in the jaws of a vice or a suitable
fixture.
Caution : Always make sure the turbine

wheel shaft and the
compressor wheel have
alignment marks before
disassembly of the CHRA.
- 151 -
• Remove the compressor wheel lock nut (61 ).
w Note : Left hand thread.
• Remove the compressor wheel (7).
EA7M4014
• Remove the remaining CHRA from the

socket and gently slide the shaft and wheel
(6) from the bearing housing (4).
• Discard the two piston ring seals (13).
Caution : Care should be taken not to

score the assembly turbine
wheel shaft.
- 152-
• Remove the heat shield (38).
---··-·-----------------
EA7M4017
• Place the bearing housing on a flat surface

and using a flat screwdriver, remove the
insert retaining ring (66).
EA7M4018
• Using two flat screwdrivers, gently remove

the oil seal plate (43).
• Remove the oil slinger (31 ).
EA7M4020
- 153-
• Remove and discard the piston ring seal
(16).
• Remove and discard the 0 ring seal (32).
• Remove the oil baffle (33).
EA7M4023
• Remove and discard the 3 flat head screws

(58).
Remove the thrust bearing (12).
-~
~
~
~
~--
EA7M4024
- 154-
---·----------------,
• If fitted remove the thrust bearing spacer
(44).
Remove the thrust collar (36). Also
t
remove flat retaining ring (77) if fitted.
• Using circlip pliers, remove and discard

the two circlips (64) and the journal
bearing (11) from the compressor end.
t
• Turn the bearing housing over and repair

the process.
3) Cleaning
With the turbocharger completely dismantled for overhaul, soak all the components in a non-
caustic metal cleaner to loosen deposits. Bead blast the turbine housing if chemicals do not
clean sufficiently.
On aluminium parts a bristle brush can be used. Never use a wire brush or metal scraper on
any turbocharger component. Ensure that all the palls are finally cleaned with an air jet,
especially drilled passages and machined apertures. Turbine Wheel: In the event of carbon
build-up, it may be necessary so carefully blast the Piston Ring
Groove area of the turbine wheel using low grade shot medium.
- 155-
w Caution : Shot blasting specific areas for long periods of time may effect component balance.
The surface adjacent to the turbine and compressor wheels on the stationary housings must
be clean, smooth and free from deposits.
w
4) Inspection
Caution : Do not attempt to straighten the turbine shaft.
(a) Place the shaft on a vee block, using

a dial gauge rotate the turbine wheel (a)
and check for movement on the dial
gauge. Replace the assembly
turbine wheel if it is bent. Max shaft
bend allowed 0.025 mm (0.001 ins).
Shaft Bend mm in.

(Max.) 0.025 0.001
EA7M4028
<Major Components>
• Assembly Turbine Wheel (6) ..,
L: (d)
(b) Inspect the piston ring groove ::·;
walls for wear.
Turbine wheel
.+:i i ' ,,,, ·'' (Jl
mm in.
piston ring groove
Single ring (Min.) 1.664 0.0665
Twin ring (Min.) 3.538 0.1393
(c) Inspect the bearing journals for excessive scratches and wear. Minor light scratches may
be tolerated.
Assembly turbine mm in.

Wheel journals
(Min.) 3.538 0.1393
(d) Inspect for cracked, bent or damaged blades but DO NOT ATTEMPT TO STRAIGHTEN
BLADES.
- 156-
• Turbine Housing (5)
Inspect the profile for damage caused
by possible contact with the rotor. Check
all threads for damage. Inspect the outer
and internal walls for cracks or flal<ing
caused by overheatin~J also check
mounting flanges for signs of distortion.
Replace with new if any of the above are
visible.
EA7M4030
• Compressor Housing (8)

Inspect the profile for dpmage due to
possible contact with the rotor. Check
the V-band groove.
Replace with new if any pf the above is
visible.
• Bearing Housing (4)

Inspect the bore for wear or score mark
on both the bearing and piston ring area.
Also check all tapped holes are clean
and free from dirt.
Replace with new if any damage is
found.
Bearing housing rr1m in.

bore (Max.) 19.063 0.75(
EA7M4032
• Compressor Wheel (7)

Inspect carefully for cra.cked, bent or
damaged blades but DO ~OT
ATTEMPT TO STRAIGHTEN BLADES.

Replace with new if any damage is
found.
EA7M4033
- 157-
<Minor Comp onents>
• Oil slinger (31) if the piston ring

Inspect an d replace are
e walls scored or
seal groov heck for
d Also c signs of
damage . flat surfaces.
rubbing on the
~
X
EA7M4034
• Oil sea I plate (43) replace I"f scored

Inspect t h e seal bore,
IL•I or damaged.
Heat shield (38) . h heat shield id

• e lace If t e
Check and r p f rubbing or
distorted or I"f signs o
crac k ·ng
I · ·ble .
are VISI
EA7M4036
5) Assembly
Rotor balance make sure that

o bl a/ways I
W Before assem y,
both compress
or whee
I and assemb y
. . .d ally balanced.
re mdtvt u
urbine wheel a f the rotor
t b lance o
~
f i
Then check a
assembly to ensure I
.t is within the
ired lim1ts. to help

requ
Ma individual item
rk up each during
l'ii:i1
" ensure correct alignment
assembly. _ 158 - EA7M4037

Rotor balance
g.mm oz. ins.
limits (Max.)
Turbine end 2.2 0.003
Compressor end 4.4 0.006
• Make sure that the circlips are always

fitted with the bevelled edge facing
the journal bearing.
Caution : Circlips (64). Premature

failure will result if the eire/ips 0
are fitted incorrectly.
EA7M4038
• Place the bearing housing (4) on a

bench with the turbine end facing
uppermost.
Fit the inner circlip (64) with the
bevelled edge facing upwards.
•
B
Lubricate the journal bearing (11) and
~
install into position.
Fit the outer circlip (64) with the
bevelled edge facing the bearing.
Turn the bearing housing over and
repeat the process.
- 159-
• Install the heat shield (38).
EA7M4041
• Install the two new piston ring seals

(13) to the assembly turbine wheel (6).
• Lubricate the shaft using clean engine

oil.
Caution : Align the piston ring seals

(13) so the gaps is positioned
180 o from the oil drain hole.
Gently press down on the
turbine wheel - a slight
rotation of the wheel will
assist in properly locating the
piston ring seals.
• Support the assembly turbine wheel

(6) and bearing housing in a suitable
fixture.
- 160-
• Install the thrust bearing spacer (44) if
fitted.
Install the thrust collar (36).
Caution : Align the balance mark on the

thrust collar with that on the
shaft.
• Using clean engine oil, lubricate the

thrust bearing (12).
Install the thrust bearing.
Install the 3 flat hear screws (58).
Using torque wrench, tighten to
required torque.
Torque value
Nm
4.5
in-lbs
40
~
~~46
• Fit the new piston ring seal (16) to the

oil slinger (31 ).
EA7M4047
• Fit flat retaining ring (77) in base of

bearing housing (4) if required.
Install oil baffle (33).
- 161 -
• Apply a small amount of oil to the 0
ring seal, install 0 ring seal (32).
• Insert the oil slinger (31) into the oil

seal plate (43).
EA7M4050
• Install the oil seal plate (43) into the

bearing housing (4).
Caution : Align the balance marks on

the oil slinger (31) with that on
the shaft end.
• Gently tap the oil seal plate (43) with a

soft hammer to seat in position.
EA7M4052
- 162-
----------------------....,
• Install the retaining ring (66).
Check correct location usin!;J a
screwdriver.
EA7M4053
u • Align the balance marks and install

the compressor wheel (7).
~
EA7M4054
• Install the compressor wheel lock nut

(61) and tighten to the torque value.
w Note : Left hand thread.
Nm in-lbs
Torque value
17 150
Caution : Ensure that the balance EA7M4055
marks are aligned on the

compressor wheel and the shaft.
- 163-
,.---------
• Locate the CHRA into the turbine
housing (5).
Install the 3 clamp plates (88) and
tighten the 6 bolts (57) to the torque
value.
Torque value Nm in-lbs

Bolts (57) 20 180
Caution : Make sure the scribe marks

are aligned.
• Secure the turbine housing and check

the trust clearance using a dial gauge.
Trust clearance mm in
Minimum 0.038 0.0015
Maximum 0.093 0.0037
• Check the radial clearance using a

dial gauge.
Radial clearance
mm in
(H20)
Minimum 0.364 0.014
Maximum 0.550 0.022
EA7M4058
• Loosely fit the V-band clamp.

Lubricate and install the 0 ring seal
(41) if fitted.
Install the compressor cover (8).
Caution : The compressor wheel blades

can be easily damaged when
the compressor housing is
installed.
- 164-
,..-----------------------,
• Install the 2 clamp plates (51), eight
lock washers (54) and tighten the 8
bolts (59) to the torque value.
Install the V-band clamp (29) and
tighten the lock nut (62) to the torque
value.
-.·.
Trust value Nm in-lbs
EA7M4060
Lock nut (62) 8.5 75
-·
Bolts (57) 8.5 75
- ...
w
Caution : Make sure the scribe marks are aligned.
- 165-
8. Troubleshooting
The following description summarizes the probable cause of and remedy for general failure by
item. Immediate countermeasures should be taken before a failure is inflamed if any symptom is
detected.
I Hard to start the engine I

t
I Fuel system admits air
~ ~I Bleed air (check feed pump)
I
'
I Clogged fuel supply piping or clogged air
vent pipe in tank.
I
j
Detect the cause and remove clogs or
obstacles.
I Clogged fuel filter ~ ~I Replace filter element with a new one.

I
I Fuel feed pump failure I

I Check for function. Service fuel pump or
replace with a new one if less discharge
volume is found.
I
I Insufficient compression I 1
Check according to "Insufficient output"
I
'
Improperly adjust valve stick or clearance in
I intake/exhaust vlaves.
I
I
Adjust clearance of intake/exhaust valves.
Cheek valve guide, spring, and rocker arm
mechanism for damage.
I Improper injection timing or valve timing. I 1

Check for injection timing and valve timing. I
sure)
'
I Clogged exhaust pipe (too high back pres-
t
I
I
Totally check exhaust system (for dented or
l twisted pipes and clogged silencer, etc.)
I Fuel injection valve failure or errors in I Check for part type No.
selection types. Service or replace fuel injection valves.
I
t
I Fuel injection pump failure
~ .. I Check, service or adjust.
I
I normally?
'
Does starting-aid in cold weather func1.:ion l
I
Check whether a proper voltage continu-
ously occurs in low temperature starting-aid
circuit while switch is turned ON.
When glow plugs are used, key switch is

turned "HEAT" position of key switch.
If glow plug is reheated, engine starts.
If not, glow plugs fail or circuit is defective.
If fire once occurs, and goes out if starter

motor is switched ON, voltage is insufficient
or circuit is defective (such as erroneous
selection of starter switch)
- 166-
I Hydraulic pressure source ~---.j Change or reduce the propeller pitch I
I
Clogged air cleaner f--~1 Clogged intake air pipe I
Clean Clean
Clogged exhaust Clogged cylinder

pipe head exhaust outlet
Clean
Air bleeding
, . . . - - - - - - - - - - - ' Clogged air vent in fuel tank
Insufficient fuel volume from feed pump I
Improper Fuel injec- Clogged fuel Fuel injec-

adjustment tion pres- injection valve tion valve
sure nozzle seizure
Adjust Clean or replace Clean
Lever link Improper Fuel pump Faulty Worn

malfunction fuel injection rack mal- delivery plunger
timing function valve barrel
Adjust Repair or Repair or Replace

replace replace
Reduced Improper clearance Defective Intake/exhaust Fatigued or

compression of intake/exhaust intake/exhaust valve stem broken valve
pressure valves valve seat seizure spring
Adjust Reshape or replace Replace Replace
Pressure
leak through
cylinder
Replace
Seizure, breakage Flaws or Flaws

and wear of piston wear of or wear
ring piston of liner
Replace Replace Replace
Refer to "Overheating"
- 167-
Hydraulic pressure source Set relief pressure of control valve
Insufficient Broken or Clogged heat lncresed exhaust

cooling water worn V-belt exchanger pressure
Add water Replace Clean Clean
Pressure cap Clogged heat- Reduction in cool-

Thermostat
clogging and exchanger
malfunction
malfunction tubes
Clean or replace Replace Clean Replace
Clean
Clogged
intake air pipe
Clean
Clogged Clogged cylinder

exhaust pipe head exhaust outlet
Clean Clean
Leakage through Cracked cylinder

head gasket head
Replace Replace
Defective fuel
injection valve
Clean or replace
Improper fuel
injection timing
Adjust Adjust
Seizure likeliness
Replace
- 168-
Hydraulic pressure source Set relief pressure of control valve
Refer to "Insufficient output."
Replace
Too early injection timing Excess injection volume I Uneven injection volume I
Adjust or replace Adjust Adjust or replace
I Improper adjustment ~~ Malfunction of lever and linkage I

Adjust Repair or replace
I Water intrusion in fuel ~· Intrusion of low-quality fuel or impurities

Replace Replace
I Improper SAE grade

Replace
I Cloggec~l Clogged intake air pipe I

Repair or replace clean or replace
Too late injection timing J

Adjust or replace
Defective valve Damaged or worn Damaged or worn

stem sealing valve stem valve guide
Breather oil rise Seizure, breakag~~ Flaws or wear Flaws or wear

wear of piston ring_j of piston of liner
'---------------------------11~! Leakage through cylinder

head gasket
~~Thermostat malfuncti~
- 169-
Starter motor will not turn Except engine seizure and ]
or output less power. [ trouble of driven machine
Disconnected
wiring
Repair Repair
Key switch Damaged or rusted Switch inner contactor Damaged switch

starter motor terminal
Replace Replace
Replace or repair
Damaged or Faulty really functioning

rusted terminals Replace
Replace or repair
Startor motor Magnet switch,

malfunction &
terminal defective contactor
, Replace or repair or repair starter motor
Replace
Hydraulic pressure source
Hydraulic system will not

operate or to slow function
I Viscosity
Replace Recommended Hydro-oil
L----,-~-----~1 Trouble in piping (Aeration cavitation)

Correct
L----,----'1----_..1 Worn spline in flange f----.-~ I

Worn gears and housing
. . ._______,f-------.1 Clogging
Clean or replace
- 170-
Battery is dead or n
[During operation]
chargeable.
v
Echarged
I
I
Discon- Coupler
Grounding ON condition
nected connec-
terminal
wiring tion
I Repair
!
E~ Short-circuit
I Replace
Key switch Switch

inner
'
Turn ON
terminals contactor
Repair or replace Replace
Electric Alternator f - - - - . , Short-circuited

appliance L----,--....J or disconnected
Replace
Replace
Faulty IC regulator] alternator
Replace alternator
Replace alternator
- 171 -
9. Special Tool List
No. Tool Names Tool No. Descriptions Applications
Front Oil Seal

EF.123-173(NOK)
Assembly Jig
Front Oil Seal

2 EF."I23-052
Puller Jig
~
Rear Oil Seal
3 EF.123-184(NOK)
Assembly Jig
~
Rear Oil Seal
4 EF."I23-048
Puller Jig
5 Valve Spring Press EF."I23-065
Crank Shaft Gear

6 EU . 2-0647
Punch
Valve Stem
7 EF.-122-089
Seal Punch
Adapter for
8 EU.,2-0530
Cylinder Pressure Test
No. 3 : CR (U.S.A CR Industries Co.) NOK (Japan NOK Co.)
- 172-
No. Tool Names Tool No. Descriptions Applications
_<>...::_o_:.-o:__a:....:ct....<L~J j
-
IC-JC
. -
CWJC
- . - "
Injection Pump EF123-015
9
Alignment Jig (Only L086TI)
~--- ---------------,
10 Piston Sleeve EF.123-064 : EF.120-208
:I (For all engines)
•B
L------------------
11 Cylinder Liner Puller EF.123-086
12 Filler Gauge 60.99901-0027
13 Filter Wrench 65.98801-0001
14 Snap Ring Plier T7610001E
15 Piston Ring Plier T7621010E
- 173-
10. Tightening Torque
• Tightening torque for major parts
Screw Strength
Major Parts Tightening Torque Remarks
(diameter x pitch) (grade)
Cylinder head bolt M14 X 1.5 10.9T 6.0 kg·m + 180 + 150 (Angle)
Connecting rod bearing cap bolt M14 X 1.5 12.9T 18.0 kg·m
Crankshaft main bearing cap bolt M16x1.5 12.9T 30.0 kg·m
Balance weight fixing bolt M12x1.5 10.9T 10.0 kg·m
Flywheel fixing bolt M14x1.5 10.9T 21.5 kg·m
Crankshaft gear fixing bolt M12x1.5 10.9T 13.0 kg·m
• Tightening torque for injection pump system
Parts Tightening Torque
Injection pump delivery valve holder 11.0- 12.0 kg·m
Nozzle holder fixing cap nut to cylinder head 7.0 kg·m
Nozzle fixing cap nut of nozzle holder 6.0 - 8.0 kg·m
High pressure injection pipe fixing cap nut Max. 2.9 - 3.2 kg·m
- 174-
e Tightening torque table for standard bolt
Refer to the following table for bolts other than described above.
Degree of strength
3.6 4.6 4.8 5.6 5.8 6.6 6.8 6.9 8.8 10.9 12.9
Diameter
X (4A) (40) (4S) (50) (5S) (60) (6S) (6G) (8G) (10K) (12K)
pitch Limit value for elasticity (kg/mm 2 )

(mm)
20 24 32 30 40 :~6 48 54 64 90 108
Tightening torque (kg•m)
M5 0.15 0.16 0.25 0.22 0.31 0.28 0.43 0.48 0.50 0.75 0.90
M6 0.28 0.30 0.45 0.40 0.55 0.47 0.77 0.85 0.90 1.25 0.5
M7 0.43 0.46 0.70 0.63 0.83 0.78 1.20 1.30 1.40 1.95 2.35
M8 0.70 0.75 1.10 1.00 1.40 1_.25 1.90 2.10 2.20 3.10 3.80
M8X1 0.73 0.80 1.20 1.10 1.50 1_.34 2.10 2.30 2.40 3.35 4.10
M10 1.35 1.40 2.20 1.90 2.70 2_.35 3.70 4.20 4.40 6.20 7.40
M10X1 1.50 1.60 2.50 2.10 3.10 2..80 4.30 4.90 5.00 7.00 8.40
M12 2.40 2.50 3.70 3.30 4.70 4_.20 6.30 7.20 7.50 10.50 12.50
M12X1.5 2.55 2.70 4.00 3.50 5.00 4.60 6.80 7.70 8.00 11.20 13.40
M14 3.70 3.90 6.00 5.20 7.50 7.00 10.00 11.50 12.00 17.00 20.00
M14X1.5 4.10 4.30 6.60 5.70 8.30 7.50 11.10 12.50 13.00 18.50 22.00
M16 5.60 6.00 9.00 8.00 11.50 10.50 17.90 18.50 18.00 26.00 31.00
M6X1.5 6.20 6.50 9.70 8.60 12.50 11.30 17.00 19.50 20.00 28.00 33.00
M18 7.80 8.30 12.50 11.00 16.00 14.50 21.00 24.20 25.00 36.00 43.00
M18X1.5 9.10 9.50 14.50 12.50 18.50 16.70 24.50 27.50 28.00 41.00 49.00
M20 11.50 12.00 18.00 16.00 22.00 19.00 31.50 35.00 36.00 51.00 60.00
M20X1.5 12.80 13.50 20.50 18.00 25.00 22..50 35.00 39.50 41.00 58.00 68.00
M22 15.50 16.00 24.50 21.00 30.00 26_.00 42.00 46.00 49.00 67.00 75.00
M22X1.5 17.00 18.50 28.00 24.00 34.00 29 . 00 47.00 52.00 56.00 75.00 85.00
M24 20.50 21.50 33.00 27.00 40.00 34.00 55.00 58.00 63.00 82.00 92.00
M24X1.5 23.00 25.00 37.00 31.00 45.00 38.00 61.00 67.00 74.00 93.00 103.00
Others : 1. The above torque rating have been determined to 70% or so of the limit value for bolt
elasticity.
2. Tension is calculated by multiplying tensile strength by cross section of thread.
3. Special screws should be tightened to 85% or so of the standard value.
For example, a screw coated with MoS2 should be tightened to 60% or so of the
standard value.
- 175-
11. Maintenance Specification Table for Major Parts
Stand value Limit

Group Part Inspection Item Correction Remark
for assembly for use
Inside diameter of ¢111-¢111.02 ¢111.222 Replace liner -

cylinder liner for wear (Limit0.2)
Need amount of Projection difference

Amount of liner
Cylinder 0.03-0.08 projection without between adjacent
projection
block & fail liners: 0.15"'
liner Correct with a Referenced length :
The flatness of upper
0.05/200
Engine surface of cylinder block surface grinder 200mm
body Hydraulic test for 1

4 Replace if leaky
minute (kg/cm 2 )
Valve seat Intake 0-0.3 - Replace valve

depression Exhaust 0-0.3 - seat
Cylinder
head & Cylinder head height 109.9 -110.1 108.4 Replace cyl. head
valve
Hydraulic test for 1
4 Replace if leaky Water temp. 70"C
minute (kg/cm 2 )
Measure at 13mm
¢110.801-
Outer dia. piston Replace liner away from lower
¢110.959
surface of piston
Clearance between Replace one worn

0.041-0.221 0.3
piston and liner more
Width of Top ring 3.50 Replace piston if

Piston piston ring 2nd ring 3.06-3.08 groove width is beyond
grooves Oil ring 4.04-4.06 specified value
Piston projection from Measure unworn

cylinder block upper 0-0.12 Must exist portion beneath the
surface rim of the upper side
Permissible weight
Major difference of each piston
±15 g 96 g v Replace piston
moving Top ring 0.40-0.65 1.5 Standard gauge

Piston ring
parts 2nd ring 0.40-0.65 1.5 Replace ring inside diameter :
gap
Oil ring 0.30-0.60 1.5 ¢108
Piston Piston ring Top ring

Replace ring or Limit for use if for
ring side 2nd ring 0.07-0.102 0.15
piston standard clearance
clearance Oil ring 0.05-0.085 0.15
Cross Install by
Direction of ring gap
120"C
Outer diameter of piston

¢41.994-42 Replace piston pir
Piston pin
pin Clearance between Replace one worn

0.009-0.015
piston pin and its bush more
- 176-
Stand value Limit
Radial run-out of journal Correct Measure In horizontal
and pin 0.01 with a grinder and vertical directions
Outside diameter of ¢83.966- Use under sized
¢83.988 ¢83 bearings
journal
¢70.971- respectively(0.25,
Outside diameter of pin ¢70
¢70.990 0.5, 0.75, 1.0)
Ellipticity of journal
0.008 0.025
and pin
Concentricity of journal
0.01 0.03
and pin
Taper of journal and pin 0.01 0.03
Clearance between Replace bearing Measure at crown
0.052-0.122 0.25
Crank crankshaft and bearing part not parting line
shaft Replace
End play of crankshaft 0.15-0.325 0.5 thrust bearing
Measure at No.4
Run-out of crankshaft 0.1 v Adjust by a press
if bended
bearing(No. 1 & 7
bearing supported)
Balance of 60 or Check dynamic Measure
crankshaft(g•cm) 60 v less balance at 400 rpm
Torque valve journal Clean out foreign
bearing cap bolt 30 Coat the bolt with objects on joining
(kg·m) engine oil surface
Measure after
Crush height of journal 0.08-0.110 tightening metal cap
bearing and releasing one
stud
Oil seal for wear( crank Replace oil seal
Major shaft rear) if oil leaking
moving End play of con-rod 0.170 - 0.248 0.50 Replace con-rod
parts Clearance between con-
rod bearing and crank 0.034 - 0.098 0.25 Replace bearing
pin
Clearance between Measure after
small end bush & 0.050-0.081 0.12 installing the bearing
piston pin and releasing one bolt
Connec- After completing of
ting rod Crush height of con-rod 0.30-0.50 bearing loosen one
bearing stud bolt & measure
Side clearance of big-
end and small-end 0.50 Replace con-rod
Allowable weight
difference per con-rods 18 g v
Torque valve of Clean out foreign
con-rod bearing cap bolt 18 Coat the bolt with objects on joining
(kg•m) engine oil surface
Diameter of cam shaft
journal ¢57.86- ¢57.88
Clearance between cam
Cam shaft and cam bush 0.12-0.17 0.24 Replace cam bust
shaft Replace thrust
End play of camshaft 0.28-0.43 0.6 washer
Correct or replace
Run-out of camshaft 0.1 the cam shaft
Clearance between idle
shaft bush and idle shaft 0.025-0.091 0.15
Timing End play of idle gear Correct or replace
gear shaft 0.043-0.167 0.3 gear
Back-lash between
gears(cam, idle, crank 0.16-0.28 0.35 Replace gear
and injection)
- 177-
Stand value Limit
Diameter of intake valve
¢8.950-¢8.970 0.02 When replacing
stem Replace valve &
valve, replace
Diameter of valve guide
¢8.935-¢8.955 0.02 valve guide alike
exhaust valve stem
Clearance Intake 0.030-0.065 0.15
between valve Replace valve & Replace one worn
stem and valve guide more
valve guide Exhaust 0.045-0.080 0.15
Thickness Intake 2.7

Max. 1 Replace valve
of valve head Exhaust 2.2
Clearance Intake 1.0
between valve
guide and valve
spring seat Exhaust 1.0
Clearance between valve Spread oil over

guide and cyl. head -0.039--0.010 valve guide and
installing hole (Press fit)
press it into the hole
Concentricity between
valve stem and valve 0.15 Without spring seat
head
Free length Approx.64
Valve Tension force
Intake (when pressed 67.9-72.1 66.5
Replace
valve to 41mm)kg
valve spring
spring Squareness
(along free 2S
Valve length direction
system Free lengt~ Approx.60
Tension
I force(when 26.9-30.3 -
n pressed to
n 38mm)kg Replace
e Squreness valve spring
r
(along free
2.5°
Exhaust length
valve direction)
spring Free length Approx. 71
Tension
0 force( when 62.7-69.3 -
u pressed to
t 41mm)kg Replace
e valve spring
r Squreness
(along free
length
2.5° -
direction)
Valve Intake 0.3
clearance Adjust
(at cold) Exhaust 0.3
Grind or replace if
Joining surface of valve
severely pitted on
stem and rocker arm
tip of rocker arm
bush
and stem
Clearance between
Replace bush
rocker arm shaft & 0.020-0.093 0.25
or shaft
rocker arm bush
Diameter of rocker arm ¢23.939-
shaft for wear ¢23.96 ¢23 75 Replace
Run-out of push rod - 0.3 Replace
- 178-
Stand value Limit
Clearance between 0.035- 0.077 0.1 Replace tappet

tappet .~ cyl. block
Valve Diameter of tappet y\19.944 ~ ¢19.965 19.89 Replace tappet
Tappet
system Replace
Tappet face in contact
with cam - - if severely worn or
deformed
Oil pressure Check oil leakage

2
4.8 or less 3.5 and clearance
Oil (normal speed)kg/cm
between each part
pressure
Oil pressure Use recommended
0.8-1.4 0.6
(idling)kg/cm 2 oil
Max. permissible Must not exceed this
- 105
Oil oil temperatureoC valve
tempera Permissible
ture oil temperature - 120
in short timeoC
Axial play Replace gear

of oil pump gear
0.055- 0.105 -
or cover
Clearance between
drive gear shaft & 0.032 - 0.077 -
oil pump cover hole
Clearance between Replace bush

drive gP.ar shaft and 0.040 - 0.09-<1 - or cover
Lubricat cover hole
Oil
ing
pump Diameter of gear shaft y\16.950- ¢16.968 ¢ Replace gear shaft ¢ 17e7
system
Diameter of driving gear ¢
yl 28.000 ~ ¢ 28.033 Replace bush ¢28e7
bush
Between crank
gear & idle 0.15- 0.25 0.8
gear
Backlash Adjust back-lash
Between oil
pump drive 0.15- 0.25 0.8
gear & idle gear
Oil pressure control

4.0 + 0.8 0.8
valve (kg/cm 2 )
By-pass valve for filter 1.8- 2.3 Replace valve

0.8
element (kg/cm 2 )
Valve By-pass valve for full oil
-
opening filter (kg/cm 2 )
pressure Relief valve for oil
10 ± 1.5
pump (kg/cm 2 )
Replace valve
Spray nozzle control
1.5-2.0
valve (kg/cm 2 )
Oil Damage of oil filter
Clean or replace
filter cartridge
- 179-
Stand value Limit
Heat exchanger &
water purnp for
corrosion, damage & Correct or replace
improper connecting
Heat
Exchang Test for leakage Submerge in water
(air pressure) (kg/cm 2 ) 3.0 and replace if air
er bubbles found
Pressure valve for

opening pressure 0.9
(kg/cm 2 )
Delivery volume 1/min

- Engine speed 2,300rpm
Check the water
- Water t~mp.85 ·c 260 Lit/min For any restrictions
- Back pressure : passage
0.5 kg/cm 2
Cooling
system Water Clearance between Replace if impeller
impeller & housing 0.35 & housing are intact
pump
Perpendicularity of Adjust by a bench
pulley 0.3 press
Fan belt depression
10- 15 15 Adjust
(with thumb)
Operating temperature Must not exceed this

Cooling 85 95
water
(permissible temp) ·c valve
temp Permissible temperature

in a short time. 'C
103 -
Thermostat
opening temp. ·c 71 Replace
Thermostat (under atmospheric pressure)
Replace if defective
Full opening temp. ·c 85
stroke min. 8mm
Fuel pipe, injection pipe
Piping & nozzle holder for Repair or replace
damage, cracks,
&
improper packing, etc.
others
Fu~fi~ercartridgefur
Replace cartridge
Fuel damage or dimple
system Injection pressure of injection
220 Adjust by shim 1st :160, 2nd : 220
nozzle (kg/cm 2 )
Operating pressure of overflow Replace valve
1.0- 1.5
valve (kg/cm 2 )
Projection height of nozzle from Replace cyl. head &
3.6-4.1
the cyl. head surfac;e(mm) nozzle
Refer to supplement
Running-in the engine
"running-in"
Inspection Compression pressure of 24 or
24-28 Correct
at Cylinder cylinder (l<g/cm 2 ) more
at 200rpm or more
completion pressure Compression pressure ±10% or less
more(20 'C)
difference of each against average Correct
cylinder
- 180-
GPC
www.gpckorea.com
#217 Jinsan-daero,
Tel : 82-55-343-9870
Jinyeong-eup, Gimhae,
Fax : 82-55-343-9875
Gyeongnam, Korea
E-mail :gpc@korea.com
USER'S MANUAL
DIESEL GENERATOR ENGINE

CONTROL & MONITORING SYSTEM
Model : ECMS 850 EH
1 I 14
GPC
www.gpckorea.com
#217 Jinsan-daero,
Tel : 82-55-343-9870
Fax : 82-55-343-9875
Gyeongnam, Korea
Contents
1. Documents and revision.
2. Introduction ofECMS 850 EH.
3. Technical specification
4. Functions.
5. Alarms and Trouble shouting.
6. Safety device.
7. Common Operation
2 I 14
#217 Jinsan-daero, Jinyeong-eup, Gimhae, Gyeongnam, Korea
www.gpckorea.com Tel : 82-55-343-9870 Fax : 82-55-343-9875 E-mail :gpc@korea.com
1. Documents and revision
File Name ENGINE CONTROL & MONITORING SYSTEM.

ECMS 850 EH User's manual.
Documents No. KMC-D-1 001/0001.
Revision date Update, remarks Relation documents
2010-05-10 Created
3/14
GPC
www.gpckorea.com
#217 Jinsan-daero,
Tel : 82-55-343-9870
Fax : 82-55-343-9875
Gyeongnam, Korea
2. Introduction of ECMS 850 EH.

ECMS 850 EH is a controller for generator engines for marine and land use.
This controller is easy to operate and maintain and composed of the following
components and used for the following marine systems.
Components
ECMS 850 EH (Main unit)
Safety Device (ECM 850 EH-SD)
Relay Block.(RB-3)
Interface Board (TBJ 2215 )
Magnetic Pick Up Sensors. (KMC-MPU 3/4 16 UNF, MPU 5/8 18 UNF.)
Applications (Generator engines)
Auxiliary engines.
Emergency and harbor engines.
Emergency engines
4 I 14
GPC
www.gpckorea.com
#217 Jinsan-daero,
Tel : 82-55-343-9870
Fax : 82-55-343-9875
Gyeongnam, Korea
3. Technical specification.
1) ECMS 850EH (Main unit.)
Dimensions 245(W) X 197(H) X 60(D) mm

Protection Front : IP55, Rear : IP 10
Power Supply DC24V
Power Consumption 24W
Ambient Temperature 0 ~ 60degreeC
Storage Temperature -5 ~ 60degreeC
Air Humidity 90%
Output relay rating DC24V3A
2) SAFETY DEVICE
Dimensions 160(W) X l20(H) X 37(D) mm

Protection Front: IP55, Back: IPlO
Power Supply DC24V
Power Consumption lOW
Air Humidity 90%
Output relay rating DC24V3A
3) RELAY BLOCK
Dimensions lOO(W) X 55(H) X 37(D) mm

Power Supply DC24V
Power Consumption 5W
Air Humidity 90%
Output relay rating DC24V 3A
5/14
GPC
www.gpckorea.com
#217 .-Jinsan-daero,
Tel : 82-55-343-9870
Fax : 82-55-343-9875
Gyeongnam, Korea
4) INTERFACE BOARD
Dimensions 200(W) X 130(H) mm

Terminal Block Rating DC24V3A
5) MAGNETIC PICK UP
Model KMC MPU 3/4 16 UNF

Material SUS303
Fitting Unit 3/4 16 UNF
Model KMC MPU 5/8 18 UNF

Material SUS303
Fitting Unit 5/8 18 UNF
6/14
GPC
www.gpckorea.com
#217 Jinsan-daero,
Tel : 82-55-343-9870
Fax : 82-55-343-9875
Gyeongnam, Korea
4. Functions
1) Operating buttons and function.
Manual Engine can be manually operated by start I stop button

on the front side of the panel. Engine follows "Three(3) starting
attemption procedures" after start button is pushed.
During manual mode, the engine can be operated by only
start I stop button on control panel
2 Auto Engine can be controlled by start I stop signals from the outside
(ex. ESB panel siginals)
3 Start It is a command switch for engine start
4 Stop It is a command switch for engine stop
5 Lamp, Bell test It is a button to test indication LED lamp,

Bell and LCD back light
7/14
GPC
www.gpckorea.com
#217 Jinsan-daero,
Tel : 82-55-343-9870
Fax : 82-55-343-9875
Gyeongnam, Korea
6 Reset It is a button to release the alarm from sounding.

Its command becomes valid when the button is pressed
after confirming the alarm by pressing bell stop button
7 Bell Stop It is a button to stop the bell sounding and it also functions
as an "alarm acknowledge" by operator at the same time
8 Unit select It is used to select the unit of temperature and pressure.

In case of temperature, oc or oF can be selected.
In case of pressure, bar or psi or kPa or kgf/cm 2 can be selected.
9 Up, Down Select up and down
10 LCD Engine status and alarm, trip monitoring

(Information ECMS 850 EH can monitor the following engine condition
Monitor)
D.C Volatage
Engine R.P.M
Cooling Fresh Water Temperature
Lubricating Oil Temperature
Lubricating Oil Pressure
Cooling fresh Water Pressure
Occurred Alarms
Incase of alarm, alarm indication LED lamp turns on

and alarm is displayed on the LCD with alarm cursor
at the same time.
When alarm is confirmed by bell stop button,
the user should check the cause of alarm.
Alarm LED lamp and alarm cursor is cleared by reset(Button 6)
* Back light on-off control

The back-light on the LCD automatically light off
if no operation for three minutes.
In order to switch on the back light, press lamp bell test button
or up-down button.
8/14
GPC
www.gpckorea.com
#217 Jinsan-daero,
Tel : 82-55-343-9870
Fax : 82-55-343-9875
Gyeongnam, Korea
2)LEDLamps
11 Power It is on when power is applied for control panel
12 Manual mode It is on when manual mode is selected
13 Auto mode & It is on when auto mode is elected and

Start st-by It is off when engine starts to run
14 * Harbour mode It is applied when generator is used for both emergency function
And harbor mode function
15 Running It is on when engine RPM reaches at running set point
16 Alarm In case of alarm, it is on. it is off when alarm is released.
17 Shutdown It is on in case of trip( shutdown) conditions.

(trip) And it is off when trip(shutdown) is released.
9/14
GPC
www.gpckorea.com
#217 Jinsan-daero,
Tel : 82-55-343-9870
Fax : 82-55-343-9875
Gyeongnam, Korea
5. Alarms and Trouble shouting

1) MODEL: ECMS 850 EH- Main unit.
Alarm Alarm Description Trouble Shooting
Check engine fuel system

and mechanical components.
It is on when engine rpm reaches
OVER SPEED TRIP This should be checked by maker's
at the over-speed set points.
engineer or equivalently qualified
engineers.
It is on when engine lubricant
LUBRICATING OIL Check engine lubricant system
pressure is lower than
LOW PRESS ALARM. and lubricant level.
the set point (alarm).
LUBRICATING OIL
It is on when lubricant pressure is Check engine lubricant system
LOW PRESSURE
lower than the set point (trip). and lubricant level.
TRIP(Shutdown)
It is on when engine cooling water

COOLING FRESH WATER Check engine cooling water system
pressure is lower than the set point
LOW PRESSURE ALARM. and cooling water level.
(alarm).
COOLING FRESH WATER It is on when engine cooling water

Check engine cooling water system
HIGH TEMPERATURE temperature is higher than
and cooling water level
ALARM. the set point (alarm).
COOLING FRESH WATER It is on when engine cooling water
Check engine cooling water system
HIGH TEMPERAURE temperature is higher
and cooling water level
TRIP( SHUTDOWN) than the set point (trip).
LUBRICATING OIL It is on when engine lubricant

Check engine lubricant system
HIGH TEMPERATURE temperature is above the set point
and lubricant level.
ALARM. (alarm).
This alarm is connected to all
alarms ofECMS 850 EH
and its output is relay contractor
"CPU ERROR" ofECMS 850 EH
signal.
can be confirmed by flickering
COMMON ABNORMAL Particularly when main cpu error
of indication LED In this case,
ALARM. ofECMS 850 EH occurs,
contact to maker to take proper
back up CPU operates and
actions.
transmitters conditions of
ECMS 850 EH to other alarm
monitoring system.
FUEL OIL VALVE It is on when F.O. valve control Check the connection conditions of
CIRCUIT FAIL. ALARM. circuit (terminal No. Yl) fails. terminal No. Yl ofECMS 850 EH.
Check emergency stop circuit.
EMERGENCY STOP
It is on when emergency stop The resistance of2W 20k0 should
CIRCUIT
circuit fails. be connected in parallel
FAIL ALARM.
to the emergency stop switch.
10/14
GPC
www.gpckorea.com
#217 Jinsan-daero,
Tel : 82-55-343-9870
Fax : 82-55-343-9875
Gyeongnam, Korea
Alarm Alarm Description Trouble Shooting
PICK UP SENSOR It is on when magnet pick up Check magnet pick up sensor

FAIL ALARM sensor fails. condition and signal line.
It is on when engine rpm reaches Check engine fuel system

ENGINE LOW RPM.
at low rpm point. and mechanical components.
LUBRICATING OIL It is on when transmitter for LO Check transmitter conditions
PRESSURE SENSOR FAIL .. LOW PRESS. ALARM fails. and transmitter signal lines.
It is on when transmitter for
COOLING FRESH WATER Check transmitter conditions
Cooling Fresh Water Low pressure
PRESSURE SENSOR FAIL. and transmitter signal lines.
alarm fails
LUBRICATING OIL
It is on when transmitter for Check transmitter conditions
PRESSURE TRIP(Shutdown)
Lubricating. Oil Low Pressure fail.. and transmitter signal lines.
SENSOR FAIL.
COOLING FRESH WATER

It is on when PT I 00 OHM sensor Check PT 100 OHM sensor
TEMPERATURE
for C.F.W. HIGH TEMP.fails. and PT I 00 OHM sensor lines.
SENSOR FAIL.
COOLING FRESH WATER It is on when PT 100 OHM sensor

Check PT 100 OHM sensor
TRIP( Shutdown) for Cooling fresh water
and PT 100 OHM sensor lines
SENSOR FAIL. HIGH TEMP. fails. (TRIP sensor)
Restart after checking engine
When the engine does not run after
START FAIL. fuel system and
the final start attempts.
mechanical components.
The "CPU ERROR" of
ECMS 850 EH can be confirmed
It is on when CPU error of
CPU ERROR. by flickering of indication LED.
ECMS 850 EH occurs.
In this case, contact to maker
to take proper actions.
It is on when battery low volt and

BATTERY Battery over volt of battery.
Check the battery and A.C. power
CHARGER FAIL. Or it is on when A.C. power
( 11 OV or 220V ) cut off.
BATTERY CHARGING It is on when battery charging

Check the battery charger fuse.
CIRCUIT ERROR. Circuit error of battery charger.
11 /14
GPC
www.gpckorea.corn
#2I7 Jinsan-daero,
Tel : 82-55-343-9870
Fax : 82-55-343-9875
Gyeongnam, Korea
2) Digital input channels.
Channel. Channel remarks. Function name.

DI I. (72, 73) Digital input channel I. • Function name is fixed according to purchase order.
DI 2. (72,74) Digital input channel 2. • Function name is fixed according to purchase order.
DI 5. (72,77) Digital input channelS. • Function name is fixed according to purchase order.
DI 6. (72, 78) Digital input channel 6. • Function name is fixed according to purchase order.
D1 7. (72, 79) Digital input channel 7. • Function name is fixed according to purchase order.
D1 8. (72,80) Digital input channel 8. • Function name is fixed according to purchase order.
DI 9. (72,8I) Digital input channel 9. • Function name is fixed according to purchase order.
DI I 0. (72,82) Digital input channel IO. • Function name is fixed according to purchase order.
3) Interface relays.
Relay Control device.
KI CONTROL POWER.
K2 MANUAL MODE.
K3 AUTO MODE.
K4 AUTO START STAND BY.
K5 RUNNING.
K6 PARALLELING.
K7 OVER SPEED TRIP.
K8 STOP.
K9 START FAIL.
KlO COMMON ABNORMALALARM(CPU ERROR.)
Kll AUXILIARY START.
Kl2 SPARE.
Kl3 SPARE.
Kl4 SPARE.
Kl5 SPARE.
12/14
#217 Jinsan-daero, Jinyeong-eup, Gimhae, Gyeongnam, Korea
www.gpckorea.com Tel : 82-55-343-9870 Fax : 82-55-343-9875 E-mail :gpc@korea.com
6. Safety Device
1) LED Lamps
Power It is on when control power is input
Running It is on when engine R.P.M reaches at running set point
Trip(shutdown) It is on when trip condition occurs
Pic-up Sensor Fail It is on when magnetic pick-up sensor fails
F.O.Valve It is on when Fuel Oil valve circuit fails(Flicker)
DI 1. with line fault monitoring.

It is on when the input switch of digital input channel 1 is on. (action)
It flickers when the input circuit of digital input channel 1 fails. (flicker)
DI 2. With line fault monitoring.

It is on when the input switch of digital input channel2 is on. (action)
It flickers when the input circuit of digital input channel2 fails. (flicker)

It flickers when the input circuit of digital input channel3 fails. (flicker)

It flickers when the input circuit of digital input channel 4 fails. (flicker)
Note
Function names for input channels DI 1, DI 2, DI 3, and DI4 are fixed according purchase order.
2W 1OK ohm resistance should be connected with parallel connection to the input switch.
13/14
GPC
www.gpckorea.com
#217 Jinsan-daero,
Tel : 82-55-343-9870
Fax : 82-55-343-9875
Gyeongnam, Korea
7. Common operation
1. Control panel should be grounded in a cable of 1.5SQ or higher.
2. Command shall be executed when all buttons for control ofECMS 850 EH are kept pressed
for more than 1.5 seconds.
3. In case of manual mode, the function of Start and Stop is executed using Start and Stop
buttons. However the functions of Remote Start and Remote Stop signals are ignored.
4. If not operated for 3 minutes, the back light automatically turns off.
It also automatically turns on when any alarm occurs. In order to tum it on manually, press
lamp & bell test button, up button, or down button.
5. In case of reset of"START FAIL", press Stop button, Bell stop, and Reset button in
sequence for safe operation.
6. The engine used time is displayed every 1/10 hour (6 minutes) and the accumulated time is
automatically displayed when the engine stops (Stop, Emergency stop or trip).
The engine shall stop according to normal procedure. The power of control panel shall not
be turned off during operation.
7. When the power of control panel is turned off using power switch, tum on the power
after 3 seconds for safe operation.
8. REMOTE START TIME ADJUST

Press CONTROL PANEL POWER OFF and RESET button. CONTROL PANEL POWER
ON and "ECMS 850 EH SETTING" MODE are displayed while Reset button is kept pressed.
Select the setting menu between Remote start time and Delay stop using Unit Select button.
Set the value using ""UP"" or ""DOWN"" button. If the setting is completed, press ""Manual""
button and ""Auto"" button at the same time to complete setting.
In case when setting is not required in ""ECMS 850 EH setting"" mode, press ""Bell stop'"'
button to directly go to Running mode.
9. Delay stop
When stopping the engine after cooling time, it is possible to set the setting time in
"ECMS 850 EH SETTING" mode. The continuous signal mode shall be applied.
10. UNIT SELECT.

Select the temperature unit using 'UP"" button while keeping Unit Select button pressed.
Select the pressure unit using ""DOWN"" button while keeping Unit Select button pressed.
When the power of control panel is turned off, the temperature unit becomes oc and the
pressure unit becomes bar.
In case of changing the units, reset the unit as you like.
11. When checking internal circuit ofthe control panel and changing parts,
be sure that the power is turned off and other devices around the panel are kept safe.
<end>
14/14
GPC
www.gpckorea.com
#217 Jinsan-daero,
Tel : 82-55-343-9870
Fax : 82-55-343-9875
Gyeongnam, Korea
USER'S MANUAL
Automatic Battery Charger
Model : BCSMP-240
1/7
GPC
www.gpckorea.com
#217 Jinsan-daero,
Tel : 82-55-343-9870
Fax : 82-55-343-9875
Gyeongnam, Korea
Contents
1. Charging capacity and configuration.
2. Main functions.
3. Display dimensions.
4. Button functions.
5. System setting.
6. Alarms and Trouble shouting.
2/7
GPC
www.gpckorea.com
#217 Jinsan-daero,
Tel : 82-55-343-9870
Fax : 82-55-343-9875
Gyeongnam, Korea
AUTOMATIC BATTERY CHARGER MANUAL

(MODEL : BCSMP-240)
1. CHARGING CAPACITY AND CONFIGURATION.

-INPUT VOLTAGE: ACIOOV~240V. 50/60Hz
-OUTPUT VOLTAGE : DC24V
-CHARGING CURRENTS : IOA(max)
-CONFIGURATION : SMPS PART and DISPLAY PART
SMPS PART DISPLAY PART
<Fig 1. Configuration>
3/7
GPC
www.gpckorea.com
#217 Jinsan-daero,
Tel : 82-55-343-9870
Fax : 82-55-343-9875
Gyeongnam, Korea
2. MAIN FUCTIONS
1) DISPLAY MAIN FUNCTION.
- SELECTION CHARGING MODE (FLOAT/EQUAL).
-INDICATION BATTERY LOW. VOLT.
-INDICATION OVER VOLT.
- AUTOMETIC DETECTION CHARGINE CIRCUIT FAIL AND BATTERY BROKEN.
-LAMP TEST BUTTON.
- CHARGINE VOLTAGE AND CHARGING CURRENT, REAL TIME DISPLAY.
2) SMPS MAIN FUCTION.

-OVER VOLTAGE PROTECTION.
-OVER CURRENT PROTECTION.
-MISS CONNECTION PROTECTION (CIRCUIT ERROR).
-OVER TEMPERATURE PROTECTION.
3. DISPLAY DESIGNATION
CHARGING AMP. OUTPUT VOLT.
FLOAT CHARGING MODE.
'---'WLAMP TEST & SYSTEM

SETTING BUTTON
<Fig2. Dispalay Designation>
4/7
GPC
www.gpckorea.com
#217 Jinsan-daero,
Tel : 82-55-343-9870
Fax : 82-55-343-9875
Gyeongnam, Korea
4. BUTTON FUNCTION
G) POWER ON/OFF BUTTON.
- ON : PUSH 1SEC.
- OFF : POWER OFF.
®CHARGING MODE SELECTION SWITCH.
-FIRST TIME POWER ON : FLOAT CHARGING MODE
-PUSH CHARGING MODE BUTTON :FLOAT MODE-> EQUAL MODE.
-ONCE THE SET CHARGING TIME, RETURN TO FLOAT MODE FROM EQUAL MODE.
@LAMP TEST & SYSTEM SETTING BUTTON.
-LAMP TEST :ALL LAMP ON CONDITION.
- SYSTEM SETTING : @BUTTON+ @BUTTON.
(PLEASE REFER TO 5. SYSTEM SETTING ).
© BATT.LOW VOLT. I @BATT. OVER VOLT.
-ON : OVER OR BELOW THE BATTERY VOLTAGE SETTING VALUE(ON) ..
-OFF :NORMAL VOLTAGE RANGE(OFF).
@BATTERY & CIRCUIT FAIL DETECTION.
-ON: !.DETECTED BATTERY CONNECTION FAIL AND CHARGING CIRCUIT FAIL.
2.STOP THE CHARGING FUNCTION.
-OFF: 1. REPAIRED THE PROBLEM.
2. POWER OFF AFTER THAN POWER ON.
5/7
'GPC
www.gpckorea.com
#217 Jinsan-daero,
Tel : 82-55-343-9870
Fax : 82-55-343-9875
Gyeongnam, Korea
5. SYSTEM SETTING
SYSTEM SETTING MODE ON :BUTTON (3) +BUTTON (2)
SYSTEM SETTING MODE OFF : BUTTON (3) + BUTTON (2)
I) LOW VOLT . SETTING MODE.

-INDICATED "Lo_" ON D.C VOLT(4).
-MARKED SETTING VALUE ON D.C AMP(5).
- SETTING : PUSH CHARGING MODE(2)
(1) 21.5V (2) 22.5V (3) 23.5V (4) 24.0V
-NEXT SETTING MODE :PUSH LAMP(3) TEST BUTTON.
2) OVER VOLT. SETTING MODE.

-INDICATED "HI_" ON D.C VOLT(4).
-MARKED SETTING VALUE ON D.C AMP(5).
- SETTING : PUSH CHARGING MODE(2)
(1) 28V (2) 29V (3)30V (4)31V
-NEXT SETTING MODE : PUSH LAMP(3) TEST BUTTON.
6/7
:GPC
www.gpckorea.com
#217 Jinsan-daero,
Tel : 82-55-343-9870
Fax : 82-55-343-9875
Gyeongnam, Korea
3) EQUAL. CHARGING TIME SETTING MODE.

-INDICATED "Equ" ON D.C AMP(4).
-MARKED SETTING VALUE ON D.C AMP(S).
-SETTING: PUSH CHARGING MODE(2) BUTTON.
(1) 30 MIN. (2) 60 MIN. (3) 90MIN (4) 120 MIN.
-NEXT SETTING MODE :PUSH LAMP TEST BUTTON.
4) CUT OUT (SETTING RECOVERY TIME AFTER CHARGING CUT OFF)

-INDICATED "Cut" ON D.C VOLT(4).
-MARKED SETTING VALUE ON D.C AMP(S)
- SETTING : PUSH CHARGING MODE BUTTON(2)
(1) !Osee. (2) 20sec. (3) 30sec (4) 60sec
-NEXT SETTING MODE : PUSH LAMP TEST BUTTON(3).
6. Alarms and Trouble shouting
Alarm Alarm remarks. Trouble shouting
It is on when battery low volt

Battery Low Volatage
and Battery over volt of battery. Check the battery
Or it is on when A.C. power and A. C. power
Battery Over Voltage
BATTERY ( llOV or 220V) cut off.
CHARGER
FAIL. Check the battery
Battery Charging It is on when battery charging charger fuse &
Circuit Error circuit error of battery charger. battery charging
line.
717
GPC
www.gpckorea.com
#217 Jinsandaero, Jinyeong-eup, Gimhae-city,
Tel : 82-55-343-9870 Fax : 82-55-343-9875
Gyeongnam, Korea
EMERGENCY GENERATOR CONTROL PANEL
PARTS LIST
MODEL NAME : ECMS850EH
Page 1/5
GPC
www.gpckorea.com
Tel : 82-55-343-9870 Fax : 82-55-343-9875
Gyeongnam, Korea
FRONT VIEW
ENCLOSU R~ c. . .. ·.·.·. • .. STEE:L380><460><200 ..

\L:,~~:~:~;,;~,- .·, ::::::·:::.:··<~ ~::.~ :·(?:~~::: . .:- .: . ·.·.·. .·.·.. ·.< .···>:->>:<::.·>:::-/:;:<.:::::~;::::::~:..: : :-:;. :::::<->·-<·. .·..
··· ':<MAlNUNIT. Vi ,~, !· .LscMs~sb-sH< .> : <···
. ></"« " : \ ";;.< ""·.·;.-..
:··· :..;;:· >·.:-: .
~.,::.-~:.:~!(\)A/\)?.<:.:-.>~~ . ·_)> · ::;:::-··. :_::;:·::::>>·< ·..:L·.·. ~:.~
.<·>;:;:>:-,::::~:· .
. :·<.: ... ··.:. ··:· ... > .·'
4 .~§~&t~N6Y!~id~§~t~H .· · · · AR~F5Lt
s•····· . • ·qq~~BQPfQVY~RSW!T¢8/c~
:'·: . ': :.:.:.:::::::-::: .. :;:.. ·.. : :-;·:::: :- ·:·: :.:;~ .<
.
.n·: AR22PR~2.·
··:::-~· ·.• ·.·
Page 2/5
GPC
www.gpckorea.com
Tel : 82-55-343-9870 Fax : 82-55-343-9875
Gyeongnam, Korea
INNER VIEW
Page 3/5
GPC
www.gpckorea.com
Tel : 82-55-343-9870 Fax : 82-55-343-9875
Gyeongnam, Korea
ACCESSORIES
Page 4/5
GPC
www.gpckorea.com
Tel : 82-55-343-9870 Fax : 82-55-343-9875
Gyeongnam, Korea
ACCESSORIES
,,,, ·····~ ·····
IEMPERATURE:SENSOR·
•.>
"""-'. ,. -: .· .·.·.~.: '
········tu13Rrc.t\1aoNP~~§UR~
··.· ..· ·:······:: ;./ ··:.-·-:· ·<
§~t.Jg()R~ } 26P rg4_;g~A <z.·
. <.·: . .. <:
~· ,.;~ <<:< ·.·•• ::. . •. :
'' •,< :;:;.~ fC c, ):·~:);..· .. >. :::·/> <:·.·~}:::·:; ''•, ;H,,, ,•,•.· < •'•. \:~~;>'; :·.···.: :. ~;
·········~A~N~-f~~·PIQK-uP•··~ENSOR ·.· •· • •·• ·• • •· ··········kMd~~PU···~~~····1:a•··UNF···I·••••······ .• • • ;•.

: >> / .... . ,•' · · · ..·. . . ·..·.·•·•·• · •· ·• •· ' i
. M~d~6ileP1cK-u~~EN~b~?;· >KMC-~Ptl3!41s~r-.M · '
Page 5/5

M-52 Emergency Generator Set (Incl. Instruction Book)

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

M-52 Emergency Generator Set (Incl. Instruction Book)

Uploaded by

Copyright:

Available Formats

FINISHED

ORA WING TYPE FOR FINAL

5 2017-05-17 Final Drawing ;u- ~

APPROVED BY S.K. Woo ~ GPC Co.,Ltd.

1.General Specification GOO

2.Gen-Set Specification G10

3.Engine Specification & Drawings D10

4.Aiternator Specification & Drawings. A10

5.Eiectric System Drawings. E10

6.Tool & Spare part

1. General Specifica ion

3L language and Utrtlt.

Recommended Fuel Oil Specification

Density at 15°C kg /m' ISO 3675 max. 2) 890.0 890

3) min. 1.40 2.00 3.00

Pour point (upper), oc d)

Winter quality ISO 3016 max. - -6 -6

Cloud point, oc ISO 3015 max. -1 6

Ash , %(m/m) ISO 6245 max. 0.01 0.01 0.01

Sediment, %(m/m) ISO 3735 max. - - 0.07

Total Existent Sediment, %(m/m) ISO 10307-1 max. - - -

Sulfur, %(m/m) ISO 8754 max. 1.0 1.5 1.5

Vanadium , mg/ kg ISO 14597 max. - - -

Recommended Lub. Oil Specification

SAE Grade Ambient Temperature

10W-30 -30oc to 30°C

10W -30°C to ooc

3. Lube Oil Chart

4. Recommended Lu~· O"I for Manufactures & Brand

Mutti Viscosity RPM DELO V1 15iW-40

EXXON Mi.ttti Viscosity DELVAC MX 15\N-40

Single Viscosity RIMULA OIL 30

VANELLUS C6 GLOBAL [ 15\111-40

CASTRO L Multi Viscosity TECTION GLOVAL 15W-40

SO 5000 GOLD or 10W-40

ulti Viscosity RUBIA 6800 15W40 1'5-W-40

Single Vi scosity RUBIA 30 30

Recommended Cpolant Specification

Calcium and Magnesium(Hardness) Maximum 170 ppm as (CaC03 +MgC03)

Water : Antifreeze Freezing Point( "C) Boiling Point("C)

- Rated Out-put 188 PS (138kW)

3. Dimension & Weight

AUTO CONTROL PANEL

$1\ 321 _!S

~!iiM!<I Y . (( CTR!\0 :HA!tT~R

SUBJECT : OVERHAULING PROCEDURE FOR PISTON

1. RE MOVING ROCKER LEVER HOUSING .

2. REMOVING CYLINDER COVER

3. REMOVING OIL PAN FROM ENGINE.

4. REMOVE BOLTS OF CONNECTING ROD.

5. PUSH UP A PISTON & CON-ROD ASS'Y IN THE BELOW ENGINE

I"'S"TON COr<NECflNC ~. (4 .::ht9)

Description Q'ty/Eng Remark

l1 ~. 2 SAE #1 Flywheel Housing 1

~. 1 Common Bed & Mounting for Engine, 1

p. 2 Vibration Isolator and Mounting Hard-wares 4

l 5.2 Normal Duty Dry Type Air Cleaner with 1

G'· ~ ooling System

~.1 Water Pump 1

6.5 Cooling Fan & Fan Drive Arrangement 1

~.2 Lube Oil Cooler 1

~.3 Lube Oil Filter 1

~.7 L.O Drain Flex. Hose 1

8. Fuel & Governing System

f-~!! 470 625 2,077 1,948