DIESEL ENGINE

WORKSHOP MANUAL
 preFaCe
This manual is to provide servicing personnel with information on the general speci-
fications, service, operating principle, troubleshooting, exploded view including part
name, removing and installing procedures for DIESEL ENGINES with high-end tech-
nology.

All information in this manual is based on the latest product information available at
the time of publication. Therefore, some of the information in this manual may differ
from the machine you have.

DAEDONG has a principle to apply update to the next edition of the manual if there is
any. However, DAEDONG has no obligation to modify the contents in this manual, es-
pecially the contents in the manual which is already distributed or published.

The modified information is available in DAEDONG`s online electronic manual system

(DEMSS).

This manual is ultimately to satisfy customers with best performance of engine. If

there is any typo, wrong information or question for this manual, feel free to contact
DAEDONG.

Nov. 2016
service division
DAEDONG INDUSTRIAL Co., Ltd.

Important Remark
• Using unspecified parts, fuel and lubricants other • We reserve the right to make changes throughout
than DAEDONG's genuine parts can damage the the entire manual at any time without notice.
engine and such damage will not be covered by
warranty.
TABLE OF CONTENTS

Chapter 1 SaFetY FIrSt

1. For SaFetY .......................................... 1- 2.6 Cautions for high pressure hoses...................1-5
1.1 Alert symbols............................................. 1-2 2.7 Use of appropriate tools and equipment.... 1-6
2.8 Handling of hazardous materials............... 1-6
. SaFetY tIpS.......................................... 1-3
2.9 Lifting/Transportation................................. 1-6
2.1 Safety gear................................................ 1-3 2.10 Handling of rotating blade,
2.2 Work place . .............................................. 1-3 shaft and driving belt..................................1-7
2.3 Safety instructions when preparing machine....1-4 2.11 Prevention of scald.....................................1-7
2.4 Avoid fires.................................................. 1-4 2.12 Disposal of environmental waste................1-7
2.5 Cautions when handling the battery.......... 1-5

Chapter  GeneraL

1. term DeFInItIon ................................. - . maIntenanCe .................................... -

1.1 Engine dimension ..................................... 2-2 6. tIGhtenInG torqUe ......................... -3
1.2 Dry weight (kg) .......................................... 2-2
6.1 General use screws, bolts and nuts ....... 2-43
1.3 Revolutions per minute ............................. 2-2
6.2 Stud Bolts ............................................... 2-43
1.4 Output ....................................................... 2-2
6.3 American standard screws, bolts
1.5 Maximum torque ....................................... 2-2 and nuts with UNC or UNF threads ........ 2-44
1.6 Specific fuel consumption (g/kWh(HPh) ... 2-2
7. tIGhtenInG torqUeS For enGIne .. -
. enGIne DImenSIonS ........................... -3
7.1 A, B series .............................................. 2-45
3. SpeCIFICatIonS ................................... - 7.2 C series................................................... 2-46
3.1. General specifications .............................. 2-5 8. part nUmBer aSSIGnment StanDarD
3.2 Engine performance curve analysis ....... 2-23 For DaeDonG BoLtS anD nUtS ........... -7
. enGIne IDentIFICatIon ................... -39 8.1 Part Number Assignment
Standard for DAEDONG Bolts................ 2-47
4.1 Engine EPA decal(a) ............................... 2-39
8.2 Part Number Assignment
4.2 Bar code for engine number(B) .............. 2-39 Standard for DAEDONG Nuts ................ 2-48
4.3 Engine number assignment standard(C) 2-40
9. UnIt ConVerSIon taBLe ................. -9
4.4 Assignment standard for
engine model code ................................. 2-41
Chapter 3 operatInG prInCIpLe

1. BoDY anD poWer traIn SYStem ... 3- 4.6 Injection nozzle ........................................3-18
4.7 CTD pump (For turbo engine) ..................3-19
. LUBrICatInG SYStem ......................... 3-6
 GoVernor anD Stop SYStem ....... 3-0
2.1 Engine oil flow ........................................... 3-6
2.2 Engine oil flow chart ................................. 3-7 5.1 Basic principle of governor system ......... 3-20
2.3 Function of lubricating system .................. 3-8 5.2 Operation of Governor ............................ 3-21

3. CooLant FLoW roUte .....................3-11 6. pCV VaLVe ........................................... 3-

 FUeL SYStem .......................................3-1 7. operatIon oF tIner Cam............... 3-

4.1 Fuel flow route .........................................3-14 8. operatIon oF FaS reDUCtIon SYStem .. 3-3
4.2 Fuel filter ..................................................3-15
9. LImIter For FaS reDUCtIon SYStem .. 3-3
4.3 Bleeding the fuel system..........................3-15
4.4 Fuel feed pump ........................................3-15 10. tUrBo CharGer .............................. 3-
4.5 Fuel injection pump ................................. 3-16
11. eCU & SenSorS ............................... 3-

Chapter  SerVICInG

1. SerVICInG SpeCIFICatIonS .............. -3 3.22 Oil pump check ....................................... 4-57
1.1 A series engine ......................................... 4-3 3.23 Thermostat.............................................. 4-58
1.2 B series engine ......................................... 4-7 3.24 Opening temperature of thermostat valve .. 4-58
1.3 C series engine ........................................4-11 3.25 Water pump ............................................ 4-58

. meaSUrement anD aDJUStment .. -16 . enGIne Component DISaSSemBLY

anD aSSemBLY (C SerIeS) .............. -9
2.1 A, B series ..............................................4-16
4.1 Cylinder head.......................................... 4-59
2.2 C series................................................... 4-23
4.2 Cylinder head check ............................... 4-61
3. enGIne DISaSSemBLY anD 4.3 Fuel injection pump ................................. 4-62
InStaLLatIon (a, B SerIeS) ............ -8
4.4 Speed control lever plate
3.1 Head cover disassembly......................... 4-28 and governor spring ............................... 4-64
3.2 Glow plug and fuel overflow pipe............ 4-29 4.5 Fuel camshaft (gear case) ...................... 4-65
3.3 Heat seal removal ................................... 4-29 4.6 Valve camshaft ....................................... 4-67
3.4 Rocker arm assembly ............................. 4-30 4.7 Valve camshaft gear side clearance....... 4-67
3.5 Cylinder head.......................................... 4-32 4.8 Valve camshaft oil clearance measurement.. 4-68
3.6 Intake and exhaust valves ...................... 4-33 4.9 Valve camshaft deflection check ............ 4-68
3.7 Injection pump ........................................ 4-35 4.10 Valve cam height measurement ............. 4-68
3.8 Governor spring and stopsolenoid.......... 4-37 4.11 Flywheel deflection and
3.9 Gear case ............................................... 4-38 crankshaft end play check ...................... 4-69
3.10 Idle gear and crank gear ......................... 4-39 4.12 Idle gear shaft, oil pump and oil pan....... 4-69
3.11 Valve camshaft ....................................... 4-40 4.13 Timing gear ............................................. 4-70
3.12 Fuel camshaft ......................................... 4-40 4.14 Idle gear side clearance ..........................4-71
3.13 Crank gears and shafts check ................ 4-41 4.15 Idle gear oil clearance measurement ..... 4-72
3.14 Piston and connecting rod ...................... 4-44 4.16 Oil pump check ....................................... 4-72
3.15 Piston and connecting rod check............ 4-46 4.17 Piston, flywheel and crankshaft .............. 4-73
3.16 Piston ring measurement ........................ 4-48 4.18 Crankshaft check .................................... 4-77
3.17 Crankshaft and flywheel ......................... 4-49 4.19 Engine component disassembly and
3.18 Metal journal bearings ............................ 4-52 assembly ................................................ 4-79

3.19 Flywheel and crankshaft check .............. 4-53 . troUBLeShootInG .......................... -89
3.20 Cylinder bore check ................................ 4-56 5.1 A,B series ............................................... 4-89
3.21 Oil pump, oil filter, relief valve 5.2 C series................................................... 4-91
and oil strainer ........................................ 4-56
Chapter  eXpLoDeD VIeW

1. eXpLoDeD VIeW (a,B SerIeS) ........... - . eXpLoDeD VIeW (C SerIeS) ............. -1
1.1 E010 Cylinder block .................................. 5-2 2.1 E010 Cylinder block ................................ 5-24
1.2 E020 Oil pan ............................................. 5-3 2.2 E020 Oil pan ........................................... 5-25
1.3 E030 Cylinder head .................................. 5-4 2.3 E030 Cylinder head ................................ 5-26
1.4 E040 Gear case ........................................ 5-5 2.4 E040 Gear case ...................................... 5-27
1.5 E050 Main bearing case ........................... 5-6 2.5 E050 Main bearing case ......................... 5-28
1.6 E070 Turbo .............................................. 5-7 2.6 E080 Valve rocker arm ........................... 5-29
1.7 E075 Boost ............................................... 5-8 2.7 E090 Cylinder head cover ...................... 5-30
1.8 E080 Valve rocker arm ............................. 5-9 2.8 E100 Camshaft ....................................... 5-31
1.9 E090 Cylinder head cover ...................... 5-10 2.9 E110 Piston crankshaft ........................... 5-32
1.10 E100 Camshaft ........................................5-11 2.10 E120 Flywheel ........................................ 5-33
1.11 E110 Piston crankshaft ............................5-12 2.11 E130 Nozzle holder................................. 5-34
1.12 E120 Flywheel .........................................5-13 2.12 E140 Fuel camshaft ................................ 5-35
1.13 E130 Nozzle holder..................................5-14 2.13 E150 Speed control plate........................ 5-36
1.14 E140 Fuel camshaft .................................5-15 2.14 E160 Engine stop lever ........................... 5-37
1.15 E150 Speed control plate........................ 5-16 2.15 E170 Governor ........................................ 5-38
1.16 E160 Engine stop lever ............................5-17 2.16 E190 Coolant pipe .................................. 5-39
1.17 E170 Governor ........................................ 5-18 2.17 E200 Cooling fan .................................... 5-40
1.18 E180 Water pump ................................... 5-19 2.18 E220 Manifold ......................................... 5-41
1.19 E190 Coolant pipe .................................. 5-20 2.19 E250 ECU ............................................... 5-42
1.20 E200 Cooling fan .................................... 5-21
1.21 E220 Manifold ......................................... 5-22
1.22 E250 ECU ............................................... 5-23
 DIESEL ENGINE
SAFETY FIRST CHAPTER 1

TABLE OF CONTENTS
1. For SaFetY .......................................... 1-
1.1 Alert symbols............................................. 1-2
. SaFetY tIpS.......................................... 1-3
2.1 Safety gear................................................ 1-3
2.2 Work place . .............................................. 1-3
2.3 Safety instructions when preparing machine....1-4
2.4 Avoid fires.................................................. 1-4
2.5 Cautions when handling the battery.......... 1-5
2.6 Cautions for high pressure hoses...................1-5
2.7 Use of appropriate tools and equipment.... 1-6
2.8 Handling of hazardous materials............... 1-6
2.9 Lifting/Transportation................................. 1-6
2.10 Handling of rotating blade,
shaft and driving belt..................................1-7
2.11 Prevention of scald.....................................1-7
2.12 Disposal of environmental waste................1-7
 SAFETY FIRST - SAFETY TIPS DIESEL ENGINE

1. for SAFETY
• Most accidents can be avoided if basic safety in-
SAFETY FIRST

structions and regulations are followed. Always fol-

low the safety regulations and avoid any dangerous
situation to prevent an accident.
• You can be unexpectedly injured if inspecting or
servicing the engine without full knowledge of it.
Read the service manual carefully before starting
servicing and follow the instructions for servicing,
maintenance and inspection to prevent any injury.

매뉴얼
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manual!
GENERAL

DSEW001A

1.1 Alert symbols

In this manual, the following safety-alert symbols are
used. Their meanings are as follows:
OPERATING PRINCIPLE

▶ Remark ▶ CAUTION

Remark ⱇ#⪣
CAUTION
SERVICING

DSEW002A DSEW004A

• Broaden your knowledge with additionally supplied • This mark indicates potentially hazardous situation
service information for optimal service. which, if not observed, may result in serious injury.

▶ Important ▶ WARNING
EXPLODED VIEW

WARNING
DSEW003A DSEW005A

• This mark indicates emphasis on information which • This mark indicates hazardous situation which, if
INDEX

can be confused when servicing. If this information not observed, may result in death or injury.
is not carefully read and observed, the engine can-
not fully function or may be damaged.

1- D379-W00
DIESEL ENGINE SAFETY FIRST - SAFETY TIPS

2. Safety TIPS
2.1 Safety gear 2.2 Work place

SAFETY FIRST
DSEW007A

GENERAL
A. VENTILATING SYSTEM

DSEW006A The service should be performed in well-ventilated

area. If the engine should be started in an enclosed
When servicing the engine, wear safety gloves, safety
place, the exhaust gas pipe should be installed.
shoes, ear plugs, safety goggles, safety helmet, work-
ing clothes, etc. appropriate for your working environ- WARNING
ment. Never wear loose fitting clothing or a tie which

OPERATING PRINCIPLE
• California Proposition 65 Warning
can be caught to the rotating part. According to the
Inhaling exhaust gas can cause cancer or damage
statistics, most accidents that occurred with rotating
the generative function leading to infertility.
parts are due to this inappropriate manner of wearing
clothes.

B. Safe working place

SERVICING
DSEW008A

The work should be done in a wide, level and safe

place to prevent slip and fall accident.
EXPLODED VIEW

C. Illumination
The work place should be well illuminated. If working in
a dark place or under the engine, use the work lamp.
The work lamp should be covered by the safety cover.
The bulb can cause fire due to leaked fuel if it is broken.

D. Safety equipment
Be sure to keep a first aid kit and fire extinguisher han-
dy at all times.

E. Clean working area

Keep the working area clean before and during work. If
INDEX

any oil or fuel is spilled, it should be cleaned up immedi-

ately.

D379-W00 1-
 SAFETY FIRST - SAFETY TIPS DIESEL ENGINE

2.3 Safety instructions when 2.4 Avoid fires

preparing machine
SAFETY FIRST

DSEW011A

• Never smoke or allow flames in your work area

GENERAL

DSEW010A when servicing the fuel system.

• Stop the engine and remove the key.
• Put "Do not operate" label on the machine if neces-
sary.
OPERATING PRINCIPLE

DSEW012A

• Keep flames or sparks away from the spray paint or

DSEW013A fuel containers and be careful of leak.

• Always disconnect the battery cable before servicing.

• Always disconnect the battery cable before servicing
the wiring to prevent fire.
• Be extra cautious of fire when welding.
SERVICING

DSEW014A

• Always keep a fire extinguisher in workshop.

EXPLODED VIEW
INDEX

1- D379-W00
DIESEL ENGINE SAFETY FIRST - SAFETY TIPS

2.5 Cautions when handling the 2.6 Cautions for high pressure hoses
battery

SAFETY FIRST
DSEW015A

• Always disconnect the negative battery cable first and

GENERAL
reconnect it last to avoid sparks from an accidental DSEW019A

short circuit. You can get injured or fire may break out.
• The hydraulic fluid leaked from high pressure hoses
or pipes can penetrate your skin.

OPERATING PRINCIPLE
DSEW016A DSEW017A DSEW020A

• Do not charge the frozen battery. Charging the frozen • Before connecting a high pressure hose or pipe,
battery can cause explosion. Let the battery warmed up stop the engine and depressurize it by valve.
to ambient temperature (16°C, 60°F) before charging. Check the bolts for tightness before starting the en-

SERVICING
•
• Keep sparks and flames (match, lighter) away from the gine after servicing the hydraulic system.
battery. The battery can explode due to the battery fluid. • Use a cardboard or plank when checking leakage.
• Never connect the battery's negative and positive
cables with metal for test. Use only tester when
checking the battery voltage.

EXPLODED VIEW

DSEW018A DSEW021A

• The battery contains the acid that can burn you. When • Never weld the high pressure pipe or the surround-
INDEX

it contacts with your eyes, you may lose your sight. ing area. The pipe or hose can be heated and ex-
plode which can lead to fire or burn.

D379-W00 1-
 SAFETY FIRST - SAFETY TIPS DIESEL ENGINE

2.7 Use of appropriate tools and 2.8 Handling of hazardous

equipment materials
SAFETY FIRST

• Use the appropriate tools in proper size. If an inap- • Do not use pressurized air to blow out hazardous
propriate tool is used, it can be slipped which can materials, such as clutch dust, with compressed
damage parts or injure you. air. Inhaling such hazardous materials can damage
• Do not confuse units (mm, inch, etc.). your health.
• Use the air impact wrench only when unscrewing
the bolts or nuts. Such wrench should not be used Remark
when assembly precisely machined parts which its
• All DAEDONG's genuine parts contain no asbetos.
tightening torque should be strictly observed. It can
cause malfunction.
• Be careful of a socket popped out due to the turning • These materials should be rinsed or wiped away
GENERAL

force when using the air impact wrench. Especially, after spraying oil.
be extra cautious when working on connection or
socket with joint.

2.9 LIFTING/TRANSPORTATION
OPERATING PRINCIPLE

DSEW030A

DSEW027A
• When using a hydraulic jack or a hoist, do not use
SERVICING

it over the limit of the equipment and the conveying

belt.
• Only use the lift attachments to lift or transport the
• Make sure that the hydraulic lock operates properly engine.
before using the hydraulic jack. Improper use of
• Use caution when lifting or transporting the engine.
lock can cause a serious accident.
Lift attachment should be located that the lifting
• Check the buttons and operating direction of the ropes, chains or belts over the centre of gravity, if
hoist before using it. Improper operation can cause no cross beam is used.
a serious accident.
• Use a hoist after full understanding the operation
EXPLODED VIEW

method. Inexperienced operation may cause seri-

ous accidents.
INDEX

1- D379-W00
DIESEL ENGINE SAFETY FIRST - SAFETY TIPS

2.10 Handling of rotating blade,

shaft and driving belt

SAFETY FIRST
DSEW028A

GENERAL
DSEW025A
• Check the surface temperature of the container be-
• Be careful not to get caught by the rotating engine fore draining the engine oil, transmission fluid, cool-
cooling fan. ant, etc. If it is hot, let it cool down before draining it.
There is danger of burning.
• Perform any service on the engine parts (muffler,
exhaust manifold, turbocharger, etc.) only when

OPERATING PRINCIPLE
they are not hot.

2.12 Disposal of environmental

waste
DSEW026A

• You can be seriously injured if your hand or clothes

is caught by the rotating fan belt or A/C belt.

SERVICING
2.11 Prevention of scald

EXPLODED VIEW

DSEW029A

• Observe all relevant environmental protection regu-

lations when disposing used oil, transmission fluid,
coolant, oil filter, etc. Otherwise, they can pollute
the environment seriously and you can be charged
in violation of regulations.

DSEW027A

Do not open the radiator cap when the radiator is

INDEX

•
hot. Hot coolant or steam can be surged leading to
a serious scald.

D379-W00 1-
memo
 DIESEL ENGINE
GENERAL CHAPTER 2

TABLE OF CONTENTS
1. TErm DEFiNiTiON ................................. 2-2 . mAiNTENANCE .................................... 2-2
1.1 Engine dimension ..................................... 2-2 . TighTENiNg TOrquE ......................... 2-3
1.2 Dry weight (kg) .......................................... 2-2
6.1 General use screws, bolts and nuts ....... 2-43
1.3 revolutions per minute ............................. 2-2
6.2 Stud Bolts ............................................... 2-43
1.4 Output ....................................................... 2-2
6.3 American standard screws, bolts
1.5 Maximum torque ....................................... 2-2 and nuts with UNc or UNF threads ........ 2-44
1.6 Specific fuel consumption (g/kWh(Hph) ... 2-2
7. TighTENiNg TOrquES FOr ENgiNE .. 2-
2. ENgiNE DimENSiONS ........................... 2-3
7.1 A, B series .............................................. 2-45
3. SpECiFiCATiONS ................................... 2- 7.2 c series................................................... 2-46
3.1. General specifications .............................. 2-5 . pArT NumBEr ASSigNmENT STANDArD
3.2 Engine performance curve analysis ....... 2-23 FOr DAEDONg BOLTS AND NuTS ........... 2-7
. ENgiNE iDENTiFiCATiON ................... 2-39 8.1 part Number Assignment
Standard for DAEDONG Bolts................ 2-47
4.1 Engine EpA decal(a) ............................... 2-39
8.2 part Number Assignment
4.2 Bar code for engine number(B) .............. 2-39 Standard for DAEDONG Nuts ................ 2-48
4.3 Engine number assignment standard(c) 2-40
9. uNiT CONvErSiON TABLE ................. 2-9
4.4 Assignment standard for
engine model code ................................. 2-41
 GENERAL - TERM DEFINITION DIESEL ENGINE

1. TErm DEFiNiTiON
1.1 ENgiNE DimENSiON
1.1.1 OvErALL LENgTh (mm)
SAFETY FIRST

refers to the maximum length in the direction of the engine’s crankshaft.

1.1.2 OvErALL WiDTh (mm)

refers to the maximum horizontal width at a right angle to the engine’s crankshaft.

1.1.3 hEighT (mm)

refers to the vertical height from the engine’s oil pan to the uppermost end of the engine.
GENERAL

1.2 DrY WEighT (kg)

refers to the weight measured without the engine filled with fuel, lubricant and coolant; does not include
accessories such as the radiator, air cleaner, muffler and cooling fan.

1.3 rEvOLuTiONS pEr miNuTE

OPERATING PRINCIPLE

1.3.1 rATED SpEED (rpm)

refers to the rated output rpm indicated in the product description as the rpm of the crankshaft.
1.3.2 mAX. rpm uNDEr NO LOAD (rpm)
refers to the rpm indicated in the product description as the engine rpm which can be continuously
maintained with the engine running at its maximum.
1.3.3 miN. rpm uNDEr NO LOAD (rpm)
refers to the rpm indicated in the product description as the engine rpm which can be continuously
maintained with the engine running at its minimum.
SERVICING

1. OuTpuT
1..1 mAXimum pOWEr (kW, hp)
refers to the maximum output which can be produced with the engine running at full load. (GVWr
conditions)
1..2 rATED pOWEr (kW, hp)
refers to the rated output indicated in the product description as the output which can be maintained
EXPLODED VIEW

for a certain amount of time at the rated rpm. (GVWr conditions)

1. mAXimum TOrquE

refers to the maximum torque indicated in the product description as the maximum torque which can be
continuously maintained at the rpm when the maximum torque indicated in the product description occurs.

1. SpECiFiC FuEL CONSumpTiON (g/kWh(hph)

The fuel consumption rate refers to the rate of fuel consumption per unit of time or unit output.
INDEX

2- D379-W00
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