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    (Approved) DX12 Tappet Replacement Manual

    Uploaded by

    Luis Ramón Argüello Real
    The document provides instructions for replacing the tappets on a DX12 engine. It details removing and installing various engine components to access the tappets, including the cylinder head cover, oil pan, camshaft gear, and tappets. Precise torque specifications are given for reinstalling each part. A test run checklist is also included to check the engine operation after reassembly.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    (Approved) DX12 Tappet Replacement Manual

    Uploaded by

    Luis Ramón Argüello Real
    141 views34 pages
    The document provides instructions for replacing the tappets on a DX12 engine. It details removing and installing various engine components to access the tappets, including the cylinder head cover, oil pan, camshaft gear, and tappets. Precise torque specifications are given for reinstalling each part. A test run checklist is also included to check the engine operation after reassembly.

    Original Title

    (Approved) DX12 Tappet replacement Manual

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    © © All Rights Reserved

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    The document provides instructions for replacing the tappets on a DX12 engine. It details removing and installing various engine components to access the tappets, including the cylinder head cover, oil pan, camshaft gear, and tappets. Precise torque specifications are given for reinstalling each part. A test run checklist is also included to check the engine operation after reassembly.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    141 views34 pages

    (Approved) DX12 Tappet Replacement Manual

    Uploaded by

    Luis Ramón Argüello Real
    The document provides instructions for replacing the tappets on a DX12 engine. It details removing and installing various engine components to access the tappets, including the cylinder head cover, oil pan, camshaft gear, and tappets. Precise torque specifications are given for reinstalling each part. A test run checklist is also included to check the engine operation after reassembly.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 34

    DX12 Tappet replacement

    . Instruction

    2019. 5
    Engine BG.
    2
    ✓

    3
    01. Oil drain & Remove cylinder head cover
    02. Removal of Rocker arm, Caliper & Pushrod
    03. Removal of Engine front items
    04. Set cylinder #1 OT
    05. Turn the engine to stand up
    06. Removal of oil pan & gasket
    07. Removal of TGCC (Timing Gear Case Cover)
    08. Removal of idle gear
    09. Removal of camshaft gear
    10. Removal of camshaft & Tappet

    4
    5
    6
    2

    5
    1

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


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

    7
    # 6 IN. DOWN # 6 EX. UP

    ‘OT’

    8
    9
    10
    Crank gear

    11
    Marking

    Marking

    [Removed idle gear]

    12
    13
    Tappets

    Tappets

    14
    01. Assembly of new tappet
    02. Assembly of camshaft, flange & camshaft gear
    03. Assembly of idle gear
    04. Assembly of TGCC
    05. Assembly of Oil pan
    06. Turn the engine on the pallet
    07. Assembly of Front oil seal
    08. Assembly of Vibration damper
    09. Assembly of Engine front items
    10. Assembly of pushrods and rocker arm
    11. Set cylinder #1 OT
    12. Valve clearance adjustment
    13. Assemble Cylinder head cover & packing

    15
    Tappets

    PART NUMBER DESCRIPTION QT'Y


    150125-00056 TAPPET,VALVE 12

    16
    Camshaft gear
    FLANGE

    FLANGE bolt (2ea) 0.9 kg.m Camshaft gear bolt (4ea) 3.1 kg.m
    17
    (C)

    (B)

    (A)

    18
    TGCC mounting bolt 11.2 kg.m
    PART NUMBER DESCRIPTION QT'Y
    400628-00038 GASKET, TGCC 1

    19
    Oil pan gasket

    DESCRIPTON BRAND PART NUMBER DESCRIPTION QT'Y


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

    20
    OIL PAN BOLT 3.1 kg.m

    21
    22
    HOLDER GUIDE

    PART NUMBER DESCRIPTION


    860104-06261 JIG;DX12 FRONT OIL SEAL JIG SET

    PART NUMBER DESCRIPTION QT'Y


    65.01510-0041 SEAL, OIL (FRONT) 1

    23
    Front Oil Seal

    GUIDE

    Front Oil Seal

    HOLDER

    24
    25
    Plate

    26
    2

    5
    1

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


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

    27
    Rocker Arm bolt (12ea) 6.2 kg.m

    28
    # 6 IN. DOWN # 6 EX. UP

    ‘OT’

    29
    6 5 4 3 2 1
    Valve Cylinder #
    adjustment IN EX IN EX IN EX IN EX IN EX IN EX

    Torque driver #1 TDC ● ● ● ● ● ●

    360 o rotation ● ● ● ● ● ●

    Valve Intake 0.4 mm


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

    PART NUMBER DESCRIPTION


    860104-02469 JIG;TORQUE DRIVER(WERA)

    Feeler gage

    30
    31

    Hose clamp, breather hose 0.6 kg.m


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

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

    31
    01. TEST BENCH & PROCEDURE

    02. TEST RUN CHECK SHEET

    32
    Air cleaner Battery set Muffler Fuel in/out Oil pressure gage IC direct to Intake Coolant tank

    Blow-by

    33
    ■ General Information
    Country Location Work Center

    Machine Model DX520LCA Machine Serial CECEH- Test Date

    Engine Suffix DX12-MBE07 Engine Serial Inspector

    ■ Test run result


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

    34

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