Doosan DE12T, P126TI Service Manual

65.99892-8051

Operation Manual

GENERATOR DIESEL ENGINE

DE12T

POLUS

P126TI

FOREWORD

This manual has been prepared to help you use and maintain the DE12T/ P126TI generator diesel engines in a safe and correct manner.

These economical and high-performance diesel engines (OMEGA combustion system) have been designed and manufactured for generator application. They meet all the requirements such as low noise, fuel economy, high engine speed, and durability.

Nonetheless, to obtain the best performance and long life of an engine, it is essential to operate it appropriately and to carry out periodic checks as instructed in this manual. We strongly urge you to thoroughly read this manual from cover to cover and to acquaint yourself fully with all the information contained in this manual.

Please contact your authorized DAEWOO dealer for the answers to any questions you may have about your DE12T/ P126TI generator engine’s features, operation, or manuals.

In order to operate the engine in the optimal conditions and to maintain its best performances, the contents in this instruction are to be thoroughly understood and observed. In addition refer to the INST ALLATION manual about DAEWOO generator engine installation instructions. All warranty claims to be addressed to;

Engine Export Team, DAEWOO Heavy Industries LTD. DAEWOO Center 541 Namdaemun-ro 5-ga, Chung-gu Seoul, Korea TEL : (82-2-726-3205~8), FAX: (82-2-726-3168)

Or to your local DEALER or DISTRIBUTOR.

DAEWOO Heavy Industries LTD.

July. 1999

CONTENTS

1. General information................................................................................................................... 1

1.1. Engine specification 1.2. Engine assembly

2. Safety regulations ...................................................................................................................... 6

2.1. General notes 2.4. Regulations designed to prevent pollution

2.2. Regulations designed to prevent accidents 2.5.

Notes on safety in handling used engine oil

2.3. Regulations designed to prevent damage

3. Technical information .............................................................................................................. 10

3.1. Engine model and serial number 3.7. Intercooler

3.2. Engine type 3.8. Fuel system

3.3. Engine timing 3.9. Cooling system

3.4. Valves 3.10. V-belt tension check and adjust

3.5. Lubrication system 3.11. Turbocharger

3.6. Air cleaner 3.12. Electrical equipment

4. Commissioning and operation............................................................................................... 26

4.1. Preparation 4.4. Operation in winter

4.2. Breaking-in 4.5. Tuning the engine

4.3. Inspection after starting

5. Inspection and maintenance .................................................................................................. 30

5.1. Periodical inspection and maintenance 5.5. Fuel system

5.2. Lubrication system 5.6. Injection nozzle maintenance

5.3. Cooling system 5.7. Turbocharger

5.4. Air intake system

6. Checking and setting .............................................................................................................. 42

6.1. Adjustment of valve clearance 6.4. Cylinder compression pressure

6.2. Adjustment of injection timing 6.5. V-belts

6.3. Tightening the cylinder head bolts

•

Appendix....................................................................................................................................

•

WORLDWIDE NETWORK

Engine Model

Items

DE12T P126TI P126TI-I

Engine type

Water-cooled, 4 cycle in-line

type

type Turbo charged

Turbo charged & intercooled

Combustion chamber type Direct injection type Cylinder liner type Replaceable dry liner Timing gear system Gear driven type No. of piston ring Compression ring 2, oil ring 1 No. of cylinder-bore

stroke (mm) 4 - 123 x 155 Total piston displacement (cc) 11,051 Compression ratio 17.1 : 1 Engine dimension (length xwidth xheight) (mm) 1,365.5 x 870 x 1,046

1,383 x 870 x 1,207 Engine weight (kg) 910 Rotating direction (from flywheel) Counter clockwise Fuel injection order 1 - 5 - 3 - 6 - 2 - 4 Fuel injection timing (B.T.D.C static) 12

° Injection pump type Zexel in-line “P” type Governor type

Mechanical governor type(RSV)

Electric governor type(GAC)

Injection nozzle type

Multi-hole type (5 hole)

Fuel injection pressure (kg/cm2) 220 1st : 160, 2nd : 220 Compression pressure (kg/cm2) 28 (at 200 rpm)

Condition

50Hz 60Hz 50Hz 60Hz 60Hz

(1,500rpm) (1,800rpm) (1,500rpm) (1,800rpm) (1,800rpm)

Continuous

280PS 336PS

Power (ISO 3046)

(206kW) (247kW)

Prime

205PS 245PS 328PS 378PS 356PS

(151kW) (180kW) (241kW) (278kW) (262kW)

Stand by

226PS 270PS 370PS 405PS 392PS

(166kW) (199kW) (272kW) (298kW) (288kW)

ntake and exhaust valve clearance (at cold) (mm)

0.3

Intake valve

Open at 18

(B.T.D.C)

Close at 34°(A.B.D.C)

Exhaust valve

Open at 46

(B.B.D.C)

Close at 14°(A.T.D.C) Lubrication method Full forced pressure feed type Oil pump type Gear type driven by crankshaft Oil filter type Full-flow, Cartridge type Lubricating oil capacity (max./min.) (lit) 23/20 Oil cooler type Water cooled Water pump Gear driven impeller type Cooling Method Pressurized circulation Cooling water capacity (engine only) (lit) 19 Thermostat type Wax pallet type (83 ~ 95

C) Alternator voltage - capacity (V - A) 24 - 45 Starting Motor voltage - output (V - kW) 24 - 6.0

1. General information

1.1. Engine specification

- 1 -

1.2. Engine assembly

1.2.1. Engine sectional view (Longitudinal)

- 2 -

EA8M1002

10 11 12 13 14 15 16 17 18

3 4 56789

1. Cooling fan

2. Exhaust valve

3. Valve spring

4. Oil filter

5. Tappet

6. Push rod

7. Piston pin

8. Piston

9. Combustion chamber

10. Crankshaft pulley

11. Vibration damper

12. Oil pump

13. Crankshaft

14. Oil pan

15. Connecting rod

16. Camshaft

17. Flywheel housing

18. Flywheel

1.2.2. Engine sectional view (Cross)

- 3 -

EA8M1003

5 6

789

1. Intake manifold

2. Fuel filter

3. Oil cooler

4. Injection pump

5. Cylinder block

6. Oil filter

7. Injection nozzle assembly

8. Rocker arm

9. Cylinder head cover

10. Exhaust manifold

11. Piston ring

12. Turbocharger

- 4 -

EA8M1004

1 2 3 12 4 27 13 18

14 20 21 26

25 24

17 15 197

11 10869

1. Cooling fan

2. Cooling water pipe

3. Oil filler cap

4. Cylinder head cover

5. Turbocharger

6. Oil drain valve

7. Alternator

8. Oil pan

9. Starter

10. Flywheel housing

11. Flywheel

12. Exhaust manifold

13. Injection nozzle assembly

14. Oil filter

15. Fuel filter

16. Oil cooler

17. Intake manifold

18. Injection pipe

19. Thermostat

20. Injection pump

21. Oil level gauge

22. Mounting bracket

23. Vibration damper

24. Water pump

25. Fan drive

26. Crankshaft pulley

27. Breather

1.2.3. Engine assembly views

1) DE12T

P126TI

- 5 -

EA8M1005

768910

14 15 16 17 18 19

20 21

22 23

24 25

345 12 13

1. Cooling fan

2. Cooling water pipe

3. Air pipe (Intercooler Intake manifold)

4. Air pipe (Air cleaner Turbocharger)

5. Turbocharger

6. Oil drain valve

7. Air pipe (Intercooler Intake manifold)

8. Oil pan

9. Starter

10. Flywheel housing

11. Flywheel

12. Exhaust manifold

13. Injection nozzle assembly

14. Oil filter

15. Breather hose

16. Oil cooler

17. Intake manifold

18. Injection pipe

19. Thermostat

20. Injection pump

21. Oil level gauge

22. Mounting bracket

23. Vibration damper

24. Water pump

25. Fan drive

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 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

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 get too close to the rotating parts. Wear close-fitting clothing.

•

Do not touch the engine 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 generator diesel 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.

- 6 -

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.

Caution :

There is a risk of burns and scalding. Do not touch oil drain valve or oil filters 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. If opening while the engine is still warm is unavoidable, comply with the instructions In the chapter entitled “Cooling”.

•

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.

•

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.

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 wrench 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. 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.

- 7 -

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 or coolant. Use only DAEWOOapproved service products (engine oil, anti-freeze and anticorrosion agent).

•

Pay attention to cleanliness, The Diesel fuel must be free of water. See “Maintenance and care”.

•

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. See “Maintenance and care”.

•

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.

•

Comply with instructions for operation of the alternator. See “Commissioning and operation”.

•

Do not let the water pump run dry. If there is a risk of frost, drain the water when the engine switched off.

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.

•

The drinking water supply may be contaminated.

•

Oil and fuel filter elements are classed as dangerous waste and must be treated as such.

2.4.2. Coolant

•

Treat undiluted anti-corrosion agent and / 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.

- 8 -

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, Anailbrush 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.

- 9 -

3. Technical information

3.1. Engine model and serial number

The engine model and serial number is located on the engine as illustrated. These numbers are required when requesting warranty and ordering parts. They are also referred to as engine model and serial number because of their location.

•

Engine serial No. (example 1 : DE12T)

EBHGA900001

Serial No. Production Year(19x9)

Engine Model Suffix

•

Engine serial No. (example 2 : P126TI)

EDIGA900001

Serial No. Production Year(1999)

Engine Model Suffix

- 10 -

Engine Number

EA8O3001

< Name Plate : General >

< Name Plate : EPA& CARB >

MODEL SPEED 1500/1800 rpm STAND-BY PRIME

SERIAL NUMBER

BORE STROKE VOLUME YEAR

DAEWOO HEAVY INDUSTRIES LTD.

IMPORTANT ENGINE INFORMATION

THIS DAEWOO HEAVY-DUTY DIESEL MODEL

EPA AND CARB STANDARDIZED ENGINE FAMILY DESIGNATION IS

TUNE-UP SPECIFICATIONS AND ADJUSTMENTS

IS CERTIFIED TO OPERATE ON

mm mm

EA9O2002

DAEWOO HEAVY INDUSTRIES LTD. ENGINE AND MATERIAL DIV. 6, MANSECOK-DONG, DONG-GU INCHEON, KOREA

TYPE 2-D DIESEL FUEL.

EA9O2003

3.2. Engine type

The Engines DE12T/ P126TI are in-line vertical water-cooled 6-cylinder four-stroke diesel engines with direct injection. DE12T is turbo-charged engine, and P126TI model is turbocharged and inter-cooled engine.

3.2.1. Cylinder block

The cylinder block is a single piece of alloy cast iron. To increase its stiffness, it is extended to a level below the crankshaft center line. The engine has replaceable dry cylinder liners and individual cylinder heads with struck-in valve seat rings and replaceable valve guides,

3.2.2. Piston con-rod / crankshaft

The forged crankshaft is a ingrate type (Counterweight is integrated with crank shaft body). Radial oil seal on crankshaft and flywheel are provided to seal the flywheel housing inside penetrations. The con-rods (connecting rods) are die-forged, diagonally split and can be removed through the top of the cylinders together with the pistons. Crankshaft and connecting rods run in steel-backed lead bronze ready-to fit type bearings.

- 11 -

3.3. Engine timing

Camshaft, oil pump and injection pump are driven by a gear train arranged at the front end.

3.4. Valves

The overhead valves are actuated via chilled cast iron tappets, push rods and rocker arms from the camshaft.

- 12 -

EA8O3002

Injection pump gear (Z = 72)

Water pump gear (Z = 29)

Camshaft gear (Z = 72)

Crankshaft gear (Z = 36)

Oil pump idle gear (Z = 31)

Oil pump drive gear (Z = 32)

Idle gear (Z = 52)

3.5. Lubrication system

The engine is equipped with force-feed lubrication. The pressure is produced by a gear pump whose drive gear is in direct mesh with the crankshaft gear at the front end of cylinder block. The oil pump draws the oil from the oil sump and delivers it through the oil cooler and oil filter to the main distributor gallery and from there to the main bearings, big-end bearings and camshaft bearings as well as to the small-end bearings and the rocker arms. The injection pump and the turbocharger are also connected to the engine lubricating system. The cylinder walls and timing gears are splash-lubricated. Each cylinder has an oil jet provided for cooling the underside of the pistons. The lube oil is cleaned in a full-flow oil filter.

3.5.1. Recommend of lubricating oil

Initial factory fill is high quality break-in oil for API Service CD. During the break-in period (50 hours), frequently check the oil level. Somewhat higher oil consumption is normal until piston rings are seated. The oil level should be maintained in the safe range between the Min. and Max. marks on the dipstick. The safe range between the marks represents approximately 3 liters. To obtain the best engine performance and engine life, grade of engine oil is recommended. Engine oils are specified by API Service, letter designations and SAE viscosity numbers. If the specified motor oil is not available, use a reputable brand of engine oil labeled for API Service CD and SAE viscosity 30 or 15w40. Refer to oil identification symbol on the container. Engine oil should be changed at the specified intervals. (800hr)

- 13 -

EA8O3003

RELIEF VALVE

CYLINDER BLOCK MAIN GALLERY

IDLE GEAR SHAFT

IDLE GEAR FACE

CRANK PIN

SPRAY NOZZLE INJECTION PUMPCRANK JOURNAL

ROCKER ARM SHAFT

CAM SHAFT BEARING

OIL FILTER

OIL COOLER

OIL PUMP

OIL STRAINER

OPENING PRESSURE

4.0 ~ 5.0 kg/cm

BY - PASS VALVE

1.8 ~ 2.3 kg/cm

OIL SPRAY VALVE

1.5 ~ 1.8 kg/cm

BY - PASS VALVE

5.0 ~ 6.0 kg/cm

RELIEF VALVE 10 + 1.5 kg/cm

VALVE ROCKER ARM

VALVETAPPET

TURBO CHARGER

3.5.2. Oil cooler

An oil cooler is provided between the oil filter and the cylinder block. This cooler is a flat tube type with turbulence inserts and operated by the coolant.

3.5.3. Oil filter

Check for oil pressure and oil leaks, and repair or replace the oil filter if necessary. Change the oil filter cartridge simultaneously at every replacement of engine oil.

- 14 -

SAE 20, 20W

SAE 10W

SAE 30

SAE 40, 50

SAE 10W - 30

SAE 5W - 20

SAE 15W - 40

SAE 10W - 40, 20W - 40, 20W - 50

-30 C

Single grade

Ambient temp

Multi grade

(-20 F)

-15 C (-0 F)

-0 C

(-32 F)

15 C (60 F)

25 C (80 F)

30 C (90 F)

EA4M1008

Engine oil viscosity - ambient temperature

Oil filter (Cartridge)

Oil filter head

EQM4010I

3.6. Air cleaner

In case that elements are deformed, damaged or if the air cleaner has a crack, replace it. By the definite interval, the elements must be cleaned and replaced.

- Cleaning of air cleaner element: Every 200 hours.

- Changing of air cleaner element: Every 600 hours.

3.7. Intercooler

The intercooler is air to air type and has a large cooling fan capacity. The intercooler life and performance depends on the intake air condition greatly. Fouled air pollutes and clogs the air fins of intercooler. As a result of this, the engine output is decreased and engine malfunction is occurred. So you always check whether the intake air systems like air filter element are worn or polluted.

- Cleaning of intercooler fins: Every 600 hours.

- 15 -

EFM1002I

Air/air intercooler with downstream

radiator

(Combined radiator)

Cooling air

Hot charge air from compressor

Recooled charge air to intake pipe (max. 50 C)

EA5O4003

3.8. Fuel system

The fuel is delivered by the fuel feed pump via the fuel filter to the injection pump and from there to the injection nozzles. The fuel is sprayed into the cylinders through nozzles fitted in screw-fit injection nozzle holders in the cylinder heads. Excessively delivered fuel and leak fuel from the nozzle flow through the return pipe back to the tank. A strainer is arranged ahead of the fuel feed pump.

1. Fuel filter 7. Delivery pipe

1a. Full water drain plug 8. Fuel pipe (manual pump filter)

2. Air bleeding screw (for fuel filter) 9. Fuel tank

3. Injection nozzle 10. Fuel return pipe

4. Overflow tube 11. Suction pipe

5. Fuel pipe (filter injection pump) 12. Feed pump

6. Overflow valve 13. Injection pump

- 16 -

EA8O3004

3.8.1. Injection pump

The in-line injection pump is driven via gears from the crankshaft. It is connected to the force feed lubricating system of the engine and consequently maintenance-free. The governor flange-mounted on the pump casing is a variable range governor designed to keep the speed set by the speed control unit constant under conditions of varying load.

Governor system for fuel injection pump consists of “Integral Actuator” and “ Speed Control Unit”.

1) Integral Actuator

2) Speed control unit for governor system The ESD5550 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. It is designed for high reliability and built ruggedly to withstand the engine environment. Simplicity of installation and adjustment was foremost in the design. Non-interacting performance controls allow near optimum response to be easily obtained. The primary features of the ESD5550 Series 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 multiengine 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.

- 17 -

Engine model P126TI GAC governor model ACE 175A Speed control unit model ESD5550

- 18 -

6.00 (152)

6.05 (165)

6.00 (152)

5.25 (133)

O 0.27 (7)

ABCDEF GHJKL NPM

CAUTION

OVERSPEED

SPEED

SPEED RAMPING

GAIN

DROOP

STABILITY

DEAD TIME COMPENSATION JUMPER

RESET TEST

SPEED CONTROL UNIT

OVERNORS MERICA

ORP

MADE IN AGAWAM, MA U.S.A

MODEL : ESD5550 S/N

C1 OFF

ENGINE SPEED CONTROL

COMPONENT WHEN INSTALLING

OR SERVICING REFER TO

PRODUCT PUBLICATION

E3E1

OFF

LEAD CIRCUIT

SOFT COUPLING

STARTING FUEL

ACTUATOR

MAGNETIC PICK-UP

PICK-UP

IDLE

BATTERY

AUX

SPED TRIM CONTROL - 5K

CLOSE FOR IDLE

CLOSE FORDROOP

10V OUTPUT

BATTERY

FUSE 15A MAX

OPTIONAL ACTUAT OR CABLE SHELDING TO MEET CE DIRECIVE

SEE SPECIFIC ACTUATOR PUBLICATION FOR PROPER WIRING OF ACTUATOR BASED ON BATTERY VOLTAGE

GROUND REFERENCE

ADD JUMPER FOR 12V BATTERY OR ACTUATOR CURRENTS ABOVE 5A

ACCESSORY INPUT

ACCESSORY POWER SUPPLY

1.03 (26)

EA6M4004

3.8.2. Fuel filter

This fuel filter has two functions not only oil filtering but also water separating. Before entering the suction chamber of the injection pump, the fuel is cleaned in a strainer of fuel feed pump and a fuel filter. Drain water in cartridge with loosening the cock under filter manually (6) from time to time. The fuel filter should be replaced at every 1,200 hours.

3.8.3. Fuel requirements

DAEWOO marine diesel engines was designed to use Number 2-D diesel fuel or equivalent that meets specification DIN 51601-DK. For maximum fuel economy, Number 2-D fuel whenever possible. When temperatures are below -7

C(20˚F), use Number 1-D fuel. If Number 1-D fuel is not available, the mixture of one kerosene to two gallons of Number 2-D fuel can be used. Once kerosene has been added, the engine should be run for several minutes to mix the fuel.

3.8.4. 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 generator service. Grade 1-D fuel should not be used in pleasure craft engines, except in an emergency.

- 19 -

5 2

EA2O4009

Fuel oil selection chart

#) Not specified In ASTM D 975 +) Differs from ASTM D 975

Note :

1.The cloud point should be 6

˚C

(10˚F) below the lowest expected fuel

temperature to prevent clogging of fuel fitters by crystals.

- 20 -

General Fuel ASTM No. 1 No. 2

DIN 51601

Classification Test ASTM 1-D ASTM 2-D

Gravity,˚API

D 287 40 ~ 44 33 ~ 37 0.815 ~ 0.855

Flash Point

D 93 100 (38) 125 (52) 131 (55)

Min. ˚F (˚C) Viscosity, Kinematic

D 445 1.3 ~ 2.4 1.9 ~ 4.1 1.8 ~ 10

CST 100 ˚F (40 ˚C ) Cloud Point ˚F

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 Insolubles D 2274 1.5 1.5 mg/100 ml, Max.

Ash, wt%, Max. D 482 0.01 0.01 Cetane Number, Min.

D 613 45 45 > 45 Distillation D 86 Temperature,

˚F(˚

IMP, Typican

350(177) 375(191)

10% Typical

385(196) 430(221)

50% Typical

45(218) 510(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.

3.9. Cooling system

The engine has a liquid-cooling system. The fresh water pump is a maintenance-free by gear from the crankshaft. Depending on the agreed extent of delivery and the design of the engine, the coolant circuit can be equipped with temperature monitors which, in the event of loss of coolant, shut the engine down.

•

Check the coolant level of the expansion tank by removing the expansion tank filler cap, and add coolant if necessary.

•

When injecting antifreeze solution, first drain out the old coolant from the cylinder block and radiator, and then clean them with cleaning solution.

•

Be sure to mix soft water with antifreeze solution.

- 21 -

Water pipe

Reserve tank

Thermostat

EJM4001I

Cylinder head

Cylinder block

Water pump

R a d

3.9.1. Coolant pressure cap

Check the pressure valve opening pressure using a expansion tank cap tester. Replace the filler cap assembly if the measured valve does not reach the specified limit. (pressure valve opening pressure : 0.9 kg/cm

)

Note :

Because it is dangerous to open the pressure cap quickly when coolant is hot, after lowering the inside pressure of the tank by slow-opening at first open it fully.

3.9.2. Anti-freeze

The anti-freeze, 50% 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.

As the ratio of antifreeze in the mixture decrease each time new coolant is added to make up for the loss coolant resulting from engine operation, Check the mix ratio with every replenishment of coolant, and top up as necessary.

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Rediater Cap

Rediater

EA5O3002

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

3.10. V-belt tension check and adjust

By the finger-pressure the belt is pressed by 10mm ~ 15mm between the fan pulley and the alternator pulley in normal condition. For the adjustment of the tension, loosen the adjusting bolts which support the alternator, adjust the tension and tighten the bolts again.

3.11. Turbocharger

The exhaust gases of the engine are passed through the turbine rotor of the turbocharger. Air compressor impeller mounted on the same shaft draws in fresh air and delivers it at a higher pressure to the cylinders. The turbocharger is naturally air-cooled. Lubrication of the main bearing is by oil under pressure from the engine lubricating system.

1. Compressor casing A. Air inlet

2. Turbine casing B. Gas outlet

3. Compressor wheel C. Gas inlet

4. Impeller D. Oil supply

5. Turbine E. Oil return

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EA8O3005

15mm

Fan

Pulley

Press hear

Crank Pulley

Alternator

Pulley

V-belt

here

EA6O3004

3.12. Electrical equipment

3.12.1. Alternator

The alternator is fitted with integral silicon rectifiers. Atransistorized regulator mounted on the alternator body interior limits the alternator voltage. The alternator should not be operated except with the regulator and battery connected in circuit to avoid damage to the rectifier and regulator.

The alternator is maintenance-free, nevertheless, it must be protected against dust and, above all, against moisture and water.

Operate the alternator according to the instructions given in the chapter.

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To Battery +

EA8O3007

Regulator

RL = 150~250 OHM

EA8O3006

P-TAB : KET GP 890545 TACHOMETER CHARGE INDICATOR ALDO SYSTEM FREQUENCY =

M6 x 1.0 THREAD BA TTER Y TERMINAL

RPM

"L" Terminal

"R" Terminal

CONNECTOR HOUSING KET MG 620042 TERMINAL KET ST 740254

24V x45A

3.12.2. Starter motor

The sliding-gear starter motor is flanged to the rear of the flywheel housing on the left-hand side. As parts of every engine overhaul, the starter pinion and ring gear should be cleaned with a brush dipped in fuel and then a coat of grease should be applied again.

Always protect starter motor against moisture.

Warning :

Always disconnect the battery earth cable before starting work on the electrical system. Connect up the earth cable last, as there is otherwise a risk of shortcircuits.

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TERMINAL "B"

M10 x P1.5

TERMINAL S/W

M5 x P0.8

EA8O3008

24V x 6.0kW

24V x6.0kW

Motor

S/W

2.5A(20oC 24V)

EA8O3009

4. Commissioning and operation

4.1. Preparation

At the time of initial commissioning of a new or overhauled engine make sure to have observed the “Technical Information for the installation DAEWOO generator engines”.

•

Oil filler neck on cylinder head cover Before daily starting of the engine, check the fuel, coolant and oil level, replenish if necessary. The notches in the dipstick indicate the highest and lowest permissible oil levels The oil required in the sump is specified in the “Engine Specification”.

Note :

The oil required to fill the oil fillers and pipes depends upon the engine and use and must be determined individually at the time of initial commissioning. (Make the Max and Min. marks of the determined quantity on the oil level gauge.)

•

Cleanliness

Ensure outmost cleanliness when handling fuels, lubricants and coolants.

4.2. Breaking-in

4.2.1. Operation of a new engine (Break-In)

Because the sliding surfaces of a new engine are not lapped enough, the oil film can be destroyed easily by overload or overspeed and the engine life-time may be shortened. Therefore the following things must be obeyed by all means.

Up to the first 2,000km (150 hours)

•

Engine should be run at fast idling until the temperature of the engine becomes normal operating condition.

•

Overload or continuous high speed operation should be avoided.

•

High speed operation with no load should be prevented.

•

Abrupt start and stop of the engine should be avoided.

•

Engine speed must be under 70% of its maximum speed.

•

Maintenance and inspection must be accomplished thoroughly.

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4.2.2. Check points for break-in

During the break-in (the initial running of the engine) period, be particularly observant as follows: a) Check engine oil level frequently. Maintain oil level in the safe range, between the “min.”

and “max.” marks on dipstick.

Note :

If you have a problem getting a good oil level reading on dipstick, rotate dipstick 180

and re-insert for check.

b) Watch the oil pressure warning lamp. If the lamp blinks, it may be the oil pick-up screen is

not covered with oil. Check oil dipstick. Add oil to the oil pan, if required. Do not overfill. If level is correct and the status still exists, see your DEALER for possible switch or oil pump and line malfunction.

Note :

Oil pressure will rise as RPM increases, and fall as 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.

c) Watch the engine water temperature gauge and be sure there is proper water circulation.

The water temperature gauge needle will fluctuate if water level in expansion tank is too low. At the end of the break-in period, remove break-in oil and replace the oil filter. Fill oil pan with recommended engine oil. Refer to following table.

4.2.3. Operating after break-in

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. Be sure to check the oil level frequently during the first 50 hours of operation, since the oil consumption will be high until the piston rings are properly seated.

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Oil pan (only) DE12T 23 liter P126TI 23 liter

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