Двигатель doosan руководство по эксплуатации

Инструкции / руководства

• Home
• Инструкции / руководства

© Copyright 2023. Все права защищены. DSEngine. Developed By Alex

1. Manuals
2. Brands
3. Doosan Manuals
4. Engine
5. D1146
6. Installation operation & maintenance

Quick Links

• Page 2
  This manual is designed to serve as an instruction for the Operation & Maintenance of the generating- set engines of Doosan POLUS series and the power unit engines: P086TI /P086TI-1/ D1146T/ D1146/ PU086T/ PU086. The POLUS means ‘Power Plus’ that is represented more powerful Doosan generating-set engines and it is marked on engine name as an initial P.

• Page 3: Table Of Contents

  CONTENTS <Operation> 1. Safety Regulations ……………………1 1.1. General Notes 1.4. Regulations Designed to Prevent Pollution 1.2. Regulations Designed to Prevent Accidents 1.5. Notes on Safety in Handling Used Engine Oil 1.3. Regulations Designed to Prevent Damage to Engine and Premature Wear 2.

• Page 4
  9.4. Breaking-in 10. Maintenance of Major Components ……………… 121 10.1. Cooling System 10.3. Fuel Injection Pump 10.2. Lubricating System 10.4. Turbocharger 11. Special Tool List ……………………167 • Appendix • Part & After service center • Applications for Doosan Engine…

• Page 5: Safety Regulations

  1. Safety Regulations 1.1. General Notes Handling diesel engines and the necessary resources is no problem when the personnel com- missioned with operation and maintenance are trained accordingly and use their common sense. 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.

• Page 6
  1.2.2. 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. •…

• Page 7: Regulations Designed To Prevent Pollution

  1.3. 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.

• Page 8
  1.5. 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.

• Page 9: General Information

  2. General Information 2.1. Engine Assembly 2.1.1. Engine sectional view (longitudinal) 16 17 EA9O1001 Cooling fan Vavle seat Intake valve Valve spring Exhaust valve Oil filter cap Cylinder head Combustion chamber Pistion Cylinder liner Push rod Tappet Camshaft Connecting rod Crankshaft pulley Vibration damper Oil Pump…

• Page 10
  2.1.2. Engine sectional view (cross) EA9O1002 Fuel filter Rocker arm Intake manifold Exhaust manifold Injection nozzle assembly Cylinder block Valve cotter Oil filter Valve stem seal Oil cooler Valve guide — 6 -…
• Page 11
  2.1.3. Engine assembly views 1) D1146/PU086 2 3 4 13 14 15 8 9 10 11 20 21 22 23 EA9O1003 Cooling fan Oil pan Intake manifold Alternator Oil drain valve Fuel filter Thermostat Flywheel Injection pump Oil filter Flywheel housing…
• Page 12
  2) D1146T/PU086T 2 3 4 5 15 16 17 18 13 14 EA9O1004 Cooling fan Cooling water pipe Air pipe Alternator (from radiator) (Turbocharger to Thermostat Oil cooler Intake manifold) Oil filter cap OIl drain valve Intake manifold Cylinder head cover Flywheel housing Fuel filter Exhaust manifold…
• Page 13
  3) P086TI 14 15 9 10 18 19 20 21 EA9O1005 Cooling fan Vibration damper Intake manifold Thermostat Oil cooler Injection pump Oil filter cap Oil fan Oil filter Air pipe OIl drain valve Oil level gauge (Turbocharger to Starter Air pipe Intake manifold) Flywheel housing…

• Page 14: Engine Specification

  2.2. Engine Specification 2.2.1. Specification Engine Model D1146/PU086 D1146T/PU086T P086TI Items 4 cycle in — line, 4 cycle in — line, 4 cycle in — line, Water — cooled Water — cooled Water — cooled Engine type type Naturally type Turbo…

• Page 15
  Condition Generating-Set Engines Continuous Prime Stand by 50 HZ 105 PS 116 PS (1,500 rpm) (77 kW) (85 kW) D1146 Standard 60 HZ 130 PS 143 PS (1,800 rpm) (96 kW) (105 kW) 50 HZ 145PS 160 PS (1,500 rpm)

• Page 16: Technical Information

  They are also referred to as engine model and serial number because of their location. EA9O2001 • Engine serial No. (example 1 : D1146) EACOA300001 Serial No. MODEL BORE Production Year(2003)

• Page 17: Engine Type

  Engine Model Suffix 3.2. Engine Type The Engines D1146/ D1146T/ P086TI/PU086/PU086T are in-line vertical water-cooled 6-cylin- der four-stroke diesel engines with direct injection. D1146/PU086 are natural aspiration engine, D1146T/PU086T are turbo-charged type, and P086TI is turbo-charged and inter-cooled engine. 3.2.1. Cylinder block The cylinder block is a single piece of alloy cast iron.

• Page 18: Engine Timing

  3.3. Engine Timing Camshaft, oil pump and injection pump are driven by a gear train arranged at the front end. Camshaft gear Injection pump gear (Z = 54) (Z = 54) Idle gear (Z = 42) Crankshaft gear (Z = 27) Oil pump idle gear (Z = 23) Oil pump drive gear…

• Page 19: Lubrication 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. • D1146/D1146T/ P086TI/PU086/PU086T D1146T/P086TI/PU086T CYLINDER BLOCK MAIN GALLERY OVER FLOW VALVE…

• Page 20
  3.5.2. Oil filter Check for oil pressure and oil leaks, and repair or replace the oil filter if necessary. Oil filter head Change the oil filter cartridge simultaneously at every replacement of engine oil. Oil filter (Cartridge) EA9O2005 3.6. Air Cleaner In case that elements are deformed, dam- aged or if the air cleaner has a crack, replace it.
• Page 21
  3.7. 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.
• Page 22
  Fuel Oil Selection Chart General Fuel ASTM No. 1 No. 2 DIN 51601 Classification Test ASTM 1-D ASTM 2-D API #) ˚ Gravity, D 287 40 ~ 44 33 ~ 37 0.815 ~ 0.855 Flash Point D 93 100 (38) 125 (52) 131 (55) ˚F (˚C…
• Page 23
  3.8. Cooling System The engine has a liquid-cooling system. The fresh water pump is a maintenance-free by V-belt from the crankshaft pulley. 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.
• Page 24
  • Since D1146/PU086, D1146T/PU086T and P086TI cylinder liner is dry type, particularly the cooling water control should be applied thoroughly. •…
• Page 25
  Note : In taking the cooling water sample, if the water in auxiliary tank were taken, it is hard to measure the accurate density. Take the cooling water sample necessarily loosen- ing the cooling water discharge plug. (2) At the state of a test paper soaked in the sampled water, after taking the paper out through water agitation, shake off the water.
• Page 26
  3.9. V-belt Tension Check and Adjust By the finger-pressure the belt is pressed Press here by 10mm ~ 15mm between the fan pulley 10~15mm and the alternator pulley in normal condi- tion. For the adjustment of the tension, loosen the adjusting bolts which support Water pump pulley the alternator, adjust the tension and tight-…
• Page 27
  3.10. Turbocharger (for D1146T, P086TI, PU086T) 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.

• Page 28: Electrical Equipment

  3.11. Electrical Equipment 3.11.1. Wiring circuit KEY SWITCH LOW OIL PRESS. OVER HEAT CHARGE (60.25501-7003) W/R LAMP W/R LAMP LAMP * OPTION HEAT START BR R1 0.85 SQ * STANDARD OIL PRESS. W/R SW 5.0 SQ STARTER (65.27441-7006) (65.26201-7063) 5.0 SQ 60 SQ * STANDARD OVER HEAT W/R SW…

• Page 29
  The alternator is maintenance-free, nevertheless, it must be protected against dust and, above all, against moisture and water. Wiring Diagram To Battery + Regulator RL = 150~250 OHM EA8O3007 Operate the alternator according to the instructions given in the chapter. 3.11.3.
• Page 30
  • P086TI (24V X 6.0kW) 24V x 6.0kW TERMINAL S/W TERMINAL «B» 24V x 6.0kW M5 x P0.8 M10 x P1.5 EA8O3008 Wiring Diagram Motor 2.5A(20 C 24V) EA8O3009 — 26 -…
• Page 31
  • D1146 / D1146T / PU086 / PU086T (24V X 4.5kW) 24V X 4.5kW EA902009 Wiring Diagram STARTER S/W MAGNET SWITCH STARTER MOTOR EA9O2010 Always protect starter motor against moisture. WARNING : Always disconnect the battery earth cable before starting work on the electrical system.

• Page 32: Commissioning And Operation

  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.

• Page 33
  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. <Recommended engine oil and capacity> Model Oil pan (only) Engine oil D1146/PU086 15.5 liter SAE 15W40 D1146T/PU086T 15.5 liter API CD or CE…

• Page 34: Operation In Winter Time

  4.3.1. Pressure of lubricating oil The normal pressure comes up to 1 kg/cm (1.0 bar) at idling and 3 ~ 5 kg/cm (3.0 ~ 4.9 bar) at maximum 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.

• Page 35: Tuning The Engine

  4.5. 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.

• Page 36: Maintenance And Care

  5. Maintenance and Care 5.1. Periodical Inspection and Maintenance In order to insure maximum, trouble-free engine performance at all times, regular inspection, adjustment and maintenance are vital. • Daily inspections in below figure should be checked every day. • The maintenance should be executed thoroughly at regular intervals. (Refer to «7.1.

• Page 37
  5.2.3. Oil exchange procedure While the oil is still hot, exchange oil as follows: • Take out the oil dip dipstick. • Remove the drain valve from oil pan, then drain out the engine oil into a con- tainer. • Reassemble the drain valve with the oil pan and the drain plug with oil filter head after draining out the engine oil.
• Page 38
  Engine oil viscosity — ambient temperature SAE 20, 20W SAE 40, 50 Single SAE 10W SAE 30 grade Ambient -30 C -15 C -0 C 15 C 25 C 30 C temp (-20 F) (-0 F) (-32 F) (60 F) (80 F) (90 F) Multi…
• Page 39
  5.3. Cooling System 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 an engine overheat or coolant blow off from the expansion tank. 5.3.1.
• Page 40
  5.3.2. Cleaning of the cooling system inside circuit (by authorized specialist personnel) When the cooling system circuit are fouled with water scales or sludge particles, the cooling efficiency will be lowered. Investigations have shown that in many cases the poor condition of the coolant and /or the cooling system accounts for damage to the water pump mechanical seal, The poor condition of the cooling system is normally due to use of unsuitable or no anti-freezing agents and cor- rosion inhibitor or defect, not early enough replaced covers for filler neck and working valves.
• Page 41
  5.3.3. Intercooler (for P086TI) 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.

• Page 42: Air Intake System

  5.4. Air Intake System 1. Connection port, fouling indicator 2. Cleaner housing 3. Clamp 4. Element 5. Hexagon nut 6. Cover 7. Dust bowl EA6O5012 5.4.1. Maintenance (only when engine is switched off) Empty the dust bowl (7) regularly. The bowl should never be filled more than halfway with dust. On slipping off the two clamps (3), the dust bowl can be removed.

• Page 43
  5.4.3. Cleaning filter elements • By compressed air (wear goggles) For the purpose, the air gun should be fit- ted with a nozzle extension which is bent 90? at the discharge end and which is long enough to reach down inside to the bottom of the element.
• Page 44
  5.5. Fuel System 5.5.1. Fuel filter • After every 200 hour of operation, drain the water and sediment from the fuel- water separator. • Shut off the engine. Use your hand to open the drain valve • Turn the valve counter clockwise approx- imately 2 ~ 3 turns until draining occurs.
• Page 45
  5.5.3. Fuel system checks Fill the tank with the recommended fuel. Keeping tanks full reduces water condensation and helps keep fuel cool, which is important to engine performance. Make sure fuel supply valves (if used) are open. To insure prompt starting and even running, the fuel system must be primed with the fuel feed pump manually before starting the engine the first time, or after a fuel filter change.
• Page 46
  5.5.5. Priming pump strainer cleaning Clean the priming pump strainer filter every 200 operation hours. The strainer filter is incorporated in the priming pump inlet side. Strainer EA9O4004 5.5.6. Bleeding the fuel system 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.
• Page 47
  • Install a nozzle to a nozzle tester. • Check injection pressure, and adjust the nozzle using the adjusting shim if the pressure does not meet the specified limit. Engine Model D1146/PU086 D1146T/PU086T P086TI Opening pressure 214 kg/cm 214 kg/cm 214 kg/cm •…
• Page 48
  5.7. Turbocharger (for D1146T/PU086T, P086TI) 5.7.1. Maintenance (by authorized specialist personnel) The turbochargers do not call for any specific maintenance. The only points to be observed are the oil pipes which should be checked at every oilchange for leakage and restrictions. The air cleaners should be carefully serviced.
• Page 49
  Dial gauge Magnetic vise Move the turbine shaft Radial play in both directions Limit of wear : 0.57mm simultaneously Oil inlet EA4M2018 — 45 -…

• Page 50: Checking And Setting

  6. Checking and Setting 6.1. Adjustment of Valve Clearance 6.1.1. General information The valve clearances are to be adjusted at the times of the following situations. • After initial 50 hour’s operation. • When the engine is overhauled and the cylinder heads are disassembled. •…

• Page 51
  Loosen the lock nuts of the rocker arm adjusting screws and push the specified feeler gauge and adjust the valve clearance with adjusting screw respectively. Model Intake Valve Exhaust Valve D1146/PU086 D1146T/PU086T 0.3 mm 0.3 mm P086TI 6.1.3. Method of adjusting the valve clearance 1) Loosen the lock-nuts aausing a ring span- ner.
• Page 52
  Timing check hole ing the notch mark of the right figure cor- responding to the injection timing is aligned with the pointer ( ) on the fly- wheel housing. D1146/PU086 P086TI D1146T /PU086T Fuel injection timing Flywheel ˚ ˚…

• Page 53: Cylinder Compression Pressure

  • Tighten the coupling fixing bolts and nuts to specified torque. Torque 6.0 ~ 6.5 kg.m EAMD021I 6.3. Cylinder Compression Pressure 1) Stop the engine after warming it up, then remove the nozzle assemblies. EA9O5003 2) Install a special tool (gauge adapter) in nozzle holder hole and connect the com- pression pressure gauge to the adapter.

• Page 54: V-Belts

  6.4. V-belts The tension of the V-belts should be checked after every 2,000 hours of operation. 1) Change the V-belts if necessary If in the case of a multiple belt drive, wear or differing tensions are found, always replace the complete set of belts.

• Page 55
  75 kg 70 kg 60 kg 20.2 mm 75 kg 70 kg 60 kg : Adopted in D1146/PU086, D1146T/PU086T and P086TI 5) Tensioning and changing V-belt • Loosen fixing bolts and nuts. • Adjust the alternator until V-belts have correct tensions.

• Page 56: Operation Tip

  7. Operation Tip 7.1. Periodic Inspection Cycle : Check & adjust : Replace Every Every Every Every Every Inspection Daily Remark 50hrs 200hrs 400hrs 800hrs 1200hrs Check for leakage(hoses, clamp) Check the water level Cooling Change the coolant water System Every Adjust the V-belt tension 2,000hrs…

• Page 57
  7.2. Trouble Shooting — 53 -…
• Page 58
  — 54 -…
• Page 59
  — 55 -…
• Page 60
  — 56 -…
• Page 61
  — 57 -…
• Page 62
  — 58 -…
• Page 63
  — 59 -…

• Page 64: Causes And Remedies

  7.3. Causes and Remedies Condition Causes Remedies • 1) Starting difficult Valve’s poor shut, stem distortion Repair or replace • (1) Compression pressure Valve spring damage Replace valve spring • Cylinder head gasket’s leak Replace gasket • Wear of piston, piston ring or liner Adjust •…

• Page 65
  Condition Causes Remedies • 4) Overheating Engine oil insufficient or poor Replenish or replace • Cooling water insufficient Replenish or replace • Fan belt loosened, worn, damaged Adjust or replace • Cooling water pump’s function lowered Repair or replace • Water temp.
• Page 66
  Condition Causes Remedies • (4) Others Wear of crankshaft, thrust bearing Replace thrust bearing • Camshaft end play increased Replace thrust plate • Idle gear end play increased Replace thrust washer • Timing gear backlash excessive Repair or replace • Valve clearance excessive Adjust valve clearance •…

• Page 67: General Information

  8. General Information 8.1. General Repair 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 for preventing the components from damage or pollution. 3.

• Page 68: Engine Characteristic

  8.2. Engine Characteristic 8.2.1. Toroidal combustion mode (D1146/PU086) The D1146 engine is operated in the toroidal combustion mode that was developed by this company with AVL Co. Australia. The feature of this mode in the fundamental structure is that there are combustion chambers in the centers of piston heads and swirling passages in the cylinder heads.

• Page 69
  8.2.3. Oil gallery cooling type piston (P086TI) Oil gallery cooling is used for the piston of P086TI generator engine. When thermal loading is high, piston cooling by means of an oil gallery in the crown is normally necessary to pre- vent crown cracking and ring sticking.

• Page 70: Maintenance

  9. Maintenance 9.1. Engine Disassembly 9.1.1. Heed at disassembly • Before disassembly, the part shelf should be prepared for various tools and repair parts. • When assembling, clean empty hand should be used and clean environment maintained. • In case of storing the disassembled parts, each part should not touch each other. •…

• Page 71
  9.1.4. Engine oil • Remove the oil drain cock of oil pan and pour the engine oil into the prepared vessel. Drain cock EA9O4001 9.1.5. Cooling fan • Remove the flange fixing bolts, then take off the flange and cooling fan. EA9M3001 9.1.6.
• Page 72
  9.1.8. Fuel filter • Remove the hollow screws of filter and tear down fuel supply and dis- charge rubber hose. • Remove fuel filter assembling bolts and disassemble the fuel filter. ED7OM009 9.1.9. Breather • Loosen the clamp screw to remove the rubber hose.
• Page 73
  9.1.12. Oil cooler • Loosen the cooling water pump and the rubber hose clamps of connected pipes, and disassemble it. • Remove the oil cooler assembling nuts and disassemble it. 9.1.13. Oil filter • Remove the oil filter assembling bolts and disassemble the oil filter assembly.
• Page 74
  9.1.16. Nozzle • Remove the fuel supply high pressure pipe and its assembling nuts that are connected between fuel injection pump and nozzle and disassemble the pipes. • After installing the special tool f o r removing nozzle temporarily, loosen the holder and then ham- mer up with a hammer which is a special tool so as for nozzle assem- bly to be disassembled.
• Page 75
  9.1.19. Intake manifold • Remove the Intake manifold assem- bling bolts and disassemble it from the cylinder head. • Disassemble the intake manifold gas- ket and scrap it. ED7OM005 9.1.20. Cooling water pipe • Remove cooling water pipe assembling bolts and disassemble the pipe for the cylinder head.
• Page 76
  • Lay the removed bolts orderly not to damage the threads at all and store. Caution : Prevent a collision between the bolt thread each other. • Take out the cylinder head gasket and scrap it. • Remove the foreign residues from the cylinder head surface and block surface. Caution : Try not to make any damage on the contact surfaces.
• Page 77
  9.1.26. Oil pump • Remove the bracket fixing bolts of oil intake pipe. • Remove the pipe assembling bolts of oil pump and disassemble intake and supply pipe. • Remove the oil pump assembling bolts, and disassemble the oil pump. EFM2025I 9.1.27.
• Page 78
  (2) Heat the piston with a electric heater, then take out the piston pin from the piston as tapping it with a round wooden bar. EAMD088I (3) Remove the piston ring with a plier. (4) Clean the piston thoroughly. 9.1.28. Cylinder liner •…
• Page 79
  • Remove the idle gear assembling bolts and disassemble the idle gear pin. 9.1.30. Fuel injection pump • Disassembly the oil hose for lubrica- tion. • R e m o v e t h e i n j e c t i o n p u m p f l a n g e assembling nuts EAMD021I…
• Page 80
  9.1.32. Fly wheel • Remove the flywheel assembling bolts and disassemble it. • The bolt removal is done by the reverse order of assembling and by the steps. EDM2072I 9.1.33. Fly wheel housing • Remove the flywheel housing assem- bling bolts and disassemble the flywheel housing.
• Page 81
  9.1.36. Bearing cap • Remove the bearing cap assem- bling bolts by the step in the reverse order of assembling, and disassemble the bearing cap. (Remove by the same way as the cylinder head bolts’ removal.) • Disassembled bearing caps are kept laid in order.
• Page 82
  9.1.39. Oil spray nozzle (D1146T, P086TI only) • Remove the valve screws of oil injec- tion nozzle and disassemble it. — 78 -…
• Page 83
  9.2. Inspection 9.2.1. Cylinder block • Clean the cylinder block thoroughly, and check for any crack or damage. • If there is any crack or severe damage, replace it and if there is minor one, correct it. • Check for any clogging or corrosion in the oil passage and water passage. •…
• Page 84
  (2) Distortion of lower surface • As shown in figure, measure the cylinder head’s distortion at 6 directions with hor- izontal ruler and clearance gauge. • If the measured value is beyond the limit value, correct it by means of the fine grinding paper or grinding machine.
• Page 85
  Dimension Standard Limit Description Intake valve stem 8.950~ 8.970 mm 8.93 mm Exhaust valve stem 8.935~ 8.955 mm 8.91 mm • Valve seat contacting faces Check the valve seat contact surface for any crack and wear, and if necessary, correct with grinding paper, and if excessive, replace it.
• Page 86
  (3) Valve seat • Contacting face amount As for the valve seat’s wear, measure the width of the contact surface with intake valve seat and exhaust valve seat. If beyond the limit value, replace the valve seat. • Assemble the valve at the valve seat of the cylinder head, and check the amount of depression of the valve from the lower portion of the cylinder head using a dial…
• Page 87
  (4) Valve spring • Visual check Check the appearance of valve spring and if necessary replace the spring. • Valve spring free length Use a vernier caliper to measure the valve spring free length. If the measured value is less than the specified limit, the valve spring must be replaced.
• Page 88
  (5) Assembling cylinder head • Clean the cylinder head thoroughly. • Replace the valve stem seal with new one, and by means of a special tool, press the stem seal into the valve guide of cylinder head. • Coat engine oil to valve stem and valve g u i d e a n d a s s e m b l e t h e v a l v e .
• Page 89
  • 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 23.978 ~ 23.959 mm…
• Page 90
  • Visual check of tappet Visually check the face of the tappets in contact with the cam for pitting, scores or cracks, and replace if severely dam- aged. If the amount of cracks or pitting is small, correct with an oil stone or grind- (1) Unevenness (2) Crack (3) Normal…
• Page 91
  9.2.4. Camshaft 1) Camshaft End play • Push the thrust plate toward the cam gear. • With a feeler gauge, measure the clear- ance between the thrust plate and camshaft journal. • If the end play is excessive, replace the thrust plate.
• Page 92
  <Clearance> Camshaft bearing Standard Limit 0.12 ~ 0.17 mm 0.24 mm Replace the bushing if the measured value is beyond the specified limit. EA0M4063 • Run-out Support the camshaft on two V blocks and check for run-out using a dial indi- cator.
• Page 93
  • If the amount of wear is beyond the limit, have the crankshaft ground 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.) EFM2047I…
• Page 94
  (3) Crankshaft run-out • Support the crankshaft on V blocks. • Turn the crankshaft with a dial indicator placed on the surface plate and take the amount of crankshaft run-out. Standard Limit 0.05 mm 0.1 mm 2) Crankshaft bearing and connecting rod (1) Visual check Visually check the crankshaft bearing and connecting rod bearing for scores,…
• Page 95
  • Connecting rod bearing clearance Install the connecting rod bearing in the connecting rod bearing cap, tighten the connecting rod cap bolts to the specified t o r q u e , t h e n m e a s u r e t h e i n s i d e diameter.
• Page 96
  3) Bearing spread and crush • Inspection Check to see that the bearing requires a considerable amount of finger pressure at reassembly operation. Spread = O A — O B EDM2047I • Crankshaft bearing crush Install the bearing and cap in the cylinder block, retighten the bolts to specified torque, unscrew out one bolt completely, then measure the clearance between the…
• Page 97
  • Connecting rod bearing crush Install the bearing and cap in the con- necting rod big end, retighten the bolts to specified torque, unscrew out one bolt completely, then measure the clearance between the bearing cap and connecting rod big end using a feeler gauge. Standard 0.3 ~ 0.5 mm EAMD064I…
• Page 98
  • Using a cylinder bore gauge, measure cylinder liner inside diameter at 3 points (cylinder top ring contacting face, middle, and oil ring contacting face on BDC) in a ˚. direction at an angle of 45 Take the mean value with the largest and smallest values excepted.
• Page 99
  (3) Piston ring side clearance • Fit the compression ring and oil ring in the piston ring groove. Feeler gauge • 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.
• Page 100
  (2) Clearance Measure the clearance between the piston pin and connecting rod bushing, and replace either of them, whichever dam- aged more, if the measured value is beyond the limit. Standard Limit 0.009 ~ 0.015 mm 0.08 mm EA3M2047 (3) Condition check Check the engaged condition of the piston and piston pin.

• Page 101: Reassembly

  9.3. Reassembly 9.3.1. 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 for engine assembly operation. •…

• Page 102
  • 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. Caution : Be careful not to generate a damage to camshaft and bush.
• Page 103
  • Heat the crankshaft gear for at least 10 ˚C minutes to 120 , then apply sealant (Loctite # 641) to the inside wall of the heated crankshaft gear evenly before inserting it to the end of crankshaft. EA8M3014 • Semi-tighten a bolt at both sides of the crankshaft, apply engine oil to journals and pins, then assemble the crankshaft…
• Page 104
  • Install the bearing cap by matching the cylinder block No. with the bearing cap EQM3058I • Apply oil to the entire part of the bearing cap bolts, then tighten in tightening sequence to specified torque. Torque 30 kg • After semi-tightening both bolts evenly, tighten them diagonally to the specified EQM3059I…
• Page 105
  Caution : When the bolts are tightened, remove the guide bar. • The flywheel housing is assembled after the new oil seal was pressed (Coat engine oil over the outside of oil seal) before in the housing by a press. If any peripheral scar was gener- ated due to oil seal at the oil seal contact surface of crankshaft, after inserting about 1 mm shim or thereabout in front of oil seal (Direction toward crankshaft.), measure and adjust.
• Page 106
  • 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 f l y — w h e e l f o r t e m p o r a r y a s s e m b l y operation.
• Page 107
  9.3.11. Cylinder liner • Stand the cylinder block so that the fly- wheel faces downward. • Thoroughly clean the liner flange fitting surface and bore inside with compressed air to prevent the entry of foreign sub- stances. • After the cleaning operation, make the cylinder liner dried up and push it into the cylinder block by hand.
• Page 108
  • Noticing the direction of the piston, make the longer side (machined with key groove on the bearing) of the connecting rod big end and the mark of ‘ ’ impressed on the inside of the piston face each other in opposite directions. On the piston head surface, the longer side of the connecting rod big end is in opposite direction from the valve seat…
• Page 109
  • Install the bearing in the connecting rod cap and apply oil. Caution : Make sure that the manufacture serial numbers impressed on the connecting rod cap and connecting rod big end are iden- tical, and install the connecting rod cap by aligning it with dowel pin.
• Page 110
  9.3.13. Timing gear case • Mount a new gasket using dowel pin on the cylinder block. • Put the time gear case to the cylinder block by aligning the dowel pin hole of timing gear case with its pin, and then assemble it by tapping lightly with an ure- thane hammer to the right and left (Particularly around dowel pin).
• Page 111
  • Install the idle gear by coinciding the marks impressed on the crank gear, cam Mark «2» gear, fuel injection pump drive gear, and Fuel injection Cranshaft gear idle gear. pump drive gear • Install a thrust washer on the idle gear Idle gear and tighten to specified torque.
• Page 112
  (1) As above adjusting method, Please coincide the indication point( ) at the flywheel housing’s inspection hole with the flywheel’s inspection angle. <Fuel injection timing> Model Timing angle ˚ D1146/PU086/D1146T BTDC 18 PU086T/P086TI BTDC 12 ˚ — 108 -…
• Page 113
  (2) Loosen the drive gear fixing bolt of injection pump a bit. (3) After turning slowly the coupling of injection pump until the fuel will drop from #1 plunger at the rate of a drop for 6 ~ 8 sec., tighten the driving gear fixing bolt of fuel pump.
• Page 114
  9.3.18. 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 • Connect water pipes and by-pass pipe to the water pump. ED7OM008 •…
• Page 115
  9.3.21. Vibration damper • Insert the vibration damper to the crankshaft, and assemble by tightening the assembling bolts at the specified tightening torque according to bolt tight- ening order. (refer to right figure.) Torque 13 kg 9.3.22. Oil pan EDM2089I •…
• Page 116
  Caution : Align the bolt holes with gasket holes to prevent damage to the gasket and tighten. 9.3.23. Oil filter • Install the oil filter onto the cylinder block, and tighten the fixing bolts. Torque 2.2 kg • I n s t a l l p a c k i n g a n d a s s e m b l e t h e cartridge using a filter wrench.
• Page 117
  • With a valve stem seal fitting jig, assemble the valve stem seal with the valve guide. • After installing valve springs and spring retainer, press the retainer with a jig, then install cotter pin. • Tap the valve stem lightly with a rubber hammer to check that the valve is assembled correctly.
• Page 118
  • Check the inside of combustion chamber for foreign substances, and carefully mount the cylinder head assembly in the block by aligning the dowel pin with the dowel pin hole. Caution : Be careful not to damage the cylinder head gasket. If the dowel pin is not in EA9M3022 alignment, lift the cylinder head again and then remount it.
• Page 119
  • As for the valve clearance, adjust it when in cold. Model Intake Valve Exhaust Valve D1146/PU086 D1146T/PU086T 0.3 mm 0.3 mm P086TI Caution : (1) Crankshaft revolution is done by hands without using a starting motor.
• Page 120
  • Adjust valve clearance with a feeler Valve clearance adjust gauge and tighten the fixing nuts to specified torque. Torque 5.0 kg EA8M3007 9.3.28. Rocker arm assembly • Apply lubricating oil to the rocker arm bush and shaft, and assemble the intermediate bracket with the rocker arm (rocker arm assembly) on the cylinder block using fixing bolts.
• Page 121
  9.3.30. Exhaust manifold • Install the exhaust manifold gasket over the stud bolts by aligning the gasket with the exhaust port on the cylinder head so that the face and back of the gasket can be positioned correctly. • Semi-assemble the exhaust manifold and install the heat resisting plate.
• Page 122
  9.3.33. Alternator • Install the alternator mounting bracket. • Install the alternator with fixing bolts to the mounting bracket. EA9M3004 9.3.34. Fuel filter • Assemble the fuel filter with the intake manifold. • Assemble the fuel feed hose according to the direction of an arrow impressed on the fuel filter head so that fuel can be fed in the sequence of FUEL FEED PUMP FUEL FILTER…
• Page 123
  9.3.36. Injection pipe • Semi-assemble a nut at both ends of the fuel high pressure pipe and tighten them up one by one to specified torque. Torque 3.0 kg • Tighten hollow screws to assemble the fuel return pipe. • Assemble the fuel return hose on the fuel injection pump.

• Page 124: Breaking-In

  9.3.39. V- Belt • Install the V-belt on the crank pulley, Press here alternator pulley and water pump pulley. 10~15mm • Adjust the V-belt tension using the ten- sion adjusting support. Water pump pulley Alternator pulley Crank pulley V-belt EA9O2006 9.3.40.

• Page 125: Maintenance Of Major Components

  10. Maintenance of Major Components 10.1. Cooling System 10.1.1. General information This engine is water-cooling type. Heat from the combustion chamber and engine oil heat are cooled down by coolant and radiated to the outside, resulting in the normal operation of the engine.

• Page 126
  Valve lift 8 mm or more (at 85 ˚C Operating temperature 71 ~ 85 3. Cooling fan and belt D1146/T, PU086/T : 590mm — 6 Fan diameter — Number of blades P086TI : 755mm — 7 Fan belt tension 15mm/ deflection by thumb 10.1.3.
• Page 127
  There are 2 kinds of thermostats according to surrounding and operating conditions. One is named by 71 ˚C type and the other is 79 ˚C • Inspecting (1) Check the wax pallet and spring for damage. Ruler (2) Put the thermostat in a container of Thermometer water, then heat the water slowly and check temperature with a thermometer.
• Page 128
  10.1.4. Diagnostics and troubleshooting Complaints Possible causes Corrections • • 1. Engine overheating Lack of coolant Replenish coolant • • Radiator cap pressure valve Replace cap spring weakened • • Fan belt loosened or broken Adjust or replace fan belt •…

• Page 129: Lubricating System

  10.2. Lubricating System 10.2.1. General descriptions • General descriptions All the engine oil pumped up from the oil pan by the gear type oil pump is filtrated through the oil cooler and oil filter, and this filtrated oil is forced through the main oil gallery in the cylinder block from where it is distributed to lubricate the various sliding parts, and fuel injec- tion pump in order to ensure normal engine performance.

• Page 130
  10.2.2. Oil pump • 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. EQM4006I (2) Remove the oil pump cover fixing nuts and disassemble the oil pump cover.
• Page 131
  (3) Measuring clearance between drive shaft and bushing a. Measure the outside diameters of the drive shaft and driven shaft, and replace if the measured values are less than the limit ( 16.95mm) Standard 16.95 ~ 16.968 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.
• Page 132
  10.3. Fuel Injection Pump 10.3.1. General information of fuel system The fuel system consists of the fuel tank, injection pump, injection nozzle, fuel filter, and fuel lines such as pipes and hoses necessary to connect those components. Fuel return pipe Overllow valve (Valve opening) pressure 1.6kgf/cm…
• Page 133
  1) D1146 (1) Injection pump : 65.11101-7269A — Model : KP-PES6AD95B410RS2 (101061-8820 ZEXEL) — Governor : KP-EP/RSV200-1350AQ49C311(105419-3930) — Plunger & barrel : 131153-1720 — Delivery valve : 131110-5120 — Feed pump : KP-FP/KE-ADS(105210-5280) — Prestroke : 4.6 ± 0.05mm (2) Nozzle holder assembly : 65.10101-7050 (9134-153C LUCAS) (3) Nozzle : 65.10102-6026 (9135-143 LUCAS)
• Page 134
  (7) Governor adjustment (D1146) Injection Pump Speed (rpm) EA9M4002 — 130 -…
• Page 135
  2) D1146T (1) Injection pump : 65.11101-7271A — Model : KP-PES6AD95B410RS2 (101061-8820 ZEXEL) — Governor : KP-EP/RSV200-1350AQ49C311(105419-3930) — Plunger & barrel : 131153-1720 — Delivery valve : 131110-5120 — Feed pump : KP-FP/KE-ADS(105210-5280) — Prestroke : 4.6 ± 0.05mm (2) Nozzle holder assembly : 65.10101-7050 (9134-153C LUCAS) (3) Nozzle : 65.10102-6026 (9135-143 LUCAS) (4) Injection pipe : 65.10301-6048 (5) Injection order: : 1 — 5 -3 — 6 — 2 — 4…
• Page 136
  (7) Governor adjustment (D1146T) Injection Pump Speed (rpm) EA9M4002 — 132 -…
• Page 137
  3) P086TI (1) Injection pump : 65.11101-7309 (106674-4120 ZEXEL) — Model : NP-PE6P120/700RS3S (106067-6010 ZEXEL) — Governor : Ghana electric control — Plunger & barrel : 134153 -2020 — Delivery valve : 134110 — 1420 — Feed pump : NP-FP/KD-PS(105237-5470) — Prestroke : 3.9 ±…
• Page 138
  4) PU086 (1) Main Specification Fuel Injection Pump : 65.11101-7269A Model Type : PES6AD Governor Type : RSV Fuel Feed Pump : 105210-4830 Cam Lift : 11 mm Injection Timing : BTDC 18° ± 1° Injection Order : 1-5-3-6-2-4 Rotating Direction : Clockwise (Viewed at driving gear side) (2) Calibration Data Nozzle &…
• Page 139
  (3) Rack Diagram Idling serve spring Stroke start or more than 14 Governor spring set Idling serve. 10.5 Spring setting 370 485 1100 1215 or LESS 1165 Pump speed (RPM) EDM5001I — 135 -…
• Page 140
  5) PU086T (1) Main Specification Fuel Injection Pump : 65.11101-7271A Model Type : PES6AD Governor Type : RSV Fuel Feed Pump : 105210-4830 Cam Lift : 11 mm Injection Timing : BTDC 12° ± 1° Injection Order : 1-5-3-6-2-4 Rotating Direction : Clockwise (Viewed at driving gear side) (2) Calibration Data Nozzle &…
• Page 141
  (3) Rack Diagram 14.0 14.0 or more Booster compensating start : 10 0.5 mm 11.2 10.5 Governor spring setting Idling serve. spring setting Q = 17 1.3MM / st (7.7) (7.0) -0.1 1190 1100 1165 Pump speed (RPM) EDM5003I — 137 -…
• Page 142
  10.3.3. Governor system (P086TI Only) Governor system for fuel injection pump consists of «Integral Actuator» and » Speed Control Unit». 1) Integral Actuator EC2OM316 <Dimension View> Fig. No. Description Q’ty Remark Frame Bearing retainer kit Ass’y Mounting bar SWP connector Mg610320 Front cover T3.2…
• Page 143
  2) Speed control unit for governor system (DWC-2000 SERIES SPEED CONTROL UNIT) <Introduction> This speed control unit performs the electronic function of the engine governing system. The speed control unit senses the pulses from the magnetic speed sensor, compares them with the speed control unit’s set point and supplies the appropriate current output to the actuator to control the engine’s fuel system.
• Page 144
  The engine speed signal is usually obtained from a magnetic speed sensor mounted in close prox- imity to the teeth of a ferrous ring gear that is driven by the engine. The frequency of the speed sen- sor signal is proportional to the engine speed. The speed control unit will accept any signal if the fre- quency is proportional to engine signal, and in the frequency range of the speed control unit (1K to 7.5K Hz.).
• Page 145
  1) Specification • Performance Isochronous Operation / Steady State Stability ……….±0.25% or better Speed Range/Governor …………….. 1K~7.5 K Hz continuous Speed Drift with Temperature …………….±0.5% Maximum Idle Adjust CW ………………..60% of set speed Idle Adjust CCW ………….….………..Less than 1200Hz Droop Range ……………..…………
• Page 146
  Reset Crank Overspeed Crank Test Speed Gain : DWC-2000 Stability : DC24V : 65.11220-7006 Starting GHANA CONTROL Fuel 826-1 Kuro 3-Dong, Duro-Gu Seoul 152-053 KOREA(DONG-IL TECKNO-TOWN) MADE IN KOREA Speed Ramping Idle Idle Speed Trim Droop Droop Autuator Pic-up Battery AUX 10V 10V POWER AUX.
• Page 147
  2) Application and installation information The speed control unit is rugged enough for mounting in a control cabinet or engine mounted enclosure or in a remote console up to 20 meters(65ft.) from the engine. Care should be taken to insure that the speed control unit, mount it vertically so that condensation will not accumulate in the speed control unit.
• Page 148
  • Start engine The speed control unit governed speed setting is factory set at approximately engine idle speed. Crank the engine with DC power applied to the governor system. The actuator will energize to the maximum fuel position until the engine starts. The governor system should control the engine at a low idle speed.
• Page 149
  Method 2 : Start the engine and control at an idle speed for a period 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. Replace the connection between Terminals M &…
• Page 150
  • Accessory input The AUXiliary Terminal N accepts input signals from load sharing units, auto synchronizers, and other governor system accessories, DWC 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.
• Page 151
  • OVERSPEED shutdown setting DWC-2000 has a Test switch to determine the OVERSPEED set point and test the engine shut- down function. If you want to adjust the OVERSPEED set point at the speed about 10% higher than the RUN set speed, use the Test switch. When the engine is operating at the Run set speed in pushing the Test switch, rotate the Overspeed Adjust.
• Page 152
  • Unsatisfactory performance If the governing system functions poorly, perform the following tests. SYMPTOM TEST PROBABLE FAULT Actuator goes to full fuel. then, disconnect speed sensor at Terminals C & D. • Do not crank. Apply If actuator still at full fuel speed control DC power to the gov- unit deffective.
• Page 153
  • Electromagnetic compatibility (EMC) EMI SUSCEPTIBILITY — The governor system can be adversely affected by large inter- fering sig- nals that are conducted through the cabling or through direct radiation into the control circuits. All DWC-2000 speed control units contain filters and shielding designed to protect the units sensi- tive circuits from moderate external interfering sources.
• Page 154
  10.3.4. Fuel feed pump 1) General descriptions and construction Priming pump Check valve Check valve Outlet Inlet side side Tappet Piston Cam shaft EQM4019I The P-type injection pump is mounted with K-ADS or KP type feed pump. These pumps have the same basic construction a n d o p e r a t i o n , a n d t h e g e n e r a l descriptions of the KP type pump are given below: The figures show its construction (above figure) and operation (following figure).
• Page 155
  Inlet side Outlet side Interruption EQM4020I 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 feed- ing 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.
• Page 156
  2) Disassembly • 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). •…
• Page 157
  5) Testing (1) Suction capacity test Connect one end of a hose to the inlet Outlet hose side of the feed pump and immerse the other end of it into the fuel tank as illus- Feed pump trated. Hold the feed pump in position about 1 m above the level of fuel in the fuel tank.
• Page 158
  10.3.5. Injection nozzle 1) General descriptions Pressurized fuel delivered from the fuel injection pump is sprayed into the combustion cham- ber past the injection nozzle at proper spray pressure and spray angle, then burnt complete- ly to achieve effective engine performance. (1) At valve closed (2) At valve opened EQM4024I…
• Page 159
  Abnormal Abnormal EFM2057I 7) Testing With the nozzle assembled to a nozzle tester and specified pressure applied, check the nozzle for fuel leakage. EAMC022I Engine Model D1146/PU086 D1146T/PU086T P086TI Opening pressure 214 kg/cm 214 kg/cm 214 kg/cm — 155 -…
• Page 160
  10.3.6. Diagnostics and troubleshooting Complaints Possible causes Corrections • 1. Engine won’t start Fuel pipes clogged or air into Correct 1) Fuel not being pumped pipe fine • out from feed pump Feed pump valve defective Replace • Feed pump piston or Push rod Disassemble, correct sticking •…
• Page 161
  Complaints Possible causes Corrections • 6. Engine output unstable supply of fuel insufficient Check feed pump • Air in fuel Bleed • Water in fuel Replace fuel • Operation of plungers unsmooth Disassemble, correct • Movement of control rack Disassemble, correct sluggish •…

• Page 162: Turbocharger

  10.4. Turbocharger 10.4.1. Main data and specifications 1) Main data and specifications Specification D1146T/PU086T P086TI Turbocharger Model Allied Signal 466721-13 Allied Signal 466721-16 50Hz: Approx. 0.76 kg/cm 50Hz: Approx. 1.56 kg/cm Air pressure at compressor outlet 60Hz: Approx. 1.00 kg/cm 60Hz: Approx.

• Page 163
  27,30,31 EFM3001I 1. Turbine shaft 15. Seal plate 2 Thrust bush 16. Thrust bearing 3. Oil shut off 17. Journal bearing 4. Fixing nut 18. Screw 5. Seal ring 19. Screw 6. Seal ring 21. Heat dissipator 7. Seal ring 22.
• Page 164
  3) Operating principle The turbocharger is a system designed to make use of the engine exhaust gas energy to charge high-density air into the cylinders, thereby to increase the engine output. 10.4.2. General descriptions The engine output is determined by the fuel delivery volume and engine efficiency.To burn the supplied fuel completely to change into effective power for the engine, the volume of air enough to burn the fuel completely should be supplied into the cylinders.Therefore, the engine output is determined substantially by the cylinder capacity, and a greater volume of…
• Page 165
  2) Compressor The compressor, which is connected to the turbine over the one and same shaft to form a rotat- ing body, takes in and compresses ambient air with rotating force transmitted from the turbine shaft. Then, the compressed air is delivered to the intake stake. This is the operating principle of the compressor.
• Page 166
  10.4.4. Precautions for operation 1) Precautions for operation of engine The following precautions should be observed when starting, operating, or stopping the engine: Operations Precautions Reasons When starting 1) Check oil level 2) Abrupt starting of the engine caus- 2) Crank the engine with starter to the engine es the engine to rotate with oil not check the increase in oil pressure…
• Page 167
  10.4.5. Walk-around check and servicing 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. 1) Intake system Pay particular attention to the air cleaner when servicing the intake system. In the case of wet-type air cleaner, if the level of oil surface is lower than specified, clean- ing effect is poor;…
• Page 168
  10.4.6. Periodical checking and servicing Make it a rule to check the turbocharger assembly for condition and contamination periodi- cally. 1) Guide for checking the rotor for rotating condition The inspection of the rotor assembly for rotating condition should be performed by the degree of unusual sound.
• Page 169
  (2) Rotor radial play Dial gauge Magnetic vise Oil outlet Radial play Move the turbine shaft Standard : 0.075~0.11mm in both directions Limit of wear : 0.12mm simultaneously Oil inlet EA8M4004 (3) If the measured axial and radial plays are beyond the limit of wear, replace or repair the turbocharger.
• Page 170
  10.4.7. Diagnostics and troubleshooting Complaints Possible causes Corrections 1. Excessive black smoke 1) Air cleaner element clogged Replace or clean 2) Restrictions in air duct Check and correct 3) Leakage at intake manifold Check and correct 4) Turbocharger seized up and not rotating Disassemble/repair or replace 5) Turbine blades and compressor blades…

• Page 171: Special Tool List

  11. Special Tool List Part No. Figure Tool Name Injection pump setting ass’y EF.123-014 (for D1146/T,PU086/T) Injection pump setting ass’y EF.123-015 (for P086TI) Oil seal(CR) insert ass’y (Front) EF.123-127 (Up to 2000.Apr) Oil seal(NOK)insert ass’y (Front) EF.123-173 (From 2000.May) Oil seal(CR) insert ass’y (Rear) EF.123-043…

• Page 172
  Part No. Figure Tool Name EF.123-065 Valve spring press EU.2-0647 Crankshaft gear punch EF.120-208 Piston sleeve 60.99901-0027 Feeler gauge T7610001E Snap ring plier T7621010E Piston ring plier EB1M7001 — 168 -…
• Page 173
  Appendix • Tightening torque for major parts Screw Strength Major Parts Tightening Torque Remarks (Diameter x pitch) (grade) 1st : 6.0 kg • 2nd : 180° Cylinder head bolt M14 x 1.5 10.9T 3rd : 150° (Angle method) 1st : 10 kg Connecting rod bearing cap bolt M14 x 1.5 12.9T…
• Page 174
  • Standard bolt tightening torque table Refer to the following table for bolts other then described above. Degree of strength Diameter 10.9 12.9 (4A) (4D) (4S) (5D) (5S) (6D) (6S) (6G) (8G) (10K) (12K) pitch Limit value for elasticity (kg/mm (mm) Tightening torque (kg •…
• Page 175
  • Maintenance specification table Stand value Limit Group Part Inspection Item Correction Remark for assembly for use Inside diameter of 111.222 111~ 111.022 Replace liner (limit 0.2) cylinder liner for wear Need amount of Projection difference Amount of liner Cylinder 0.03~0.08 projection without between adjacent projection…
• Page 176
  Stand value Limit Group Part Inspection Item Correction Remark for assembly for use Radial run-out of journal Correct Measure In horizontal 0.01 and pin with a grinder and vertical directions Outside diameter of 83.966~ Use under sized journal 83.988 bearings 70.971~ respectively(0.25, Outside diameter of pin…
• Page 177
  Stand value Limit Group Part Inspection Item Correction Remark for assembly for use 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…
• Page 178
  Stand value Limit Group Part Inspection Item Correction Remark for assembly for use Clearance between 0.035 ~ 0.077 Replace tappet tappet & cyl. block Valve Diameter of tappet 19.94~ 19.965 19.89 Replace tappet Tappet system Replace Tappet face in contact if severely worn or with cam deformed…
• Page 179
  Stand value Limit Group Part Inspection Item Correction Remark for assembly for use Radiator & water pump for corrosion, damage & Correct or replace improper connecting Submerge in water Test for leakage and replace if air (air pressure) (kg/cm bubbles found Radiator Pressure valve for opening pressure (kg/cm…

CONTENTS

WORLDWIDE NETWORK

1.2. Engine assembly

1.2.1. Engine sectional view (Longitudinal)

1

EA8M1002

1.2.2. Engine sectional view (Cross)

7 8 9

2

11

3

12

4

5

6

EA8M1003

1.2.3.Engine assembly views

1)DE12T

5

22

25

24

EA8M1004

2) P126TI

20 21

EA8M1005

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.

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.

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.

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.

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.

EFM1002I

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.

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

— Cleaning of intercooler fins: Every 600 hours.

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.

4

6

13

8

12

10

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.

6.00 (152)

5.25 (133)

O 0.27 (7)

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

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.

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.

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.

Water pipe

Thermostat

EJM4001I

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.

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.

5

C

EA6O3004

3.12. Electrical equipment

3.12.1.Alternator

The alternator is fitted with integral silicon rectifiers. A transistorized 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.

24V x 45A

«L» Terminal

«R» Terminal

CONNECTOR HOUSING

KET MG 620042

TERMINAL

KET ST 740254

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.

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.

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.

<Engine Oil capacity>

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.

4.5. 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 a definite 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 years, preferably in the spring. Components that affect power and performance to be checked are:

•Components affecting fuel injection ;

Nozzle, delivery valve, fuel filter, water separator, etc.

•Components affecting Intake & exhaust ; Air filter, inter-cooler, turbo, silencer, etc.

•Components affecting lubrication & cooling ; Air & oil filter, antifreeze, etc.

5. Maintenance and care

5.1. Periodical inspection and maintenance

In order to insure maximum, trouble-free engine performance at all times, regular inspection,

adjustment and maintenance are vital.

•Daily inspections in below figure should be checked every day.

•The maintenance should be executed thoroughly at regular internals. (refer to appendix “General Engine Inspection Cycle”.)

5.2.Lubrication system

5.2.1.Exchanging of lubrication oil

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. Refill and drain oil pan every 50 hours of operation or 6 months whichever occurs first. At the end of the breakin period (50 hours), change the oil sump oil and replace the oil filter.

5.2.2.Oil level

Check the oil level in the engine sump daily

necessary.

Caution : Do not add so much engine oil that the oil level rises above the max. marking on the dipstick. Over lifting will result in damage to the engine.

While the oil is still hot, exchange oil as follows:

•Take out the oil dip dipstick.

•Remove the drain valve from oil pan and the drain plug form oil filter head, then drain out the engine oil into a container.

5.2.4. Replacement of oil filter cartridge

Caution : Don’t forget tightening the drain plug after having drained engine oil.

EA7O5004

•Lightly oil the O-ring and turn the oil filter

until sealing face is fitted against the O-ring. Turn 1-1/4 turns further with the filter wrench.

Note : It is strongly advisable to use DAEWOO genuine oil filter cartridge for replacement.

5.3. Cooling system

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 an engine overheat or coolant blow off from the expansion tank.

5.3.1.Coolant draining

a)Remove the pressure cap.

b) Open the drain valve at the radiator lower part to drain the coolant as the right figure.

Drain Valve

EA5O4002

5.3.3.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.

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

•Cleaning

In order to maintain the heat transfer efficiency of the intercooler, it is necessary to clean it at regular intervals.

Cleaning of intercooler fins : Every 600 hours.

5.4.Air intake system

1.Connection port, fouling indicator

EA6O5012

5.4.1.Maintenance (only when engine is switched off)

Empty the dust bowl (7) regularly. The bowl should never be filled more than halfway with dust.

On slipping off the two clamps (3), the dust bowl can be removed. Take off the cover (6) of the dust bowl and empty.

Be careful to assemble cover and bowl correctly.

There is a recess in the cover rim and a lug on the collector which should register. Where the filter is installed horizontally, watch for “top” mark on cleaner bowl.

5.4.2.Changing filter element

Caution : Do not allow dirt to get into the clean air end.

On removing the hexagon nut, take out the dirty cartridge and renew or clean.

Wipe the cleaner housing with a damp cloth, in particular the sealing surface for the element.

EA6O5013

Notice : Unless the maximum number of cleanings (up to 5 x) have been done, the filter cartridge should be renewed every two years or 4,000 hours operation.

5.4.3. Cleaning filter elements

•By washing

Before washing, the element should be precleaned by means of compressed air,

cartridge must be dry before it is reinstalled.

Never use steam sprayers, petrol (gasoline), alkalis or hot liquids etc. to clean the filter elements.

•Knocking out dirt by hand

In emergencies, when no compressed air or cleaning agent is available, it is possible to clean the filter cartridge provisionally by hitting the end disk of the cartridge with the ball of one’s thumb.

Under no circumstances should the element be hit with a hard object or knocked against a hard surface to loosen dirt deposits.

•Checking the filter cartridge

5.5.1.Fuel filter

•After every 1,200 hour of operation, drain the water and sediment from the fuelwater separator.

•Shut off the engine. Use your hand to

open the drain valve 6 .

•Turn the valve counter clockwise approximately 2 ~ 3 turns until draining occurs. Drain the filter sump of water until close fuel is visible.

•Turn the valve clockwise to close the drain valve. Do not over tighten the valve, overtightening can damage the threads.

5.5.2.Replacement of fuel filter

•Tighten the filter until the gasket contacts the filter head surface.

•Tighten the filter on additional one-half to three-fourths of a turn with the filter wrench, on as specified by the filter manufacturer.

Notice : Mechanical over tightening of the filter can distort the thread or damage the filter

element seal.

5.5.3.Fuel system checks

Fill the tank with the recommended fuel. Keeping tanks full reduces water condensation and helps keep fuel cool, which is important to engine performance.

Make sure fuel supply valves (if used) are open.

To insure prompt starting and even running, the fuel system must be primed with the fuel feed pump manually before starting the engine the first time, or after a fuel filter change. Refill at the end of each day’s operation to prevent condensation from contaminating the fuel. Condensation formed in a partially filled tank promotes the growth of microbial organisms that can clog fuel filters and restrict fuel flow.

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. DAEWOO recommends installation of a fuel water separator on generator units.

5.5.4.Fuel Contamination and water trap

In the generator environment, the most 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 content to a minimum in storage tanks.

If diesel fuel which contains moisture is used the injection system and the cylinder liners / pistons will be damaged. This can be prevented to same extent by filling the tank as soon as the engine is switched off while the fuel tank is still warm (formation of condensation is prevented). Drain moisture from storage tanks regularly. Installation of a water trap upstream of the fuel filter is also advisable.

Notice : A galvanized steel tank should never be used for fuel storage, because the 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.

EA7O5009

5.5.6. Bleeding the fuel system

•After the whole air is pulled out, close the valve of the filter.

•Confirm the resistance of fuel delivery by the repetition pressing of the feed pump cap, Pressure and turn the feed pump cap simultaneously to close it.

5.5.7.Injection pump

•Check the fuel injection pump housing for cracks or breaks, and replace if damaged.

•Check and see if the lead seal for idling control and speed control levers have not been removed.

•No alterations must be made to the injection pump. If the lead seal is damaged the warranty on the engine will become null and void.

•We strongly recommended that any faults developing in the injection pump should be taken care of by authorized specialist personnel.

5.6. Injection Nozzle Maintenance (by authorized specialist personnel)

The injectors are designed to spray the fuel

delivered by the injection pump directly into the spherical combustion chamber in the piston crown.

The injector consists of the nozzle and the nozzle holder.

A copper seal fitted to the injector ensures gas-tight seating and good heat dissipation.

The opening pressure of the nozzle is

EA0M3003

adjusted by means of shims at the compression spring.

•Install a nozzle to a nozzle tester.

•Check injection pressure, and adjust the nozzle using the adjusting shim if the pressure does not meet the specified limit.

•Check nozzle spray patterns and replace if damaged.

Caution : The injection lines are designed for high operating pressures and should thus be

handled with particular care.

•When mounting the pipes to the engine take care of good fitness.

•Do not bend pipes to permanent deformation (not for replacing the nozzles either).

•Do not mount any heavily bent pipes.

•Avoid bending the pipes at the ends by more than 2 to 3 degrees.

In case of faults in the injection system which might have resulted in excessive operating pressures, not only the failed part but also the injection line has to be replaced.

5.7. Turbocharger

5.7.1. Maintenance (by authorized specialist personnel)

The turbochargers do not call for any specific maintenance.

The only points to be observed are the oil pipes which should be checked at every oil change for leakage and restrictions.

The air cleaners should be carefully serviced.

Furthermore, a regular check should be kept on charge air exhaust gas pipes. Any leakages should be attended to at once because they are liable to cause overheating of the engine. When operating in highly dust or oil-laden atmospheres, cleaning of the air impeller 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 using a plastic scraper.

If the air compressor should be badly fouled, it is recommended that the wheel be allowed to

• Measuring radial clearance

Dial gauge

Magnetic vise

Oil

Outlet

Oil inlet

EA4M2018

6. Checking and setting

6.1. Adjustment of valve clearance

6.1.1.General information

The valve clearances are to be adjusted at the times of the following situations.

•After initial 50 hour’s 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. The valve clearance of the cold engine are as follows.

— Intake valves : 0.3mm

—Exhaust valves : 0.3mm

6.1.2.Adjusting order of the valve clearance

1)After letting the #1 cylinder’s piston come at the compression top dead center by turning the crankshaft, adjust the valve clearances.

2)Loosen the lock nuts of rocker arm adjusting screws and push the feeler gauge of specified value between a rocker arm and a valve stem and adjust the clearance with adjusting screw respectively and then tighten with the lock nut.

3)As for the valve clearance, adjust it when in cold, as follow.

—After reinsuring the valve clearances, retighten if necessary.

4)No. 1 Cylinder is located at the side where flywheel was installed.

• Tighten the drive shaft connecting flange fixing bolts to specified torque.

• Install the oil delivery pipe and return pipe.

•The tightening by excessive torque may cause the damages of the cylinder head gaskets, the flanges of cylinder liners and the cylinder head bolts, therefore obey the regular torque.

—45 —

6.4.Cylinder compression pressure

1)Stop the engine after warming it up, then remove the nozzle assemblies.

EA9O5003

2) Install a special tool (gauge adapter) in nozzle holder hole and connect the compression pressure gauge to the adapter.

3) Cut off fuel circulation, rotate the starter, then measure compression pressure of each cylinder.

EA9O5004

— Testing conditions : at water temperature of 20 °C and speed of 200 rpm (10 turns)

6.5. V-belts

The tension of the V-belts should be checked after every 2,000 hours of operation.

(1)Change the V-belts if necessary

If in the case of a multiple belt drive, wear or differing tensions are found, always replace the complete set of belts.

(2)Checking condition

Check V-belts for cracks, oil, overheating and wear.

(3)Testing by hand