Daewoo P158LE Operation & Maintenance Manual Download Page 162

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Head Office

Hwasu-Dong 7-11, Dong-Gu, Incheon, Korea.
Tel : 82-32-760-1114 Fax : 82-32-762-1546

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ASIA & OCEANIA

Daewoo Heavy Industries Australia Pty. Ltd

Suite 5, Level 4,20 Charles St., Parramatta NSW 2150, Australia
Tel : 61-2-9633-4544 Fax : 61-2-9633-5266

Daewoo Machinery Co., Ltd

No.83 WenHwa 1st. Road, Kueishan Hsiang, Taoyuan Hsien,
Taiwan R.0.C
Tel : 886-3-327-5576 Fax : 886-3-327-3013

Xinjiang Daewoo Machinery Co., Ltd

No, 178, Hetanbei Road, Wurumuqi, Xinjiang, China
Tel : 86-991-463-2217 Fax : 86-991-461-8641

Dajian(Tianjin) Mechanical Construction Co., Ltd

No.87 Gongxing Road, Tanggu, Tianjin, china
Tel : 86-222-521-0540 Fax : 86-222-521-0714

Daewoo Heavy Industries Yantai Co., Ltd

#28, Wuzhishan Road, Eco. & Tech, Development Zone,
Yantai, Shandong, China
Tel : 86-535-638-2000 Fax : 86-535-638-2004

Daewoo Construction Machinery Co., Ltd

3rd Floor, k-1 Bld.,19-4, Nishi-shinbashi 2-Chome,
Minato-Ku, Tokyo, Japan
Phone : 81-3-3433-8400 Fax : 81-3-3433-8648

NORTH AMERICA

Daewoo Heavy Industries America Corp.

2905 Shawnee Industrial Way, Suwanee,
Georgia 30024, U. S. A
Tel : 1-770-831-2200 Fax : 1-770-831-0480

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8 York Avenue, West Caldwell, N.J. 07006, U.S.A

Tel : 1-973-618-2500 Fax : 1-973-618-2501

Daewoo Heavy Industries America Cleveland Office

4530 Renaissance Parkway, Warrensville Heights, OH 44128,
U.S.A
Tel : 1-216-595-1212 Fax : 1-216-595-1214

Daewoo Rep. C/O Boeing Co.

P.O.Box 3707 M/S 39-AH, Seattle, WA 98124-2207, U.S.A
Tel : 1-425-266-0478 Fax : 1-425-266-0518

EUROPE

Euro Daewoo U,K Ltd

Daewoo House, Unit 6.3 Nantgarw Park, Cardiff
CF47QU, U.K. / Tel : 44-1443-84-2273 Fax : 44-1443-84-1933

Daewoo Maschinen Vertriebs GmbH

Hans-Bockler strasse 29, D-40764, Langenfeld-Fuhrkamp,
Germany / Tel : 49-2173-8509-20 Fax : 49-2173-8509-60

Euro Daewoo S. A

1A Rue Achille Degrace 7080 Frameries Belgium
Tel : 32-65-61-3231 Fax : 32-65-61-3238

Euro Daewoo S. A France

2Eme Etage, 1/3 Avenue Pavlov, Z.A.I. Des Bruyeres 78190
Trappes France
Tel : 33-1-3016-2140
Fax : 33-1-3016-2144

SOUTH AMERICA

Daewoo Maquinas I Equipamentos Ltda

AV Tres Andradas 519- Jd. Piratininga - CEP
06230-050- Osasco - SP - Brazil
Phone : 55-11-3686-0177 Fax : 55-11-3686-0970

DHIAC Colombia Liaison Office

Diagonal127 A No. 17-34 Oficina 302
Bogota, Colombia

AFRICA

Daewoo Heavy Industries South Africa Pty. Ltd

60C Electron Road Isando 1600, Johannesburg, South Africa
Phone : 27-11-974-2095 Fax : 27-11 -974-2778

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Summary of Contents for P158LE

Page 1: ...65 99897 8076A Operation Maintenance Manual GENERATOR DIESEL ENGINE...

Page 2: ...d to indicate the type of service operations to be performed Removal Adjustment Installation Cleaning Disassembly Pay close attention Important Reassembly Tighten to specified torque Align the marks U...

Page 3: ...r Cleaner 3 4 Fuel System 3 9 Electrical Equipment 3 5 Turbocharger 4 COMMISSIONING AND OPERATION 21 4 1 Preparations 4 4 During Operation 4 2 Starting 4 5 Shutting Down 4 3 Running In 5 MAINTENANCE A...

Page 4: ...9 2 Inspection 9 4 Breaking In 10 MAINTENANCE OF MAJOR COMPONENTS 112 10 1 Cooling System 10 4 Turbocharger 10 2 Lubricating System 10 5 Installation 10 3 Fuel Injection Pump 11 SPECIAL TOOL LIST 145...

Page 5: ...tion for the first time read the operating instructions carefully and familiarize yourself with the critical points If you are unsure ask your DHI representative For reasons of safety we recommend you...

Page 6: ...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 When using compressed air e g for cleaning the radiator wear goggles K...

Page 7: ...inutes 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 ma...

Page 8: ...ents creams etc or wear protective gloves Clean skin which has been in contact with engine oil Wash thoroughly with soap and water A nailbrush is an effective aid Certain products make it easier to cl...

Page 9: ...6 17 18 19 11 10 EA6O1004 1 Piston 11 Vibration damper 2 Combustion chamber 12 Oil spray nozzle 3 Valve 13 Oil pan 4 Tappet 14 Oil suction pipe 5 Cam shaft 15 Oil pump relief valve 6 Turbocharger 16 F...

Page 10: ...14 11 3 4 5 6 7 EA6O1005 1 Cylinder head 8 Cylinder block 2 Cylinder head cover 9 Oil filter 3 Push rod 10 Oil cooler 4 Injection pump 11 Connecting rod 5 Intake manifold 12 Exhaust manifold 6 Injecti...

Page 11: ...Oil filler cap 18 Air pipe 3 Cylinder head cover 11 Pick up sensor Air cleaner to turbocharger 4 Turbocharger 12 Oil cooler 19 Fuel filter 5 Oil drain valve 13 Alternator 20 Air pipe 6 Oil pan 14 Exh...

Page 12: ...r cap 18 Air pipe 3 Cylinder head cover 11 Pick up sensor Air cleaner to turbocharger 4 Turbocharger 12 Oil cooler 19 Fuel filter 5 Oil drain valve 13 Alternator 20 Air pipe 6 Oil pan 14 Exhaust elbow...

Page 13: ...cap 18 Air pipe 3 Cylinder head cover 11 Pick up sensor Air cleaner to turbocharger 4 Turbocharger 12 Oil cooler 19 Fuel filter 5 Oil drain valve 13 Alternator 20 Air pipe 6 Oil pan 14 Exhaust elbow...

Page 14: ...10 6 7 2 11 4 9 Fuel injection timing B T D C static 16 Injection pump type Bosch in line P type Governor type Electrical governor type Injection nozzle type Multi hole type 4 hole Fuel injection pre...

Page 15: ...327 kW 362 kW P158LE 1 60 HZ 498 PS 546 PS 1 800 rpm 366 kW 402 kW 50 HZ 399 PS 437 PS 1 500 rpm 293 kW 321 kW P158LE 2 60 HZ 447 PS 491 PS 1 800 rpm 329 kW 361 kW 50 HZ 541 PS 602 PS 674 PS 1 500 rpm...

Page 16: ...so referred to as engine model and serial number because of their location Engine serial No example 1 P158LE EAZOA300001 Engine serial No example 2 P180LE EASOA300001 Engine serial No example 3 P222LE...

Page 17: ...ngs on crankshaft and flywheel are provided to seal the crankcase penetrations The connecting rods are die forged diagonally split and can be removed through the top of the cylinders together with the...

Page 18: ...d bearings and camshaft bearings as well as to the small end bearings and the rocker arms 14 1 Oil suction pipes 2 Oil pumps 3 Oil relief valves 4 Oil cooler 5 Oil filter 6 Bypass valve 7 Main oil gal...

Page 19: ...tent of delivery and the design of the engine the lube oil circuit can be equipped with oil pressure monitors advance warning and cut off function which shut the engine down in the event of a sudden l...

Page 20: ...njections in the cylinder heads Excessive fuel delivered and leak fuel from the injectors flow through the return pipe back to the tank 16 1 Fuel tank 5 Fuel pipe connector 2 Strainer 6 Injection pump...

Page 21: ...ntering the suction chamber of the injection pump the fuel is cleaned in a fuel filter 3 5 Turbocharger The exhaust gases of the engine are passed through the turbine rotor of the turbocharger Air imp...

Page 22: ...r element are worn or polluted Cleaning of intercooler fins Every 600 hours 3 7 Cooling The engine has a liquid cooling system The water pump is a maintenance free impeller pump driven by V belts from...

Page 23: ...nder and piston wear 3 9 Electrical Equipment 1 Alternator The alternator is fitted with integral silicon rectifiers A transistorized regulator mounted on the alternator body interior limits the alter...

Page 24: ...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...

Page 25: ...uels lubricants and coolants Use approved fuels lubricants and coolants only as otherwise the manufacturer s guarantee will be null and void 4 2 Starting Insert key in starting lock Moving control lev...

Page 26: ...perature should be approx 80 to 85 C The charge warning light of the alternator should go out when the engine is running 1 Alternator In order to avoid damage to the alternator observe the following i...

Page 27: ...anel to stop After the engine has been running at a high load level do not shut it down immediately but allow it to idle about 5 minutes so that temperatures may equalize Remove key from starting lock...

Page 28: ...age to the engine The oil level should be checked with the engine horizontal and only after it has been shut down for about 5 minutes 5 1 2 Oil drainage With the engine at operating temperature remove...

Page 29: ...st engine performance and engine life Engine oil is specified by API service lettered designations and SAE viscosity numbers If the specified engine oil is not available use a reputable brand of engin...

Page 30: ...l filter Cleaning of the lubricating oil is effected in a full flow oil filter with paper cartridges A bypass valve ensures continuity of oil supply if the filter elements should be clogged After drai...

Page 31: ...owls Renew filter cartridges Thoroughly clean all other parts in cleaning fluid do not allow cleaning fluid to enter the oil circuit NOTE To prevent the seal from twisting hold the filter bowl firmly...

Page 32: ...perature to prevent clogging of fuel fitters by crystals 28 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 3...

Page 33: ...every 200 hours of operation the fuel strainer connected upstream of the fuel lift pump should be cleaned 5 2 3 Fuel filter After every 200 hour of operation drain the water and sediment from the fuel...

Page 34: ...livered 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 gasket fitted to the injector ensure...

Page 35: ...st oil before use The cutter can also be clamped in a lathe Polish needle seat with wooden cleaning tool preferably by chucking the needle in a lathe at the pintle end Clean the spray holes of nozzles...

Page 36: ...gned for high operating pressures and should thus be handled with particular core When mounting the pipes to the engine take care of good fitness Do not bend pipes to permanent deformation not for rep...

Page 37: ...er cap with working valves to the first notch Let off pressure and then close this cap again After this the cap on filler neck can be removed without risk of scalding Coolant must be added at the fill...

Page 38: ...umstances and fit a new one as soon as possible afterwards 5 4 2 Draining of coolant Drain coolant as follows when cooling system has cooled down Remove cover from filler neck of radiator Remove drain...

Page 39: ...pressor casing Caution Do not skew it and clean in 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 soa...

Page 40: ...ilter is installed horizontally watch for top mark on cleaner bowl 5 6 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...

Page 41: ...to soak in lukewarm washing solvent for10 minutes and then move it to and for in the solvent for about 5 minutes Rinse thoroughly in clean water shake out and allow drying at room temperature The cart...

Page 42: ...eats and rubber gaskets or for bulges and dents etc in the metal jacket Cracks and holes in the paper pleating can be established by inspecting the cartridge with a flashlight Damaged cartridges shoul...

Page 43: ...edge in the sight hole of the flywheel housing shouted now coincide with the degree marked on the flywheel corresponding to the specified start on fuel delivery position If not the start of delivery s...

Page 44: ...inder is located at the side where cooling water pump was installed 6 2 1 Valve clearance adjust procedure After letting the 1 cylinder s piston come at the compression top dead center by turning the...

Page 45: ...ngine and 12 cylinder engine or 7 10 cylinder engine cylinder s valves overlap Adjust the valve clearance corresponding to of lower lists After reinsuring the valve clearances retighten if necessary 8...

Page 46: ...4 8 1 5 7 2 Intake Exhaust valve Valve overlapping on cylinder 1 6 5 10 2 7 3 8 4 9 Intake Exhaust valve Adjusting valves on cylinder 7 3 8 4 9 1 6 5 10 2 Intake Exhaust valve Valve overlapping on cyl...

Page 47: ...all the special tool compression gauge adapter at the nozzle holder hole and connect the compression pressure gauge there Condition Water temperature 20 C Engine rotation 200rpm 10 rotation 43 EFM1004...

Page 48: ...the cylinder head gasket must always be changed 2 Standard and repair length of cylinder head bolts Checking Re using old cylinder head bolts check them ad follows Length During tightening the bolts a...

Page 49: ...belt tension is possible only by using a V belt tension tester 4 Measuring tension Lower indicator arm 1 into the scale Apply tester to belt at a point midway between two pulleys so that edge of cont...

Page 50: ...g adjusting bolt 3 Remove fixing bolts Remove lock nut Adjust nut until V belts have correct tensions Retighten lock nut and fixing bolts To replace the V belts loosen lock nut and swing alternator in...

Page 51: ...akage for intercooler hoses clamp Intake Clean and change Exhaust the air cleaner element System Clean the inter cooler air fins Clean the turbo charger Check the leakage fuel line Clean the fuel stra...

Page 52: ...Replace Inspect of other parts Check valve clearance Normal Adjust Check cylinder head gasket Replace Normal Engine disassembly valve assembly piston cylinder liner etc Fuel Inspect amount of fuel Non...

Page 53: ...air Replace Repair Replace Repair Replace Repair Replace Replenish Replace Replace Damage Check cooling water pump Engine disassembly Fuel unit Inspect fuel quality Poor Clean and replace with specili...

Page 54: ...Check injection timing Adjustment Disassemble engine or injection pump Inspect injection pipe Check Turbocharger Repair Replace Disassemble injection pump or engine Others Inspect air cleaner Clean R...

Page 55: ...Normal Normal Normal Check cooling temperature Inspect oil quality Check oil relief valve Retighten Replace Disassemble engine Too high Refer to engine overhea Water fuel mixed in oil Disassemble engi...

Page 56: ...re Disassemble injection pump Inspect head gasket Disassemble engine valve assembly piston cylinder liner etc Adjust Replace Adjust Adjust Check valve clearance Replace Causes according to Use Conditi...

Page 57: ...al Retighten Replace Check compressed pressure Engine disassembly piston cylinder liner Disassemble cylinderhead valve stem seal Inspect air cleaner Clean Replace 7 Engine Knocking Inspect combustion...

Page 58: ...Repair Replace Generator Check fan belt tension damage Normal Normal Electrolytic liquid s standard Replenish Battery room damage Replace Battery self discharge Charging Battery over charging Inspect...

Page 59: ...ed Repair or replace Fuel pipe system clogged Repair Air suction amount insufficient Clean or replace air cleaner Supercharger poor Repair or replace 2 Output insufficient Compression pressure Disasse...

Page 60: ...d crankshaft Oil supply insufficiency as clogging Clean oil passage at oil passage progresses 3 Piston piston pin Piston clearance increase as the wear Replace piston piston ring of piston and piston...

Page 61: ...on Correct position improper Piston skirt part damaged or Replace piston abnormal wear Oil ring s oil return hole clogged Replace piston ring Oil ring s contact poor Replace piston ring 2 Oil level lo...

Page 62: ...ld be discarded and new ones should be prepared for installation as normal function of the parts can not be maintained if these parts are reused 7 To facilitate proper and smooth reassemble operation...

Page 63: ...ry in the crown is normally necessary to prevent crown cracking and ring sticking The design of the gallery the design and location of the oil spray nozzle and the quantity of oil flowing in the galle...

Page 64: ...l care is needed Since P158LE P180LE P222LE POLUS series generator engine of D28 base engine cylinder liner is wet type particularly the cooling water control should be applied thor oughly The density...

Page 65: ...after refilling with clean fresh water Amount of Anti freeze in winter 8 3 2 Fan belt Use a fan belt of specified dimensions and replace if damaged frayed or deteriorated Check the fan belt for belt t...

Page 66: ...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 200 hours 8 3 5 Air Cleaner In case that...

Page 67: ...ance Adjust Procedure After letting the 1 cylinder s piston come at the compression top dead center by turning the crankshaft adjust the valve clearances Loosen the lock nuts of rocker arm adjusting s...

Page 68: ...4 8 1 5 7 2 Intake Exhaust valve Valve overlapping on cylinder 1 6 5 10 2 7 3 8 4 9 Intake Exhaust valve Adjusting valves on cylinder 7 3 8 4 9 1 6 5 10 2 Intake Exhaust valve Valve overlapping on cyl...

Page 69: ...ected injection pressure is less than the specified value 285 kg cm 2 adjust using the adjusting shims Check the atomizing state and replace it if abnormal 8 3 10 Fuel Injection Pump Check the housing...

Page 70: ...ment a leakage or clogging of oil pipes should be inspected Air cleaner should be maintained carefully for nut or foreign material not to get in Periodic inspection should be applied on the compressed...

Page 71: ...other In disassembling torn parts should be laid in disassembled order 9 1 Engine Disassembly Engine parts disassembly procedures are as follows 9 1 1 Oil Level Gauge Take out the oil level gauge 9 1...

Page 72: ...sassemble the alternator 9 1 7 Vibration Damper Remove the fixing bolts for crankshaft pulley in reverse order of assembling and disassemble the crankshaft pulley and vibration damper 9 1 8 Oil Filter...

Page 73: ...ssemble the thermostat Remove the cooling water pump fixing bolts and disassemble the cooling water pump 9 1 10 Starting Motor Remove the starting motor fixing nuts and disassemble the starting motor...

Page 74: ...the oil cooler By removing the cooler housing fixing bolts and disassemble the oil cooler housing from the cylinder block 9 1 14 Turbocharger Loosen the hose clamp for connecting the intake stake and...

Page 75: ...Exhaust Manifold Remove the exhaust manifold fixing bolts and tear the manifold from the cylinder head 9 1 17 Intake Manifold Remove the manifold fixing bolts and tear the manifold down from the cyli...

Page 76: ...Injection pump 9 1 20 Cylinder head cover Remove the fixing bolts and tear the cylinder head cover down 9 1 21 Nozzle holder By means of a special tool loosen the nozzle holder assembly and take it ou...

Page 77: ...il pan fixing bolts and separate the pan Remove the oil pan gasket and scrap it 9 1 25 Oil Pump Remove the oil suction pipe fixing bolts and tear them down Remove the oil relief valve fixing bolts and...

Page 78: ...the oil seal holder fixing bolts and tear down Remove the oil seal and gasket from the oil seal holder and scrap them 9 1 28 Flywheel Remove the flywheel fixing bolts in the order of disassembling an...

Page 79: ...mingle with the metal bearings and bearing caps randomly To prevent mixing temporarily assemble the metal bearings to the corresponding bearing caps in turn 9 1 31 Camshaft and Tappet Pull out the ta...

Page 80: ...ylinder liner measurement Assemble the cylinder liner at the cylinder block and measure inner diameter at upper middle lower that is 3 steps by 45 O interval and calculate the average values after eli...

Page 81: ...hydraulic test or a magnetic powder test Hydraulic test is same as for cylinder block Distortion of cylinder head bottom face 1 Distortion at the lower face Measure the amount of distortion using a st...

Page 82: ...er but if severe replace it If valve head thickness H becomes less than 1 6mm for intake and 1 3mm for exhaust replace the valve b Valve guide Insert the valve into valve guide and measure the clearan...

Page 83: ...fromthelowerface measure the projection amount of valve If the measured value is more than the use limit replace the valve seat Valve seat thickness Valve seat angle The disassembly of valve seat can...

Page 84: ...that the measured value exceeds the limit value replace it Perpendicularity regular e Assembling Cylinder head Clean the cylinder head thoroughly Coat the valve stems and valve guides with engine oil...

Page 85: ...surement a Rocker arm bracket Single unit type with a shaft Measure the outer diameter of rocker arm bracket with outside micrometer at the position that the rocker arm is installed and in case that i...

Page 86: ...ut if severe replace them Place the push rod on the surface plate and rolling it Inspect the curving degree with a clearance gauge and if abnormal replace it Run out D Rocker Arm Reassembling Inspect...

Page 87: ...eck With inspecting the cam surface for any damage with naked eyes and correct any minor scratches by means of an oil stone grinding and if severe replace it Cam lobe height Use a micrometer to measur...

Page 88: ...rance between camshaft journal and body Camshaft bearing replacement Remover installer Camshaft run out With placing the camshaft on the 2ea of V blocks and inspect the run out of the camshaft adjust...

Page 89: ...acked ones Journal and pin diameter With outside micrometer measure the outside diameter of crank journal and crank pin at the direction and position of the figure shown and take the wear Crankshaft j...

Page 90: ...Crankshaft a Place the crankshaft on the V block b Place the dial gauge on the surface plate and measure the run out of crankshaft rotating the crankshaft 2 Inspection on crankshaft bearing and connec...

Page 91: ...hen after tightening the bearing cap at the specified torque and again after tearing apart the bearing cap measure the flatten plastic gauge thickness by pick it up This is the oil clearance With the...

Page 92: ...piston for any wear crack and scratch and particularly inspect carefully at the ring grooves for any wear With the outside micrometer measure the piston s outside diameter the measuring position is 71...

Page 93: ...her one that is more severe 3 Piston ring and ring groove Inspection In case of piston ring s wear damage or engine overhaul replace piston rings Gap clearance Measure the piston ring cut part Insert...

Page 94: ...side diameter and if the value is same as the use limit value or less replace it Piston pin and connecting rod bush clearance Inspect the clearance between the piston pin and the connecting rod bush i...

Page 95: ...parts If it is more than the use limit value replace the connecting rod 6 Piston reassembling After heating the piston at the piston heater for about 5 min 120 150 C by aligning the piston pin hole w...

Page 96: ...nozzle assembly between the vise holder and disassemble it Remove the nozzle nuts and disassemble the inner parts Inspect the disassembled parts if there is any damage replace it Assembling can be don...

Page 97: ...case of low or high injection pressure adjust by adding or reducing the spring tension adjusting shims In case that atomizing state is not good it should be replaced 93 EFM2057I Normal Abnormal Abnor...

Page 98: ...preliminary re assembly After completing the engine re assembly operation check if there is missing parts or shortage of parts Keep your hands clean during the working 9 3 2 Cylinder block Cover the...

Page 99: ...9 3 6 Crankshaft Put the wear ring into the heater to heat it up to 150 200 C level push it over the crankshaft by means of a jig Assemble the main bearing to the cylinder block and coat it with engin...

Page 100: ...ening order tighten them with 30 kg m and with rotating angle method 90 10 and tightening order is as follows Bearing cap bolt s tightening order 1 First step Coat the bolts with engine oil 2 Second s...

Page 101: ...it carefully not to be deviated or damaged by means of special tool Mandrel for assembling Attach the gasket on the surface of cylinder block where the flywheel housing is to be installed In order to...

Page 102: ...es place then install it using a hammer Do not allow the temperature of the ring gear to exceed 200 C 390 F By means of mandrel press in the wear ring at the backward face Install two guide bolts for...

Page 103: ...9 3 13 Piston Line up the piston assembly in the order of cylinder number and fit the bearings to the connecting rods and bearing caps However take care not to swap between the connecting rods and bea...

Page 104: ...threads by hands 3 Third step Tighten to about 7 kg m with wrench 4 Fourth step By means of torque wrench tighten to 10 kg m 5 Fifth step Finally assemble by means of rotation angle method 90 10 Howev...

Page 105: ...n the fixing bolts in the zigzag method 9 3 15 Vibration damper Assemble the vibration damper tightening firstly by the crankshaft pulley and the fixing bolts Insert the crankshaft pulley assembly to...

Page 106: ...all the guide tube and insert the oil level gauge 9 3 18 Cylinder head Blow the cylinder head bolt holes with compressed air to remove the foreign material cleanly Wipe off cleanly the junction part o...

Page 107: ...tionally rotating 90 Standard length of bolt and use limit from the head seat face to tip Take care for the foreign material not to get into the cylinder head suction passages 9 3 19 Nozzle Put the ne...

Page 108: ...e filler gauge of specified value between rocker arm and valve stem Tighten the adjusting screw using a driver until the inserted feeler gauge can be taken a slight resistance between the valve stem a...

Page 109: ...ive gear with injection pump pointer Fit the injection pump in the appropriate position using a special tool Special tool no EF120 189 After fixing the jig hole on the limit cap of the injection pump...

Page 110: ...ug screw assembled in case cover on the injection pump drive gear Some cases are needed to remove cover assembly And turn the crank pulley so that the mark on pointer provided on injection pump coinci...

Page 111: ...hing mark FB on the flange surface of the drive gear by turning the flange in the oblong holes of the drive gear 4 Tighten the bolt M8 to specified torque 2 2kg m not to move the drive gear 5 After co...

Page 112: ...gasket to the inlet flange and assemble by tightening the fixing bolts Assemble both sides by the above method Attach the gasket to the equalizing pipe that connects the intake manifolds of both side...

Page 113: ...method as above both sides are assembled 9 3 31 Intake Stake Connect rubber hoses between the intake stake and turbocharger and assemble by tightening clamps 9 3 32 Fuel injection pipe Connect the fue...

Page 114: ...tor and water pump pulleys with V belts by inserting them into the respective pulleys Adjust the alternator support nut until the belt tension can be 10mm 15mm by pushing with thumb 9 3 35 Idle pulley...

Page 115: ...ge 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 I...

Page 116: ...jacket of the cylinder block and water passage of the cylinder head to absorb the heat of the combustion chamber The water absorbing the oil heat and combustion chamber heat goes on to the thermostat...

Page 117: ...ermostat valve the bypass circuit is closed and the water passage to the radiator is opened so that the coolant is forced to flow into the radiator Item Specification 1 Water pump Centrifugal type Typ...

Page 118: ...quickly as bellows type one to a variation of temperature of coolant Such relatively slow reaction is mainly due to the large heat capacity of the wax pellet type thermostat Therefore to avoid a sharp...

Page 119: ...ng into water jacket Replace cylinder head gasket due to broken cylinder head gasket 2 Engine overcooling Thermostat inoperative Replace thermostat Ambient temperature too low Install radiator curtain...

Page 120: ...ns Lubricating system Forced pressure circulation Oil pump type Gear type Relief valve opening 8 5 10 kg cm2 pressure Adjusting valve for spray nozzle Opening pressure 1 6 1 9 kg cm2 Item Specificatio...

Page 121: ...inder liner worn Replace cylinder liner Piston rings sticking Replace pistons and or piston rings Valve guide oil seals or valve Replace guides or valve stem worn 2 Oil pressure too low Poor oil Use s...

Page 122: ...n View Fig No Description Q ty Remark 1 Frame 1 2 Bearing retainer kit Ass y 1 3 Mounting bar 1 8 SWP connector 1 Mg610320 11 Front cover 1 T3 2 13 Shaft 1 15 Return spring guide Ass y 1 16 Oil seal 1...

Page 123: ...mance adjustments gain and stability All adjustments are accessible from the front cover The primary features of the DWC 2000 Series speed control unit are the engine STARTING FUEL and SPEED RAMPING a...

Page 124: ...sed with clockwise rotation of the gain adjustment The gain adjustment has a non linear range of 33 1 The stability adjustment when advanced clockwise increases the time rate of response of the govern...

Page 125: ...upply 24VDC Battery System Transient and Reverse Voltage Protected Polarity Negative Ground Case Isolated Power Consumption 50 mA continuous plus actuator current Maximum controllable actuator current...

Page 126: ...TOR CABLE SHIELDING TO MEET CE DIRECTIVE ADD JUMPER FOR 12V BATTERY OR ACTUATOR CURRENTS ABOVE 5A AUX 10V POWER FUSE 15A MAX SPEED TRIM CONTROL 5K CLOSE FOR IDLE CLOSE FOR DROOP Run Crank Reset Starti...

Page 127: ...stray speed signals may be introduced to the speed control unit With the engine stopped adjust the gap between the magnetic speed sensor and the ring gear teeth The gap should not be any smaller than...

Page 128: ...Then back off slightly CCW 1 8 turn beyond the point where stability returns Excellent performance should result from these adjustments If instability cannot be corrected or further performance improv...

Page 129: ...ent control When the engine is at idle speed the speed control unit applies droop to the governor system to insure stable operation Speed droop operation Droop is typically used for the paralleling of...

Page 130: ...governor system accessories Up to 20ma of current can be drawn from this supply Ground reference is Terminal G Caution a short circuit on this terminal can damage the speed control unit Wide range rem...

Page 131: ...m Inoperative If the engine governing system does not function the fault may be determined by performing the voltage tests described in steps 1 2 3 and 4 and refer to meter polarity Should normal valu...

Page 132: ...0VDC a SPEED adjustemnt set above desired speed b Defective speed control unit 2 If the voltage reading is above 6 0VDC a Actuator or likage binding 3 if the voltage reading is below 4 0VDC 4 Gain set...

Page 133: ...pe can be further classified as fast or slow instability Fast instability is a 3Hz or faster irregularity of the speed and is usually a jitter Slow periodic instability is below 3Hz can be very slow a...

Page 134: ...054 5 Injection order 1 5 7 2 6 3 4 8 6 Injection timing BTDC 16 130 A Test condition Nozzle Holder Ass y 1 688 901 105 Opening pressure 208 5 1 5 bar for injection pump Injection pipe ID OD L 3 0 x 8...

Page 135: ...njection order 1 6 5 10 2 7 3 8 4 9 6 Injection timing BTDC 16 131 A Test condition Nozzle Holder Ass y 1 688 901 105 Opening pressure 208 5 1 5 bar for injection pump Injection pipe ID OD L 3 0 x 8 0...

Page 136: ...ction order 1 12 5 8 3 10 6 7 2 11 4 9 6 Injection timing BTDC 16 132 A Test condition Nozzle Holder Ass y 1 688 901 105 Opening pressure 208 5 1 5 bar for injection pump Injection pipe ID OD L 3 0 x...

Page 137: ...llied Signal T45 Allied Signal TV51 Rated Revolution rpm 111 800 92 200 82 000 Intake Air Quantity m 3 sec 0 26 0 32 0 40 Compression Efficiency 75 5 75 0 77 5 Compression Ratio 3 00 2 80 2 90 1 Impel...

Page 138: ...Seal ring 19 Screw 6 Seal ring 21 Heat dissipator 7 Seal ring 22 Compressor housing 8 Compressor wing wheel 23 Clamp 9 Turbine housing 24 Bolt 10 Bolt 27 Liquid gasket 11 Clamp 30 Loctite 13 Bearing h...

Page 139: ...bad effect at bearing part there are the seal ring and heat dissipator 10 4 3 2 Compressor It is connected to the same shaft with the turbine to make a revolving assembly and receive the revolving for...

Page 140: ...at after the confirming above retighten the pipe connecting parts without fail and proceed with the normal starting 1 Perform idling operation for about 5 min immediately after engine starting 2 Vario...

Page 141: ...operation for 5min and then stop it 1 If the pressure is too low abnormal wear or stuck may be caused Or if too high the oil leak may be generated 2 If the engine operation were continued with abnorm...

Page 142: ...for the super charging effect will be lowered the installed states of various parts must be paid with careful attention Since the parts that reach to high temperature during operation such as the turb...

Page 143: ...turbocharger 10 4 6 2 End play Inspecting Points of Rotor Disassemble the turbocharger from the engine and should inspect the end plays in axial and circumference direction In case of disassembling t...

Page 144: ...hand lubricate journal and thrust bearing Clean the pipe and oil outlet pipe between engine and oil inlet and confirm if there is any pipe damage or foreign material In order for oil not to leak from...

Page 145: ...age 1 Gas leak from various parts of exhaust system 2 Air cleaner s elements clogged 3 Turbocharger s pollution or damage 4 Air leaks from discharge part of compressor side 1 Revolving parts contact 2...

Page 146: ...may contact the flywheel housing bore as the right figure Measure the eccentrics of flywheel housing bore by rotating the flywheel The eccentrics should not exceed 0 2 mm 3 Measuring deformation of f...

Page 147: ...ixed at the Generator installing platform and the bed rail 3 Aligning center The center alignment of engine and Generator is the most important factor for the extension of life cycle Output shaft flan...

Page 148: ...drop etc Example of fuel system installation The position of fuel tank should be high than the engine fuel pump but when it is compelled to install at lower position its lift should be within 1 m and...

Page 149: ...RR 2 EF 120 183 Valve stern oil seal installer 3 EI 00308 0084 Nozzle holder extractor 4 EU 2 0532 Compression gauge adapter 5 EI 03004 0225 Nozzle plug socket 6 EF 120 189 Injection pump alignment 7...

Page 150: ...0027 Feeler gauge 11 T7610001E Snap ring plier 12 EI 00308 0084 Valve cotter extractor 13 EF 120 069 F W H Pin Installer 14 E1 05508 0185 CRS Wear Ring Installer 15 EF 120 032 Cam Gear SUB JIG 16 EF...

Page 151: ...e 90 Cylinder head M15 x 2 12 9 8kg m 15kg m Angle 90 Angle 90 Cylinder head cover M8 8 8 2 2 Fuel injection nozzle holder M28 CK60 7 0 5 Fuel injection pipe M14 x 1 5 2 5 Cam shaft timer M10 10 9 9 R...

Page 152: ...148 Specification Screw Strength Tightening Torque kg m M12 x 1 5 5 M14 x 1 5 8 M16 x 1 5 8 M18 x 1 5 10 Plug screw M22 x 1 5 10 M24 x 1 5 12 M26 x 1 5 12 M30 x 1 5 15 AM10 x 1 0 5 AM14 x 1 5 8...

Page 153: ...0 45 0 4 0 55 0 47 0 77 0 85 0 9 1 25 0 5 M7 0 43 0 46 0 7 0 63 0 83 0 78 1 2 1 3 1 4 1 95 2 35 M8 0 7 0 75 1 1 1 1 4 1 25 1 9 2 1 2 2 3 1 3 8 M8x1 0 73 0 8 1 2 1 1 1 5 1 34 2 1 2 3 2 4 3 35 4 1 M10...

Page 154: ...127 990 128 010 128 0 01 Liner s roundness columness upper 0 01 from top up to 168mm Liner s roundness columness lower 0 015 from bottom up to 85mm Liner s projection 0 04 0 08 measure at 4 place Pist...

Page 155: ...per engine 50g Perpendicularity of large end inside diameter 0 035 reference to Large end part s inside roundness columness 0 01 con rod side face Large end part s inside straightness 0 005 Paralleln...

Page 156: ...25 3 585 3 597 Oversize 0 50 3 710 3 722 Oversize 0 75 3 835 3 847 Oversize 1 00 3 960 3 972 Main bearing oil gap 0 066 0 132 Main bearing spread 0 3 1 2 Thrust bearing s spread 0 3 1 2 Flywheel Ring...

Page 157: ...s outside diameter 18 028 18 046 18 25 S7 Valve guide assembly locking piece 0 010 0 046 Valve seat s shaking 0 04 reference to valve guide Valve Valve lift 14 1 spring Projecting amount of valve guid...

Page 158: ...8 5 10bar Spray nozzle Operating pressure 1 6 1 9bar Crossing pressure 1 3 1 6bar Tip diameter 2 Backlash crankshaft gear oil pump drive gear 0 10 0 45 Oil pump housing s depth gear width 43 000 43 0...

Page 159: ...on Korea Tel 82 32 760 1526 Fax 82 32 762 1522 http www enginepark com Parts Center 85 1 Palgok Ei dong Sangnok gu Ansan shi Kyunggi do Korea Tel 82 31 400 2206 Fax 82 31 400 2255 http cs dhiltd co kr...

Page 160: ...0rpm kW PS kW PS kW PS 1 500rpm Marine Propulsion Engines L034 L034TIH L034TIM L136 L136T L136TL L136TI L086TIH L086TIM MD196T MD196TI 51 70 3 000 88 120 3 000 107 145 3 300 118 160 2 200 147 200 2 20...

Page 161: ...0 750 9 11 14 17 18 23 18 23 24 30 24 30 45 56 55 69 77 96 105 131 155 194 155 194 182 228 235 294 250 313 290 362 327 409 364 455 409 511 445 556 541 676 9 11 13 17 16 20 16 20 22 27 22 27 40 50 48 6...

Page 162: ...0 Fax 1 973 618 2501 Daewoo Heavy Industries America Cleveland Office 4530 Renaissance Parkway Warrensville Heights OH 44128 U S A Tel 1 216 595 1212 Fax 1 216 595 1214 Daewoo Rep C O Boeing Co P O Bo...

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Daewoo P158LE, Operation & Maintenance Manual

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