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#ПСМ

ТАКОЙ УВЛЕКАТЕЛЬНЫЙ ДЕНЬ

Сегодня вторую половину дня, как и собирался, провёл на выставке Нефтегаз-2023

Делюсь главными впечатлениями:

1. 70 % участников выставки — китайцы ????????.
2. Запомнилась история китайского завода. Не буду тыкать здесь известного российского производителя бурового оборудования, но часто производство даже у бывших советских заводов полного цикла выглядит именно так: китайский завод попросили российскими буквами нанести название и логотип.
3. У нас основная тема сегодня — это производители буровых насосов. Сейчас доля китайцев на рынке в России близка к 100 %. Задача правильно выбрать китайцев.
4. Американский CAT просит китайцев не продавать двигатели в Россию. Так что хочешь купить мотор, возьми у нагрузки китайский суповой набор.
5. Ключевые компоненты много какого китайского оборудования американские (автоматические трансмиссии, механизмы отбора мощности, контроллеры и т.д.).
6. В Китае 30-40 производителей. От шильдиковтирателей до огромных завод полного цикла.
7. Производителей из других дружественных стран — Турция, Иран на выставке 0.0…1 % условно.
8. Все китайцы просят после встречи сфоткаться. Видно нужен отчёт что не зря съездили.
9. Все взяли русских переводчиков, но, блин, они ничего не понимают в предмете разговора. Так что наша тактика на найм собственного «китайца» точно оправдана.
10. Каждый раз смотришь сайт и ролик за день до выставки и думаешь: «Почему мы решили не участвовать ????‍♂️». Выходишь с выставки и думаешь, что участие в выставках — это ????

24.04.2023 07:27:14

#ПСМ

НЕФТЕГАЗ-2023

Завтра (один день) планирую быть на выставке в Экспоцентре. Пишите, кто хочет пересечься.

Андрей Медведев
23.04.2023 11:10:15

#БИЗНЕС

ЗОЛОТАЯ КОНУРА vs. ЗАВОД

Ради интереса решил погуглить стоимость этого помещения конкрного типа на Остоженке рядом с Храмом Христа Спасителя в Москве (начало так называемой «Золотой Мили»). Оказалась, что мы примерно за такую же стоимость собираемся построить новый завод ПСМ Прайм 2.

Думаю для большинства инвесторов в России выбор очевиден.

Андрей Медведев
23.04.2023 05:40:53

#БИЗНЕС

ДЕЛО МОЕЙ ЖИЗНИ

В четверг к нам приезжал очень важный клиент и спросил моего коллегу (сам я был в Москве и Питере в этот день): «Зачем Андрей занимается этим бизнесом. Его же в десятки раз не масштабируешь и в Forbes так не попадешь».

Вот кратко мой ответ:

1. Я горжусь, чем я занимаюсь. И это все же про быть, а не про казаться. Очень рад, что я продаю не воздух, а крутое железо. И с каждым годом мы делаем всё более сложный и качественный продукт.
2. Я кайфую от того, что я делаю. У нас крутая команда и люди, с которыми приятно каждый день общаться, иногда 24/7. Классные офисы и заводы, где рад проводить большую часть своего жизненного времени.
3. Я каждый день развиваюсь. Новые проекты, новые навыки, новое общение, новые путешествия и т.д. И всё это в огромном количестве каждый день.
4. Я за почти 18 лет абсолютно не устал это делать, а наоборот, иногда даже жалко, что время летит так быстро.
5. Я уверен, что если ты каждый день херачишь, как сумасшедший с головой, то в один прекрасный момент ты вытащишь лотерейный билет на несколько десятков, а может и сотен миллиардов (ставки с каждым годом растут, и это не может не радовать). И это будет заслуженно.

P.S. В Forbes я обязательно попаду. Иначе зачем всё это ????????

Андрей Медведев
22.04.2023 10:07:24

#ПСМ

ИНЖИНИРИНГОВЫЙ ЦЕНТР

В итоге выбрали такой вариант. Дальше разработаем свою уникальную картинку на стену в виде кода (ASCII-графика, например).

Отвечаю на замечания из предыдущего поста на эту тему:
1. Что open space (в ПСМ, как я писал, это не обсуждается).
2. Также у нас принципиальная позиция, что инженеры должны быть в близком контакте с производством, а не в изолированном мире.

Андрей Медведев
21.04.2023 04:34:32

#ПСМ

НАШИ НОВЫЕ ДРУЗЬЯ ????????

Вчера за ужином наши китайские партнеры сказали (правда после нескольких настоек и пару бокалов пива) что Си Цзиньпин, когда вернулся со встречи с Путиным в России, собрал крупнейшие китайские государственные компании производителей двигателей. На этом собрании он сказал, что надо помочь нашим российским партнерам, а им параллельно захватить российский рынок.

Мы активно строим работу сейчас с китайскими партнерами, и у меня запланировано 2 визита туда — в мае и в июне. Меня только несколько беспокоит их понимание, что деваться нам здесь некуда и надо использовать ситуацию по полной.

Например, российско-китайскому СП Волжский индустриальный двигатель, когда только всё начиналось, китайская сторона неплохо подняла цены. И сейчас китайский газовый Baudouin на 500 кВт стоит почти как раньше немецкий MAN.

Главное всё же сейчас — выстроить ВЗАИМОВЫГОДНОЕ сотрудничество ???????? ???????? win-win ????????????, а так я за дружбу и жвачку.

Андрей Медведев
18.04.2023 09:00:49

#ПСМ

ИНЖИНИРИНГ

Одним из главных фундаментов бизнеса ПСМ несомненно является инжиниринг. В нашей структуре есть Управление Главного Конструктора, в котором работает около 30 человек. Они находятся на одной из наших производственных площадок — ПСМ Красный Бор.

Наша задача существенно нарастить свои компетенции в этом блоке бизнеса (новые группы и специалисты), чтобы мы как в производственных возможностях были не досягаемы для конкурентов. ????

Кроме того, я уже транслировал на годовом собрании сотрудникам компании важную вещь. За 2 года мы должны достичь такой среды в компании, что не важно, где человек работает — в офисе ПСМ Сити в Башне Федерация или на производстве в Тутаеве или Ярославле, условия труда должны быть одинаковые.

В этом году у нас в плане инвестиций куча всего, но дизайн-проекта и ремонта Инжинирингового центра не было. Но в январе мы решили, что надо это сделать как можно быстрее за счет других статей расходов.

Сейчас план такой: в апреле утвердить визуализацию, дальше рабочая документация и в июне начать ремонт, чтобы край в августе сдать коллегам новое, красивое и современное рабочее пространство.

У нас было в работе 4 таких варианта. Угадайте, на каком мы остановились и уже прорабатываем детали.

МЫ РАЗВИВАЕМ РОССИЙСКОЕ ЭНЕРГЕТИЧЕСКОЕ МАШИНОСТРОЕНИЕ И ДЕЛАЕМ ЭТО КРАСИВО ????

Андрей Медведев
16.04.2023 01:22:24

#ЖИЗНЬ

БАСКЕТБОЛ ⛹️

До сегодня я один раз в жизни был на баскетболе и это был плей-офф НБА Вашингтон Уизардс — Бостон Селтикс. Это было топ-шоу ????, пример мощнейшей коммерциализации спорта и звезда.

Сегодня тоже была довольно эмоционально и постарались сделать шоу (Баста исполнил гимн ЦСКА).

Что удивительно и тогда Айзея Томас и сегодня Каспер Уэйр самые маленькие игроки (175 и 177 см) на площадке набрали больше всего очков и сделали игру. Сегодня вообще интересно у ЦСКА были лучшими самый маленький американец ???????? и самый высокий серб ???????? (213 см).

Не все так просто в этом мире: маленькие и большие, американцы, русские и сербы бьются за одну победу.

Андрей Медведев
15.04.2023 08:21:20

65.99892-8051

Operation Manual

GENERATOR DIESEL ENGINE

DE12T

POLUS

P126TI

FOREWORD

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

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

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

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

In order to operate the engine in the optimal conditions and to maintain its best performances, the contents in this instruction are to be thoroughly understood and observed.

In addition refer to the INSTALLATION manual about DAEWOO generator engine installation instructions.

All warranty claims to be addressed to;

Engine Export Team,

DAEWOO Heavy Industries LTD.

DAEWOO Center 541

Namdaemun-ro 5-ga, Chung-gu

Seoul, Korea

TEL : (82-2-726-3205~8), FAX: (82-2-726-3168)

Or to your local DEALER or DISTRIBUTOR.

DAEWOO Heavy Industries LTD.

July. 1999

1. General information

1.1. Engine specification

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2.2.2.During maintenance and care

•Always carry out maintenance work when the engine is switched off. If the engine has to be maintained while it is running, e.g. changing the elements of change-over filters, remember that there is a risk of scalding. Do not get too close to rotating parts.

•Change the oil when the engine is warm from operation.

Caution :

There is a risk of burns and scalding. Do not touch oil drain valve or oil filters with bare

hands.

•Take into account the amount of oil in the sump. Use a vessel of sufficient size to ensure that the oil will not overflow.

•Open the coolant circuit only when the engine has cooled down. If opening while the engine is still warm is unavoidable, comply with the instructions In the chapter entitled “Cooling”.

•Neither tighten up nor open pipes and hoses (lube oil circuit, coolant circuit and any additional hydraulic oil circuit) during the operation. The fluid which flow out can cause injury.

•Fuel is inflammable. Do not smoke or use naked lights in its vicinity. The tank must be filled only when the engine is switched off.

•Keep service products (anti-freeze) only in containers which can not be confused with drinks containers.

•Comply with the manufacturer’s instructions when handling batteries.

Caution :

Accumulator acid is toxic and caustic. Battery gases are explosive.

2.2.3.When carrying out checking, setting and repair work

•Checking, setting and repair work must be carried out by authorized personnel only.

•Use only tools which are in satisfactory condition. Slip caused by the worn open-end wrench could lead to Injury.

•When the engine is hanging on a crane, no-one must be allowed to stand or pass under it. Keep lifting gear in good condition.

•When checking injectors, do not put your hands under the jet of fuel.

Do not inhale at atomized fuel.

•When working on the electrical system disconnect the battery earth cable first. Connect it up again last in prevent short circuits.

2.3.Regulations designed to prevent damage to engine and premature wear

1)Never demand more of the engine than it was designed to yield for its intended purpose. Detailed information on this can be found in the sales literature. The injection pump must not be adjusted without prior written permission of DAEWOO.

—7 —

— 8 —

Health precautions

•Avoid prolonged or repeated skin contact with used engine oil.

•Protect your skin by means of suitable agents (creams etc.) or wear protective gloves.

•Clean skin which has been in contact with engine oil.

—Wash thoroughly with soap and water, A nailbrush is an effective aid.

—Certain products make it easier to clean your hands.

—Do not use petrol, Diesel fuel, gas oil, thinners or solvents as washing agents.

•After washing apply a fatty skin cream to the skin.

•Change oil-soaked clothing and shoes.

•Do not put oily rags into your pockets.

Ensure that used engine oil is disposed of properly. — Engine oil can endanger the water supply —

For this reason do not let engine oil get into the ground, waterways, the drains or the sewers. Violations are punishable. Collect and dispose of used engine oil carefully.

For information on collection points please contact the seller, the supplier or the local authorities.

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3.5. Lubrication system

The engine is equipped with force-feed lubrication.

The pressure is produced by a gear pump whose drive gear is in direct mesh with the crankshaft gear at the front end of cylinder block.

The oil pump draws the oil from the oil sump and delivers it through the oil cooler and oil filter to the main distributor gallery and from there to the main bearings, big-end bearings and camshaft bearings as well as to the small-end bearings and the rocker arms.

The injection pump and the turbocharger are also connected to the engine lubricating system. The cylinder walls and timing gears are splash-lubricated.

Each cylinder has an oil jet provided for cooling the underside of the pistons. The lube oil is cleaned in a full-flow oil filter.

3.5.1.Recommend of lubricating oil

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

Engine oil should be changed at the specified intervals. (800hr)

—13 —

3.5.2.Oil cooler

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

3.5.3.Oil filter

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

Oil filter (Cartridge)

Oil filter head

EQM4010I

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3.9.1. Coolant pressure cap

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4.3. Inspections after starting

During operation the oil pressure in the engine lubrication system must be monitored. If the monitoring devices register a drop in the lube oil pressure, switch off the engine immediately. And the charge warning lamp of the alternator should go out when the engine is running.

•Do not disconnect the battery or pole terminals or the cables!

•If, during operation, the battery charge lamp suddenly lights up, stop the engine immediately and remedy the fault in the electrical system!

•Engine should be stopped if the color, the noise or the odor of exhaust gas is not normal.

•Confirm the following things through warning lamps and gauge panel.

4.3.1.Pressure of lubricating oil

The normal pressure comes up to 1 kg/cm2 (1.0 bar) at idling and 3 ~ 5 kg/cm2 (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.

4.3.2.Temperature of cooling water

The cooling water temperature should be 78 ~ 85˚C in normal operating conditions. Abnormally high cooling water temperature could cause the overheating of engine and the sticking of cylinder components. And excessively low cooling water temperature increases the fuel consumption, accelerates the wears of cylinder liners and shortens the engine lifetime.

4.4. Operation in winter time

Pay special attention to the freezing of cooling water and the viscosity of lubricating oil.

4.4.1.Prevention against the freeze of cooling water

When not using anti-freeze, completely discharge the whole cooling water after engine running. The freeze of cooling water causes the fatal damages of the engine. Because the anti-freeze is used to prevent cooling water from freeze, consult “The amount of anti-freeze”.

4.4.2.Prevention against excessive cooling

Drop of thermal efficiency caused by excessive cooling increases fuel consumption, therefore prevent the engine from excessive cooling. If the temperature of coolant does not reach to normal condition (78 ~ 85˚C) after continuous operation, examine the thermostat or the other cooling lines.

4.4.3.Lubricating oil

As cold weather leads to the rise of oil viscosity, engine speed becomes unstable after starting. Therefore the lubricating oil for winter should be used to prevent this unstability. Refer to “Lubricating System section”.

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5.2.3. Oil exchange procedure

•Thereafter shut down the engine. After waiting for about 10 minutes measure the quantity of oil and refill the additional oil if necessary.

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c) Loosen the coolant drain plug.

Loosen the coolant drain plug of the cylinder

block.

EAMD001I

Caution : When removing the pressure filler cap while the engine is still hot, cover the cap with a rag, then turn it slowly to release the internal steam pressure This will prevent a person from scalding with hot steam spouted out from the filler port.

5.3.2.Cleaning of the cooling inside system 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 corrosion inhibitor or defect, not early enough replaced covers for filler neck and working valves.

If twice in a short time the water pump of an engine develops leases or the coolant is heavily contaminated (dull, brown, mechanically contaminated, grey or black sings of a leakage on the water pump casing) clean the cooling system prior to removing that water pump as follows.

a)Drain coolant.

b)Remove thermostats, so that the whole cooling system is immediately flown through when cleaned.

c)Fill the cooling system with a mixture of potable water and 1.5% by volume of cleaner. (Henkel P3T5175)

d)Warm up engine under load. After a temperature of 60˚C is reached, run engine for a further 15 minutes.

e)Drain cleaning fluid.

f)Repeat steps c) and d).

g)Flush cooling system.

h)Replace drain plug by drain plug with a bore of 8mm diameter.

i)Fill cooling system with hot water.

j)Run engine at idle for 30 minutes. At the same time continuously replenish the water leaking from the bore in drain plug by adding fresh water.

Periodically clean the circuit interior with a cleaner.

— Cooling system cleaning interval: Every 1,200 hours.

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5.5. Fuel system

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soak in a vessel with solvent and to clean it then with a stiff brush. In doing so, take care to see that only the compressor wheel is immersed and that the turbocharger is supported on the bearing casing and not on the wheel.

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6.1.3 Method of adjusting the valve clearance

5)Measure the clearance one more time and if necessary adjust again.

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•Tighten the coupling fixing bolts and nuts to specified torque.

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1. Manuals
2. Brands
3. Doosan Manuals
4. Engine
5. DE12T
6. Operation & maintenance manual

• Page 2
  /P126TI /P126TI-1/DE12T. 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. On the other hand, intial D stands for standard engine prior to POLUS version.

• 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 ……………… 113 10.1. Cooling System 10.3. Fuel Injection Pump 10.2. Lubricating System 10.4. Turbocharger 11. Special Tool List ……………………163 • Appendix • Part & After service center • Applications for Doosan Engine…

• Page 5: General Notes

  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
  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 Òjust as goodÓ. 4) In addition to the above, note the following points.
• Page 8
  Health precautions ¥ Avoid prolonged or repeated skin contact with used engine oil. ¥ Protect your skin by means of suitable agents (creams etc.) or wear protective gloves. ¥ Clean skin which has been in contact with engine oil. — Wash thoroughly with soap and water, A nailbrush is an effective aid. — Certain products make it easier to clean your hands.

• Page 9: Engine Assembly

  2. General Information 2.1. Engine Assembly 2.1.1. Engine sectional view (Longitudinal) 14 15 EA8M1002 1. Cooling fan 7. Piston pin 13. Crankshaft 2. Exhaust valve 8. Piston 14. Oil pan 3. Valve spring 9. Combustion chamber 15. Connecting rod 4. Oil filter 10.

• Page 10
  2.1.2. Engine sectional view (Cross) EA8M1003 1. Intake manifold 7. Injection nozzle assembly 2. Fuel filter 8. Rocker arm 3. Oil cooler 9. Cylinder head cover 4. Injection pump 10. Exhaust manifold 5. Cylinder block 11. Piston ring 6. Oil filter 12.
• Page 11
  2.1.3. Engine assembly views 1) DE12T 3 12 4 13 18 11 10 20 21 26 EA8M1004 1. Cooling fan 10. Flywheel housing 19. Thermostat 2. Cooling water pipe 11. Flywheel 20. Injection pump 3. Oil filler cap 12. Exhaust manifold 21.
• Page 12
  2) P126TI / P126TI- 9 10 14 15 16 17 18 20 21 EA8M1005 1. Cooling fan 8. Oil pan 18. Injection pipe 2. Cooling water pipe 9. Starter 19. Thermostat 3. Air pipe 10. Flywheel housing 20. Injection pump (Intercooler Intake manifold) 11.
• Page 13
  2.2. Engine Specification Engine Model DE12T P126TI P126TI-1 P126TI- Items Water-cooled, 4 cycle in-line Water-cooled, 4 cycle in-line type Engine type type Turbo charged Turbo charged & intercooled Combustion chamber type Direct injection type Cylinder liner type Replaceable dry liner…

• Page 14: Engine Model And Serial Number

  They are also referred to as engine model and serial number because of their location. EA8O3001 ¥ Engine serial No. (example 1 : DE12T) EBHOA300001 MODEL BORE Serial No. SPEED 1500/1800…

• Page 15: Engine Type

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

• Page 16: Engine Timing

  3.3. Engine Timing Camshaft, oil pump and injection pump are driven by a gear train arranged at the front end. Injection pump gear Camshaft gear Water pump gear (Z = 72) (Z = 72) (Z = 29) Idle gear (Z = 52) Crankshaft gear (Z = 36) Oil pump idle gear…

• Page 17: Lubrication System

  3.5. Lubrication System The engine is equipped with force-feed lubrication. The pressure is produced by a gear pump whose drive gear is in direct mesh with the crankshaft gear at the front end of cylinder block. The oil pump draws the oil from the oil sump and delivers it through the oil cooler and oil filter to the main distributor gallery and from there to the main bearings, big-end bearings and camshaft bearings as well as to the small-end bearings and the rocker arms.

• Page 18: Air Cleaner

  3.5.1. Oil cooler An oil cooler is provided between the oil filter and the cylinder block. This cooler is a flat tube type with turbulence inserts and operated by the coolant. 3.5.2. Oil filter Check for oil pressure and oil leaks, and repair or replace the oil filter if necessary.

• Page 19
  3.7.1. 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.
• Page 20
  Fuel oil selection chart General Fuel ASTM No. 1 No. 2 DIN 51601 Classification Test ASTM 1-D ASTM 2-D Gravity, û D 287 40 ~ 44 33 ~ 37 0.815 ~ 0.855 Flash Point D 93 100 (38) 125 (52) 131 (55) û…
• Page 21
  3.8. 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.
• Page 22
  For the improper control might give the fatal damage to the cooling water pump and cylinder liners, detail care is needed. ¥ Since DE12T , P126TI and P126TI- cylinder liner is dry type, particularly the cooling water control should be applied thoroughly.
• Page 23
  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 24
  3.9. V-belt Tension Check and Adjust By the finger-pressure the belt is pressed by Press hear here 10mm ~ 15mm between the fan pulley and 15mm the alternator pulley in normal condition. For Alternator the adjustment of the tension, loosen the Pulley Pulley adjusting bolts which support the alternator,…

• Page 25: Electrical Equipment

  3.11. Electrical Equipment 3.11.1. 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.

• Page 26
  3.11.2. Starter motor The sliding-gear starter motor is flanged to the rear of the flywheel housing on the left-hand side. When the starting key switch is turned on, the starter motor pinion flies out and engages the ring gear of the flywheel. Then the main contact is closed, current flows, and the engine is started.

• Page 27: Preparation

  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 ÒTechnical Information for the installation DAEWOO generator enginesÓ. ¥ Oil filler neck on cylinder head cover Before daily starting of the engine, check the fuel, coolant and oil level, replenish if necessary.

• Page 28
  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> Oil pan (only) DE12T 23 liter P126TI/P126TI- 23 liter 4.2.3. Operating after break-in When starting a cold engine, always allow the engine to warm up gradually.

• Page 29: Inspection After Starting

  4.3. Inspections after Starting During operation the oil pressure in the engine lubrication system must be monitored. If the mon- itoring devices register a drop in the lube oil pressure, switch off the engine immediately. And the charge warning lamp of the alternator should go out when the engine is running. ¥…

• Page 30
  4.5. Tuning the Engine The purpose of an engine tune-up is to restore power and performance thatÕs 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 itÕs seldom advisable to attempt an improvement in performance by correction of one or two items only.

• Page 31: Periodical Inspection And Maintenance

  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 «…

• Page 32
  5.2.3. Oil exchange procedure While the oil is still hot, exchange oil as fol- lows: ¥ 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. Drain Plug EA8O5001 ¥…
• Page 33
  ¥ Recommend of lubricating oil Initial factory filling is high quality break-in oil (API Service CH-4 grade). During the break- in period (50 hours), check the oil level frequently. Somewhat higher oil consumption is nor- mal until piston rings are seated. The oil level should be maintained in the safe range between Min.

• Page 34: Cooling System

  5.2.4. Replacement of oil filter cartridge At the same times of oil exchanges, replace the oil filter cartridge. ¥ Drain engine oil by loosening the drain Cartridge plug on the filter head. Caution : DonÕt forget tightening the drain plug after having drained engine oil.

• Page 35
  c) Loosen the coolant drain plug. Loosen the coolant drain plug of the cylinder block. EAMD001I Caution : When removing the pressure filler cap while the engine is still hot, cover the cap with a rag, then turn it slowly to release the internal steam pressure This will pre- vent a person from scalding with hot steam spouted out from the filler port.
• Page 36
  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.

• Page 37: 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 38
  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 û at the discharge end and which is long enough to reach down inside to the bottom of the element.

• Page 39: Fuel System

  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 approxi- mately 2 ~ 3 turns until draining occurs.

• Page 40
  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 41
  5.5.5. Priming pump strainer cleaning Clean the priming pump strainer every 200 operation hours. The strainer is incorporated in the priming pump inlet side joint bolt. Clean the strainer with the compressed air and rinse it in the fuel oil. Strainer(Inner) EA7O5009 5.5.6.
• Page 42
  ¥ 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. DE12T P126TI / P126TI- 1st : 160kg/cm Opening pressure 220kg/cm…
• Page 43
  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.
• Page 44
  Dial gauge Magnetic vise Outlet Move the turbine shaft Radial play in both directions Limit of wear : 0.57mm simultaneously Oil inlet EA4M2018 — 40 -…

• Page 45: Adjustment Of Valve Clearance

  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 hourÕs operation. ¥ When the engine is overhauled and the cylinder heads are disassembled. ¥…

• Page 46
  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 DE12T 0.3 mm 0.3 mm P126TI / P126TI- 6.1.3 Method of adjusting the valve clearance…

• Page 47: Adjustment Of Injection Timing

  Check hole flywheel clockwise until showing the notch mark of the right figure corresponding to the injection timing is aligned with the pointer ( ) on the flywheel housing. DE12T P126TI/P126TI- Fuel injection timing 12¡ 16¡ (B.T.D.C static) Injection timing…

• Page 48
  ¥ Tighten the coupling fixing bolts and nuts to specified torque. 6.0 kg . m Torque EAMD021I ¥ Tighten the drive shaft connecting flange fixing bolts to specified torque. 7.5 ~ 8.5 kg . m Torque ¥ Install the oil delivery pipe and return pipe. 6.3.
• Page 49
  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 50
  75 kg 70 kg 60 kg 20.2 mm 75 kg 70 kg 60 kg : Adopted in DE12T and P126TI / P126TI- (5) Tensioning and changing V-belt ¥ Remove fixing bolts. (1) ¥ Remove lock nut. (2) ¥ Adjust nut (3) until V-belts have correct tensions.

• Page 51: Periodic Inspection Cycle

  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 52: Trouble Shooting

  7.2. Trouble Shooting 1. Engine Starting Impossible Starting motor operation poor Starting motor revolution Inspection of battery electorlytic Engine Fuel Ilquid amount & gravity Inspect air cleaner Inspect amount of fuel Normal Too low Normal None Normal Polluted Ajustment Recharging Replace or Replenish clean element…

• Page 53
  2. Engine Overheated Operating state 1. Overload 2. Radiator core clogged Fuel unit Cooling unit 3. Continuous over-run Check coolant Fuel excessive supply Inspect fuel quality Normal Too low Poor Check fan belt Clean and replace Repair Check injection nozzle tension wear with specilied fuel Replace…
• Page 54
  3. Output Insufficient Engine Installation improper Check for coupling Fuel unit Others alignemnt Check for air mixing Inspect air cleaner Adjust or replace in fuel coupling Normal Clean Relpace Inspect fuel supply pump Inspect air leakage Inspect engine control Normal Clean Replace of air piping line rod, link, cable, etc.
• Page 55
  4. Oil pressure lowered Check if oil pressure gauge indicates wrongly Check oil amount Too low Normal Use recommended oil Check cooling (replenish) temperature Too high Normal Refer to engine overhea Inspect oil quality Normal Check oil relief Water & fuel mixed Improper valve in oil…
• Page 56
  5. Fuel Consumption Excessive Causes according to Use Conditions 1. Overload 2. Govemor’s Arbitrary Adjustment 3. Full Speed Operation for Long time 4. Sudden Speed Change from Low to Inspect fuel leakage High Speed Normal Oil leakage Inspect injection nozzle (injection pressure Adjust Replace atomizing state etc.)
• Page 57
  6. Oil Consumption Excessive Cause according to use conditions 1. Excessive oil infusing 2. Continuous operation in low or extremely cold state Inspect oil leakage Inspect air cleaner Clean Replace Normal Oil leakage Check oil quality Internal External Retighten Check compressed Replace with Replace pressure…
• Page 58
  8. Battery Discharge Generator Wiring Switch Battery Inspect cut wire Check fan belt Check electrolytic shorts and loose tension & damage liquid amount connections Repair Replace Normal Battery over Battery self Battery room Electrolytic charging discharge damage liquid’s standard Inspect generator Charging Voltage regulator Replace…
• Page 59
  7.3. Causes and Remedies Condition Causes Remedies ¥ ValveÕs poor shut, stem distortion Repair or replace 1) Starting difficult ¥ (1) Compression pressure Valve spring damage Replace valve spring ¥ Cylinder head gasketÕs leak Replace gasket ¥ Wear of piston, piston ring or liner Adjust ¥…
• Page 60
  Condition Cause Remedies 5) Engine noisy For noises arise compositely such asrota ting parts, lapping parts etc., there is nec essity to search the cause of noises accu rately. ¥ (1) Crankshaft As the wear of bearing or crankshaft Replace bearing & progress, the oil clearances increase.
• Page 61
  Condition Cause Remedies 7) Oil Consumption Excessive ¥ (1) Oil level elevated Clearance between cylinder iner & Replace piston ¥ Wear of piston ring, ring groove Replace piston, piston ring ¥ Piston ringÕs damage, stick, wear Replace piston ring ¥ Piston ring openingÕs disposition Correct position improper…

• Page 62: 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 63
  POLUS P126TI, P126TI- DE12T (DE12 series) generator diesel engines discharge very low level of haz- ardous exhaust gases such as smoke, nitro- gen oxide, hydrocarbon, or carbon monoxide and thus ensure high performance and low fuel consumption.
• Page 64
  9. Disassembly and Reassembly of Major Components 9.1. Disassembly 9.1.1. General precautions ¥ Maintenance operation should be carried out in a bright and clean place. ¥ Before disassembly, provide parts racks for storage of various tools and disassembled parts. ¥ Arrange the disassembled parts in the disassembly sequence and use care to prevent any damage to them.
• Page 65
  9.1.3. Engine oil ¥ Take out the oil dipstick. ¥ Remove the oil drain valve of oil pan and drain out the engine oil into a prepared container. Drain valve EA8O5001 9.1.4. Alternator belt ¥ Loosen the tension adjusting nut installed on the alternator bracket, and take off the alternator belt.
• Page 66
  9.1.7. Guide tube of oil level gauge ¥ Loosen the flange nut installed on the oil pan to remove the guide tube. EQM3005I 9.1.8. Fuel filter ¥ Remove fuel hoses connected to the fuel injection pump, take off the bracket fixing bolts, then disassemble the fuel filter.
• Page 67
  9.1.11. Injection pipe ¥ Unscrew the hollow screws to disassem- ble the fuel return pipe. ¥ Remove the nuts installed on the fuel injection pump and nozzles, then disas- semble the injection pipe. EQM3009I 9.1.12. Intake manifold ¥ Remove the air hose connected to the fuel injection pump.
• Page 68
  9.1.14. Exhaust manifold ¥ Release the exhaust manifold fixing bolts, disassemble the exhaust manifold, then remove the heat shield and gasket. NOTE : Make sure to release the nuts one after another because the exhaust manifold will removed if you unscrew two nuts simultaneously.
• Page 69
  9.1.17. Water pump ¥ Remove the water pipe connected to the expansion tank. ¥ Remove the water pipe and hoses con- nected to the water pump. ¥ Unscrew the water pump fixing bolts and remove the water pump. 9.1.18. Injection pump ¥…
• Page 70
  9.1.20. Fan drive pulley ¥ Remove the bolts and disassemble the fan drive pulley. 9.1.21. Vibration damper ¥ Unscrew the pulley fixing bolts and dis- assemble the pulley-vibration damper assembly. ¥ Unscrew the vibration damper fixing bolts and disassemble the damper from the pulley.
• Page 71
  9.1.24. Fuel injection pump drive assembly ¥ Unscrew the injection pump drive shaft bearing housing fixing bolts and remove the injection pump drive assembly which the shaft, gear, bearings, and housing are put together. EAMD027I 9.1.25. Cylinder head cover ¥ Unscrew the cover fixing bolts and dis- assemble the cover.
• Page 72
  9.1.28. Cylinder head ¥ Unscrew the cylinder head fixing bolts and take off the cylinder head. ¥ Remove the cylinder head gasket. EAMD031I 9.1.29. Valve and valve stem seal ¥ Compress the valve spring retainer using a jig and take off the valve cotter pins. ¥…
• Page 73
  9.1.31. Oil pan ¥ Stand the engine with the flywheel hous- ing facing the bottom. ¥ Release the oil pan fixing bolts, remove the stiffeners then disassemble the oil pan. EAMD034I 9.1.32. Oil pump and oil pipe ¥ Unscrew the oil suction pipe bracket bolts, releasing the pipe fixing bolts, then disassemble the oil suction pipe assem- bly.
• Page 74
  ¥ Remove the piston pin snap rings, take off the piston pin, then disconnect the connecting rod from the piston. ¥ Disassemble the piston rings using ring pliers. ¥ Use care not to interchange the disas- sembled parts and keep them in the sequence of cylinder No.
• Page 75
  9.1.37. Oil seal ¥ Take off the rear oil seal using an oil seal disassembling jig. ¥ If only the inside guide ring is removed, use a special tool to take off the outside seal. 9.1.38. Flywheel housing ¥ Loosen the housing fixing bolts disas- semble the flywheel housing.
• Page 76
  9.1.41. Timing gear case ¥ Unscrew the case fixing bolts and disas- semble the timing gear case. EAMD046I 9.1.42. Crankshaft ¥ Remove the bolts from bearing caps. ¥ Remove the main bearing cap fixing bolts in the order of assembling. ¥…
• Page 77
  9.2. Inspection 9.2.1. Cylinder block 1) Clean the cylinder block thoroughly and make a visual inspection for cracks or damage. 2) Replace if cracked or severely damaged, and correct if slightly damaged. 3) Check oil and water flow lines for restriction or corrosion. 4) Make a hydraulic test to check for any cracks or air leaks.(Hydraulic test) : Stop up each outlet port of water/oil passages in the cylinder block, apply air pressure of about 4kg/cm…
• Page 78
  3) flatness Measure flatness of the intake/exhaust manifolds fitting surfaces on the cylinder head using a straight edge and a feeler gauge. Standard Limit 0.05 mm 0.2 mm 4) Hydraulic test Hydraulic test method for the cylinder head is same as that for cylinder block. 9.2.3.
• Page 79
  • Valve head thickness Measure the valve head thickness, and replace the valve if the measured value is beyond the limit. Dimension Standard Limit Description Intake valve 1.5 mm 1 mm or less Exhaust valve 1.5 mm 0.9 mm or less EFM2037I 2) Valve guide Install the valve into the valve guide and…
• Page 80
  3) Valve seat • Contacting face amount Measure the contacting face between intake valve and exhaust valve seat for valve seat wear, and replace if the mea- sured value exceeds the specified limit. Valve contact width Contact width ✝✞✟✏❆☛✌ Standard Limit 1.5 mm 2.0 mm…
• Page 81
  For assembling of a new valve seat, by putting it among the dry ices of an ice box previ- • ously for about 2 hours for the cold shrinkage, and press it in the cylinder head by a special tool. (bench press) Apply the valve lapping compound on the valve head seating face and lap the valve seat by •…
• Page 82
  • Valve spring tension Use a spring tester to measure the valve spring tension if the measured value is less than the specified limit, the valve spring must be replaced. Spring Set Length Limit force Spring tester Valve Spring Intake 61.8 ~ Tension at 37mm 61.8 kg…
• Page 83
  2) Rocker arm • Visual check Visually check the face of the rocker arm in contact with the valve stem end for scores and step wear. If the wear is small, correct it with an oil stone or grind- ing paper of fine grain size. Rocker arm with a considerable amount of step wear should be replaced.
• Page 84
  • 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 damaged. If the amount of cracks or pitting is small, Unevenness Crack Normal correct with an oil stone or grinding ❘❏❆✔✠✟☛…
• Page 85
  9.2.5. Cam shaft 1) Cam • Cam lobe height Standard Limit Cam journal diameter(A,B) 59.86 ~ 59.88 mm 59.52 mm Use a micrometer to measure the cam journal diameter. I II If the measured number is less than the I II specified limit, camshaft…
• Page 86
  • Run-out Support the camshaft on two V blocks and check for run-out using a dial indi- cator. Correct or replace the cam shaft if the amount of run-out is beyond the value indicating need for servicing. Standard Limit 0.05 mm 0.2 mm EA0M4066 3) Cam shaft end play…
• Page 87
  2) Wear With an outside micrometer measure the • diameter of the crankshaft journals and pins in the directions as shown, and compare the measured values to deter- mine the amount of wear. If the amount of wear is beyond the limit, •…
• Page 88
  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 9.2.7. Crank shaft bearing and connection rod bearing 1) Visual check Visually check the crankshaft bearing and connecting rod bearing for scores, uneven…
• Page 89
  • Connecting rod bearing clearance Install the connecting rod bearing in the connecting rod bearing cap, tighten the connecting rod cap bolts to the specified torque, then measure the inside diame- ter. • 28 kg Torque 83.02 ~ 83.092 mm Standard Dia.
• Page 90
  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 bearing cap and cylinder block using a feeler gauge.
• Page 91
  9.2.8. Piston 1) Visual check Visually check the pistons for cracks, scuff or wear, paying particular attention to the ring groove. 2) Clearance between the piston and cylinder liner With an outside micrometer, measure • the piston outside diameter at a point 18mm away from the lower end of pis- ton skirt in a direction at a right angle to the piston pin hole.
• Page 92
  9.2.9. Piston rings 1) Visual check Replace the piston rings with new ones if detected worn or broken when the engine is overhauled. 2) Piston ring gap Insert the piston ring into the upper por- • tion of the cylinder liner bore so that it is held at a right angle to the cylinder liner wall.
• Page 93
  4) Piston ring tension With a tension tester, measure piston ring tension. Replace the piston ring if the measured value is beyond the limit. Standard Top ring 2.27 ~ 3.41 kg 2nd ring 2.0 ~ 3.0 kg Oil ring 4.03 ~ 5.57 kg 9.2.10.
• Page 94
  9.2.11. Connecting rod 1) Distorsion Check the connecting rod for distortion. As shown in the figure below, install the connecting rod to the connecting rod tester, and check for distortion using a feeler gauge. If the connecting rod is found distorted, never re-use it but replace with a new one.
• Page 95
  9.3. Reassembly 9.3.1. General precautions ¥ Wash 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 96
  ¥ 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 assem- ble them while turning the camshaft. ¥…
• Page 97
  ¥ Semi-tighten a bolt at both sides of the crankshaft, apply engine oil to journals and pins, then assemble the crankshaft with the cylinder block by tightening the fixing bolts. ¥ Install the oiled thrust washers with the oil groove facing outward. ¥…
• Page 98
  ¥ 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 specified torque using a torque wrench as follows. EQM3059I <Tightening order>…
• Page 99
  9.3.8. Flywheel ¥ 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 fly- wheel for temporary assembly opera- tion. ¥ Install bolts in the remaining holes, take out the guide bar, then install a bolt in the hole where the guide bar had been inserted.
• Page 100
  9.3.11. Timing gear ¥ Install the oil pump idle gear onto the No.7 bearing cap. ¥ Install a thrust washer over the camshaft Idle gear pin and assemble the cam gear by aligning it with camshaft key groove. Torque 3.1 kg ¥…
• Page 101
  9.3.12. Timing gear case cover ¥ Install dowel pin on the timing gear case. ¥ Mount a gasket by aligning the fixing bolt holes with those on the gasket. ¥ Align the dowel pin with the cover pin hole, then install the cover with light tap. ¥…
• Page 102
  9.3.15. Piston and connecting rod ¥ Use a piston heater to heat the piston approximately 100 ûC (212 ûF ) for 5 min- utes. ¥ Align the piston pin hole with the oiled connecting rod small end and press the piston pin (by lightly tapping with a rub- ber hammer) to assemble the connect- ing rod with the piston.
• Page 103
  ¥ Identify the mark «Y» or «TOP» on the ring end to prevent the top and bottom of the piston ring is interchanged each other and make the marked top face upward. Note : Be sure to make the piston ring end marked face(«Y»…
• Page 104
  ¥ Wet the fixing bolts with oil, semi-tighten them with hand, tighten them to specified torque using a torque wrench as follows. <Tightening order> (1) First stage : Coat engine oil over bolts (2) Second stage : Temporary screw the bolt about 1 ~ 2 threads (3) Third stage : With torque wrench, tighten at about 15 kg.m (4) Fourth stage : With torque wrench, tighten up to about 22 kg.m (5) Fifth stage : Finally, tighten in the specified torque 28kg.m with torque wrench .
• Page 105
  9.3.18. Oil pan ¥ Mount gasket and put the oil pan there- ¥ Place stiffeners and tighten bolts. ¥ Align the bolt holes with gasket holes to prevent damage to the gasket and tight- en to specified torque. Torque 2.2 kg ¥…
• Page 106
  9.3.20. Nozzle tube ¥ Apply sealant (LOCTITE # 620) to the nozzle tube and place the O-ring over the cylinder head fitting face on the nozzle tube, then install the nozzle tube in the cylinder head. ¥ Install a guider of the nozzle tube insert assÕy (Guider + Expander) the cylinder Guider head, then tighten the nozzle fixing nuts.
• Page 107
  ¥ 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. Be careful not to damage the head gasket. If the dowel pin is not in alignment, lift the cylinder head again and then remount it.
• Page 108
  As for the valve clearance, adjust it when in cold, as follow. Model Intake Valve Exhaust Valve DE12T 0.3 mm 0.3 mm P126TI / P126TI- — By cranking the engine, let #6 cylinderÕs valves overlap.
• Page 109
  ¥ Adjust valve clearance with a feeler Valve clearance adjust gauge and tighten the fixing nuts to specified torque. 4.4 kg . m Torque EA8M3007 9.3.22. Rocker arm assembly ¥ Apply lubricating oil to the rocker arm bush and shaft, and assemble the inter- mediate bracket with the rocker arm using fixing bolts.
• Page 110
  9.3.24. Oil cooler ¥ Install the oil cooler onto the oil cooler cover. ¥ Carefully apply the gasket to prevent oil leakage. ¥ Do not damage the gasket and install the cover onto the cylinder block. ¥ Connect a connection pipe between the water pump and oil cooler.
• Page 111
  ( ) on the fly- wheel housing. DE12T P126TI/P126TI- Fuel injection timing 12¡ 16¡ (B.T.D.C…
• Page 112
  ¥ Tighten the Coupling fixing bolts and nuts to specified torque. Torque 6.0 kg ¥ Tighten the drive shaft connecting flange fixing bolts to specified torque Torque 7.5 ~ 8.5 kg EAMD021I ¥ Install the oil delivery pipe and return pipe.
• Page 113
  9.3.30. Power take-off ¥ Assemble the power take-off sub assem- bly. EA8M3010 9.3.31. 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.
• Page 114
  9.3.33. Starter ¥ Assemble the starter in position on the flywheel housing. ED5OM009 9.3.34. Intake manifold ¥ Fit a gasket on the intake manifold before assembling the intake manifold. EQM3011I 9.3.35. Injection pipe & fuel return pipe ¥ Assemble the injection pipe according to specified torque as blow Nut size Torque…
• Page 115
  9.3.36. 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 FUEL INJECTION PUMP.
• Page 116
  9.3.39. Cooling fan ¥ Install the cooling fan and flange, then tighten the fixing boltd. EQM3106I 9.3.40. V- belt ¥ Install the V-belt on the crank pulley, Press here alternator pulley and fan drive pulley. 15mm ¥ Adjust the V-belt tension using the ten- Alternator sion adjusting bolt.
• Page 117
  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.
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  10.1.2. Water pump ¥ Loosen the bolt (16) to disassemble the housing cover (15). ¥ Heat the impeller (6) slightly, then remove it using a puller jig. ¥ Remove the mechanical seal. ¥ Unscrew the socket bolt (12) and remove the shaft and bearing assembly from the housing. ¥…
• Page 119
  10.1.3. Thermostat ¥ General descriptions and main data To radiator The thermostat maintains a constant tem- û perature of coolant (71 ~ 85 C) and improves thermal efficiency of the engine by preventing heat loss. Namely, when the temperature of coolant Bypass is low, the thermostat valve is closed to valve…
• Page 120
  10.1.4. Diagnostics and troubleshooting Complaints Possible causes Corrections ¥ ¥ 1. Engine overheating Lack of coolant Replenish coolant ¥ ¥ Radiator cap pressure Replace cap valve spring weakened ¥ ¥ Fan belt loosened or Adjust or replace fan belt broken ¥…

• Page 121: Lubricating System

  10.2. Lubricating System 10.2.1. General descriptions and main data ¥ 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 injection pump in order to ensure normal engine performance.

• Page 122
  10.2.2. Oil pump ¥ Disassembly (1) Disassembly of oil pump drive gear a .Unscrew the screw and disassem- ble 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.
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  (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. Limit 16.95 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.
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  10.2.4. Diagnostics and troubleshooting Complaints Possible causes Corrections ¥ ¥ 1. Oil consumption Poor oil Use suggested oil ¥ ¥ excessive Oil seal or packing leaky Replace ¥ ¥ Pistons or piston rings worn Replace pistons and/or pis ton rings ¥…

• Page 125: Fuel System

  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. EA8O3004 1. Fuel filter 7.

• Page 126
  Make sure that servicing should be performed at the professional maintenance shop as authorized by Bosch or Zexel Company. For adjustment of fuel injection volume, refer to the ÔSpecifications of fuel injection pumpÕ described on the following pages. 1) DE12T (1) Main data and specifications Part No. : 65.11101-7222(106672-9920)
• Page 127
  (8) Governor adjustment Rack limit over 14 11.0 10.8 Idle spring Set : 6.5 -0.5 +5 _ 250 400 PUMP SPEED (rpm) EA8M4001 — 123 -…
• Page 128
  2) P126TI / P126TI- (1) Main data and specifications Part No. : 65.11101 -7310 (106674-4130 ZEXEL) Model : NP-PE6P120/700RS3S (106067-6020) Governor : Ghana Control (DWA-2000) Plunger & barrel 12, right hand double helix 30 lead Delivery valve : 90mm /st ( 7 x 2.35mm) Fuel feed pump : NP-FP/KD-PS (105237-5470) Pre-stroke…
• Page 129
  10.3.3. Governor System (P126TI/ P126TI- ) Governor system for fuel injection pump consists of ÒIntegral ActuatorÓ and ÒSpeed Control UnitÓ. 10.3.3.1. Integral actuator EC2OM316 <Dimension View> Fig. No. Description QÕty Remark Frame Bearing retainer kit AssÕy Mounting bar SWP connector Mg610320 Front cover T3.2…
• Page 130
  10.3.3.2. 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.
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  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.).
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  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 ………….É.É……..Less than 1200Hz Droop Range …………É..ÉÉ……
• Page 133
  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 134
  2) Application and installation information The speed control unit is rugged enough for mounting in a control cabinet or engine mounted enclo- sure 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.
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  ¥ 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 136
  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 137
  ¥ 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.
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  ¥ 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.
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  ¥ 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 140
  ¥ 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 141
  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 and operation, and the general descriptions of the KP type pump are given below: The figures show its construction (right figure) and operation (below figure).
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  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 feeding operation, air must be bled from the fuel lines.
• Page 143
  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 144
  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 1m above the level of fuel in the fuel tank.
• Page 145
  10.3.5. Injection nozzle 1) General descriptions Pressurized fuel delivered from the fuel injection pump is sprayed into the combustion chamber past the injection nozzle at proper spray pressure and spray angle, then burnt completely to achieve effective engine performance. (1) At valve closed (2) At valve opened EQM4024I 2) 1-spring type…
• Page 146
  (2) Reassembly ¥ After removing carbon deposit, sub- merge the nozzle in diesel oil and clean ¥ Replace all the gaskets with new ones. ¥ Assemble the parts and tighten them to specified torque. (3) Adjustment ¥ Remove the cap nut and assemble a nozzle to a nozzle tester.
• Page 147
  3) 2-spring type (1) Disassembly EQM4029I 1. Nozzle holder body 13. Lift pin 2. Push rod 14. Pin 3. Primary spring 15. Spacer 4. Adjusting screw 16. Pin 6. Gasket 17. Retaining nut 7. Cap nut 30. Gasket 10. Adjusting shim 31.
• Page 148
  (2) Inspection and adjustment a. Adjusting the primary opening pres- sure. Install the plate of plate assembly (157944-9520) onto a vise. Note : Use the plate assembly (157944-9520) in fixing a nozzle holder having a flange. A nozzle holder without flange should be EQM4030I directly installed onto a vise.
• Page 149
  f. Install the pin (16) and nozzle (A) onto the spacer. EQM4034I g. After installing the gasket (6:157892-1500) on the nozzle, use the cap nut (7:157892- 4000 : SW22mm) to fix the nozzle onto the nozzle holder. Note : While tightening nut, keep checking to see if the lock pin…
• Page 150
  j. Assemble the push rod (2), primary spring (3), and adjusting screw (4) on the nozzle holder in the order described. k. Install the gasket (6) and cap nut (7) onto the adjusting screw(4). l. Assemble the nozzle and nozzle holder assembly to the nozzle tester (105785- 1010).
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  ¥ Inspecting the needle valve for full lift a. Install gasket (026508-1140) and plug (157892-1600 : SW12mm) onto the adjusting retaining nut (157892-1400). EQM4042I b. Install the nozzle holder on the plate with the cap nut facing upward. c. Install the holder(157892-4100: SW12 mm) into the cap nut.
• Page 152
  f. Install the dial gauge on the holder assem- bly so that the pin is brought into contact with the upper end of the push rod, then fix the pin with the nut. Note 1 : Fix the dial gauge so that a stroke of 2 mm or so can be mea- sured.
• Page 153
  ¥ Inspection of pre-lift a. If the nozzle tester handle is released with the needle valve engaged in a full lift condition, the tester pressure drops, being accompanied by decrease in the needle valve lift value (indicated value on the dial gauge). kgf / cm EQM4049I Tester pressure…
• Page 154
  c. If the measured pre-lift value deviates from the specified limit, replace the pin (14, 16), lift piece (13), spacer (15), and nozzle assembly (A) with a new Ònozzle service kitÓ. EQM4053I ¥ Inspection of secondary opening pressure a. After confirming the pre-lift, operate the nozzle tester and increase the internal pressure up to 350 ~ 450 kgf/cm to fully…
• Page 155
  ¥ Adjusting secondary opening pressure a. In the event that the measured value deviates from the specified limit, readjust the primary opening pressure if the amount of deviation is small. (to the stan- dard range of the primary opening pres- sure) — If the secondary opening pressure is lower than the standard value: Adjust the…
• Page 156
  ¥ Retaining nut a. Take out the dial gauge, nut, holder and gasket from the cap nut (7). b. Remove the adjusting retaining nut and gasket, and install the original retaining nut(SW 19mm). Cap nut 6.0 ~ 8.0 kg . m Tightening torque EQM4036I ¥…
• Page 157
  10.3.6. Diagnostics and troubleshooting Complaints Possible causes Corrections 1. Engine wonÕt start (1) Fuel pipes clogged or air into pipe line Correct 1) Fuel not being pumped (2) Feed pump valve defective Replace out from feed pump (3) Feed pump piston or push rod sticking Disassemble, correct 2) Fuel not being injected (1) Fuel filter element restricted…
• Page 158
  Complaints Possible causes Corrections 6. Engine output (1) Supply of fuel insufficient Check feed pump unstable (2) Air in fuel Bleed (3) Water in fuel Replace fuel (4) Operation of plungers unsmooth Disassemble, correct (5) Movement of control rack sluggish Disassemble, correct (6) Nozzles defective Disassemble, correct…

• Page 159: Turbocharger

  10.4. Turbocharger 10.4.1. Main data and specifications 1) Main data and specifications Specification DE12T P126TI/P126TI- Turbocharger Model Allied Signal T45 Allied Signal TV51 50Hz: Approx. 1.1 kg/cm 50Hz: Approx. 1.5 kg/cm Air pressure at compressor outlet 60Hz: Approx. 1.2 kg/cm 60Hz: Approx.

• Page 160
  3) Construction Turbine housing Retainer ring Bolt Plug Bearing O-ring Crank Thrust collar Compressor wheel V-band Screw Wheel Thrust bearing Bolt Piston ring Thrust space Clamp Wheel shroud Piston ring Compressor housing Center housing Seal ring Elbow Retainer ring Seal ring Retainer Bearing Rear plate…
• Page 161
  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 compressed air is charged into cylinders of given capacity, the greater engine output can be obtained as a greater volume of air charged into the cylinders burns so…
• Page 162
  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) Crank the engine with starter to 2) Abrupt starting of the engine the engine check the increase in oil pres- causes the engine to rotate with…
• Page 163
  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 164
  10.4.6. Periodical checking and servicing Make it a rule to check the turbocharger assembly for condition and contamination periodically. 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 165
  (3) If the measured axial and radial plays are beyond the limit of wear, replace or repair the turbocharger. 3) Guide for disassembling/cleaning and checking the turbocharger First, disassemble the turbocharger from the engine and clean/check it with the oil inlet and outlet plugged with tape and so on.
• Page 166
  10.4.7. Diagnostics and troubleshooting Complaints Possible causes Corrections 1. Excessive black 1) Air cleaner element clogged Replace or clean smoke 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 Disassemble/repair or replace…

• Page 167: Special Tool List

  11. Special Tool List Part No. Figure Tool Name DPN-5337 Nozzle tube insert assÕy EF.123-082 Nozzle tube extractor EF.123-015 Injection pump setting assÕy EF.123-173 Oil seal(NOK) insert assÕy (FR) EF.123-194A Oil seal(NOK) insert assÕy (RR) EF.123-317A Oil seal(NOK)puller assÕy (FR) EF.123-316A Oil seal(NOK) puller assÕy (RR) EF.123-347…

• Page 168
  Part No. Figure Tool Name EF.123-066 Valve stem seal punch EU.2-0131 Valve clearance adjust assÕy EF.123.-065 Valve spring press EU.2-0647 Crankshaft gear punch 60.99901-0027 Feeler gauge T7610001E Snap ring plier T7621010E Piston ring plier EF.120-208 Piston Ring Compressor — 164 -…
• Page 169
  Appendix ¥ Tightening torque for major parts Screw Strength Major Parts Tightening Torque Remarks (Diameter x pitch) (grade) 1st : 6kg.m 2nd : 90û Cylinder head bolt M14 x 1.5 10.9T 3rd: 90û Dodecagon Finished : 90û (angle torque) Cylinder head cover bolt 8.8T 1.2 kg.m 1st : 15 kg.m…
• Page 170
  ¥ Standard bolt tightening torque table Refer to the following table for bolts other than described above. Degree of strength 10.9 12.9 Diameter (4A) (4D) (4S) (5D) (5S) (6D) (6S) (6G) (8G) (10K) (12K) pitch Limit value for elasticity (kg/mm (mm) Tightening torque (kg .
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