Daedong 3C093 User manual

FOREWORD
DAEDONG Corporation wishes to thank you for purchasing your new DAEDONG diesel engine. Your new engine is
the result of many years of research and development and high quality manufacturing; and we are confident that
your new engine will provide many years of safe, reliable and economical operation. This Operator’s Manual is
intended to help you get the maximum return on your investment and to ensure your safety.
1
379O001A
(1) Engine model name and serial number
We recommend that you thoroughly read and under-
stand this Operator’s Manual before handling, storing,
installing, operating or servicing the engine.
It is the policy of DAEDONG to incorporate new technol-
ogy and product improvements on an ongoing basis. In
order to provide the latest technology and the best en-
gine available, there may be some minor differences
between this manual and your engine. Consult your
dealer if you have any questions.
Should your engine require parts or service, please con-
tact your local DAEDONG dealer. Your dealer will need
the following information in order to assist you.
1. Engine make, model number and serial number.
2. Names and code numbers of parts to be ordered.
3. Make and model number of the machine in which
the engine is installed.

SAFETY FIRST
The “SAFETY ALERT SYMBOL” is used throughout this manual and on the engine decals to
warn of potential injury. Always read and follow these instructions carefully.
Signs Description
WARNING
CAUTION
IMPORTANT
Hazards or unsafe practices which COULD result in severe
injury or death.
Equipment failure or property damage could result if instruc-
tions are not followed.
Hazards or unsafe practices which COULD result in personal
injury.
NOTE Provides general instructions for safe and proper operation.

SAFETY INSTRUCTIONS .........................................5
NAME OF PARTS ......................................................9
OPERATING THE ENGINE ...................................... 11
PRE-START ENGINE CHECKS .........................12
STARTING AND STOPPING THE ENGINE........12
CHECKS DURING OPERATION ........................ 14
BREAK-IN AND CHECKS ........................................ 17
DAILY CHECKS .................................................. 18
BREAKE-IN ......................................................... 18
PERIODIC CHECKS ........................................... 19
MAINTENANCE........................................................21
FUEL ...................................................................22
ENGINE OIL ........................................................24
RADIATOR (optional)........................................... 26
AIR CLEANER (optional) .................................... 31
BATTERY (optional) ............................................32
FAN BELT............................................................34
LONG-TERM STORAGE .................................... 34
TROUBLESHOOTING .............................................35
WIRING DIAGRAMS ............................................... 41
SPECIFICATIONS....................................................45
INDEX ....................................................................... 49
TABLE OF CONTENTS

1. SAFETY INSTRUCTIONS

6 DIESELENGINE
379O102A
4. An engine should never be operated in the presence of
combustible vapors since an explosion may result.
DAEDONG bears no responsibility when an engine is oper-
ated improperly or in a hazardous environment.
5. Use diesel fuel only. Never mix gasoline or alcohol with
diesel fuel. Fuel mixtures will damage the engine and may
cause an explosion.
6. Make sure that all drains and caps are tightly closed and all
fluid levels are correct before starting. Always check for
leaks and ensure that any loose parts are repaired before
operating the engine. Loose parts are the operator’s re-
sponsibility and may cause damage or injury if ignored. Air
intake connections must always be tight to prevent dust
ingestion.
Operators of any experience level should carefully read and
understand this manual as well as any documentation that
came with the equipment in which the engine is installed or
attached. Carefulness and following proper procedures is your
best defense against accidents and equipment failure. It is the
sole responsibility of the owner to instruct all operators in safe
and proper operation.
379O101A
1. Engine exhaust fumes are extremely dangerous. Never
run an engine in an enclosed space without proper
ventilation. Be sure that bystanders and livestock are pro-
tected from exhaust gases. Carbon monoxide is colorless
and odorless, and can cause sickness or death.
2. Always stop the engine before refueling, cleaning or ser-
vicing the engine.
3. Never remove the radiator cap or coolant reserve tank cap
when the engine is hot. Escaping steam and coolant will
cause severe injury to you and any bystanders. Always
check the coolant level when the engine is cold.

SAFETY INSTRUCTIONS 7
379O103A
7. The oil, fuel and cooling systems all operate under pressure.
Always check for and relieve the pressure before discon-
necting or removing any part of these systems. Never check
for leaks with your hand. High pressure fluids may not be
visible and may penetrate your hand causing serious injury.
Always wear eye protection when servicing or repairing
pressurized systems.
8. Replace fasteners, if needed, with the same grade of
fastener. Using a lower grade (lower strength) fastener
may cause equipment failure and possibly personal injury.
379O104A
9. Dispose of all fluids and hazardous materials in accor-
dance with local environmental regulations and common
sense. Never drain oils, coolants or fuels onto the ground.
Do not place fluids, filters or batteries in with household
wastes. Determine the appropriate disposal method be-
fore removing hazardous materials from the engine.
10. To prevent injury and equipment damage when servicing
the engine; always use the proper tools, know how to use
them correctly and keep them in good condition. Wear eye
protection.

8 DIESELENGINE
11. Thoroughly read and understand this manual before oper-
ating the engine. Contact your DAEDONG dealer if you
have any questions.
12. It is the owner’s responsibility to train other operators be-
fore they use this engine. All operators should read and
understand this manual.
379O105A

2. NAMES OF PARTS

10 DIESELENGINE
(1) Intake manifold
(2) Speed control lever
(3) Engine stop lever
(4) Fuel injection pump
(5) Fuel feed pump
(6) Cooling fan
(7) Front crankshaft pulley
(8) Oil filter
(9) Coolant drain cock
(10) Oil fill cap
(11) Exhaust manifold
(12) Alternator
(13) Starter
(14) Oil level dipstick
(15) Oil pressure switch
(16) Flywheel
(17) Oil drain plug
(18) Oil pan
4
3
5
9
12
6
7
8
17
12
13
14
18
10
11
15
16
379O201A
NAMES OF PARTS

3. OPERATING THE ENGINE
PRE-START ENGINE CHECKS ...............................12
STARTING AND STOPPING THE ENGINE............12
CHECK DURING OPERATION ................................14

12 DIESELENGINE
STARTINGAND STOPPING THE ENGINE
STARTING
1. Set the fuel cock to the “ON” or “OPEN” position.
2. The engine stop lever must be in the “START” position.
3. Set the speed control lever at about half throttle.
4. Turn the starter switch to the “ON” position.
5. Verify that the oil pressure and charge lights are on.
6. In cold weather (for cold engine starts), turn the starter
switch counterclockwise to the “PREHEAT” position for 6
to 8 seconds. (Do not operate glow plugs continuously for
more than 180 seconds).
Current
11A
(for each plug)
Preheating time
6 second
Glow temperature
900°C
(1652°F)
7. Turn the key to the “START” position to engage the starter
motor. Release the key immediately as the engine starts.
8. Verify that the oil pressure and charge lights are now off.
If either light is on, stop the engine immediately and see
page 14 for troubleshooting instructions.
9. Run at a moderate speed until the engine reaches a normal
operating temperature before doing work.
PRE-START ENGINE CHECKS
Always check the engine and make sure it is ready for safe
operation before starting – See page 18 for details.
IMPORTANT
!Before installing the engine, be sure that
the equipment is on firm, level ground.
!Do not run the engine on gradients.
!!
!!
!Never use starting fluid or gasoline in the
air intake. Engine damage will result, and an
explosion may occur.

OPERATINGTHE ENGINE13
10. The oil pressure light should remain off during operation. If
the light comes on, stop the engine immediately to avoid
the possibility of severe engine damage, and check the
following:
!!
!!
!Correct oil level.
!!
!!
!Verify that the engine contains clean oil of the proper
viscosity.
!!
!!
!Check for faulty wiring.
If the light still remains on, do not use the engine and consult
your DAEDONG dealer.
CAUTION
To avoid personal injury :
!Keep children or non-essential bystanders
away from the engine while it is running.
IMPORTANT
!Do not turn the starter switch to “START”
while the engine is running.
!If the engine does not start in 10 seconds,
wait 30 seconds and repeat the starting
sequence. Never run the starter motor con-
tinuously for more than 20 seconds.
!Always warm up the engine before working.
Using a cold engine will shorten its life.
(1) SPEED CONTROL LEVER
(2) ENGINE STOP LEVER
(A) “IDLING”
(B) “OPERATION”
(C) “START and OPERATION”
(D) “STOP”
1. Disengage any load from the engine.
2. Return the speed control lever to the “IDLE” position.
3. Move the engine stop lever to the “STOP” position.
4. Turn the starter switch to “OFF” and remove the key.
5. Return the engine stop lever to the “START” position for the
next start.
STOPPING
2
1
A
D C
B
379O301A

14 DIESELENGINE
OIL PRESSURE LAMP
The oil pressure lamp comes on when the oil pressure drops
below a safe level. If the lamp comes on during operation:
1. Stop the engine immediately.
2. Check for oil leaks.
3. Check the engine oil level (page 24)
If the warning persists, do not use the engine. Consult your
DAEDONG dealer for service.
FUEL
The fuel tank should never be allowed to become completely
empty. An empty tank will allow air into the fuel system; and
the engine will not operate without bleeding the fuel system.
EXHAUST SMOKE
The engine exhaust should be colorless during normal opera-
tion within the rated output of the engine. Continuous dark
emissions or smoke may indicate improper usage or an engine
malfunction.
CHECK DURING OPERATION
COOLING SYSTEM
If steam or coolant is escaping from the overflow tube; stop
the engine, allow it to cool, and check the following and cor-
rect as needed.
1. Check for cooling system leaks.
2. Check for obstructions that block cooling air.
3. Clean any dirt or debris from the radiator core (fins & tubes).
4. Check and adjust the fan belt tension.
5. Ensure that the system is filled to the correct coolant level
with the proper mix of anti-freeze and water.
6. Check the radiator cap for proper type and condition.
CAUTION
To avoid personal injury :
!DO NOT remove the radiator cap or the cool-
ant reserve tank cap while the engine is hot.
Pressurized steam or coolant will escape
and cause serious injury to you and any
bystanders. Check the coolant level only
when the engine is cold.

OPERATINGTHE ENGINE15
STOPTHE ENGINE IMMEDIATELY:
1. If the engine speed suddenly changes.
2. If there is an unusual noise.
3. If the engine exhausts suddenly darkens.
4. If the oil pressure or temperature light come on.
REVERSED ENGINE ROTATIONAND REMEDIES
While not common, it is possible for a diesel engine to run
backwards. The engine will lose lubrication and be severely
damaged if allowed to run in this condition. Shut the engine
down immediately.
HOW TO TELL WHEN THE ENGINE RUNS BACKWARDS
1. Oil pressure will drop suddenly. The oil pressure light will
come on.
2. The sound of the engine will change. Exhaust gases will
come out of the air intake.
3. A loud knocking sound will be heard.
REMEDIES
1. Stop the engine immediately using the engine stop lever.
2. Check the air cleaner and rubber parts of the air intake
system for damage. Replace as needed.

4. BREAK-IN AND CHECKS
DAILY CHECKS........................................................18
BREAK-IN .................................................................18
PERIODIC CHECKS ................................................ 19

18 DIESELENGINE
BREAK-IN
During the engine break-in period, the following actions are
critical to engine performance and life.
1. Change engine oil and oil filter after first 50 hours of opera-
tion (See pages 24 to 26).
2. In cold weather, always allow the engine to warm up be-
fore using.
DAILYCHECKS
Regular maintenance is an important factor in preventing down-
time and accidents. Always make the following checks before
operating the engine.
NOTE :
All service and maintenance should be done on a firm, level
surface.
Oil or water leaks
Engine oil level and contamination
Amount of fuel
Amount of coolant
Dust in air cleaner
Damaged parts and loosened
bolts and nuts
Color of exhaust fumes
Unusual engine noise
Item Ref.page
Parts which had trouble in previous operation
By walking
around the
machine
By starting
the engine
-
22 - 31
24
22
26
31
-
14
15

BREAK-INAND CHECKS19
PERIODIC CHECKS
Check fuel lines and air intake connections
Change engine oil
Clean air cleaner element
Clean fuel filter
Check battery electrolyte level
Check and adjust fan belt tension
Check cooling system hoses & tighten
Replace oil filter
Replace fuel filter
Clean sediment from fuel tank
Flush cooling system
Replace fan belt
Clean battery terminals and recharge
Replace air cleaner element
Check and adjust valve clearance
Fuel injection nozzle inspection (It follows in the EPA rule)
Change engine coolant
Replace battery
Replace cooling system hoses and clamps
Replace fuel hoses and clamps
50 hours
100 hours
200 hours
400 hours
500 hours
1-2 months
1 year or as needed
800 hours
1500 hours
2 years
Interval Item Ref.Pgae
23
25
31
24
33
34
29
26
24
-
28
34
33
31
-
-
28
32
29
23