Daewoo P158LE Manual

65.99897-8076A
Operation &
Maintenance Manual
GENERATOR DIESEL ENGINE

FOREWORD
This manual is designed to serve as an instruction for the Operation & Maintenance of generating-set
engines of Daewoo POLUS series: P158LE /P180LE /P222LE. The POLUS means ‘Power Plus’ that
is represented more powerful Daewoo generating-set engines and it is marked on engine name as an
initial P.
The first half is for operation and the latter half is for maintenance like disassembling, inspecting and
re-assembling etc in order to help an understanding for the maintenance procedure more easily.
To keep the best performance and the durability of engine for a long time, CORRECT OPERATION
and PROPER MAINTENANCE are essential.
In this manual, the following symbols are used 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 Use special tools of manufacturer
Directional Indication Lubricate oil
Inspection Lubricate grease
Measurement
If you have any question or recommendation in connection with this manual, please do not hesitate
to contact our head office, dealers or authorized service shops near by your location for any
services. Also some figures in this manual may be different from the actual appearance of the
engine because of explaining them with the representative figure among these models
For the last, the contents of this instruction manual may be changed without prior notice for some
quality improvement. Thank you.
Nov. 2003
DAEWOO Heavy Industries & Machinery LTD.
www.enginepark.com

CONTENTS
1. SAFETY REGULATIONS.............................................................................................................1
1.1. General Notes
1.2. Regulations Designed to Prevent Accidents 1.4. Regulations Designed to Prevent Pollution
1.3. Regulations Designed to Prevent Damage 1.5. Notes on Safety in Handling Used Engine Oil
to Engine and Premature Wear
2. GENERAL INFORMATION ..........................................................................................................5
2.1. Engine Assembly 2.3. Engine Model and Serial Number
2.2. Engine Specification
3. TECHNICAL INFORMATION .....................................................................................................13
3.1. Engines 3.6. Intercooler
3.2. Engine Lubrication 3.7. Cooling
3.3. Engine Cooling System 3.8. Air 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 AND CARE......................................................................................................24
5.1. Engine Lubrication 5.4. Cooling
5.2. Fuel System 5.5. Turbocharger
5.3. Injector Maintenance 5.6. Air Cleaner
6. CHECKING AND SETTING .......................................................................................................39
6.1. Checking and Adjusting Injection Timing 6.3. Tightening Cylinder Head Bolts
6.2. Checking and Adjusting Valve Clearance 6.4. V-belts
7. OPERATION TIP ........................................................................................................................47
7.1. Periodic Inspection Cycle 7.3. Causes and Remedies
7.2. Troubleshooting
8. MAINTENANCE INFORMATION ...............................................................................................58
8.1. General Repair Instructions 8.3. Preventive Maintenance
8.2. Engine Characteristics

9. DISASSEMBLY AND REASSEMBLY OF MAJOR COMPONENTS.........................................67
9.1. Engine Disassembly 9.3. Re-assembly
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
•Appendix..................................................................................................................................147
•Parts & After service center
•Applications for Daewoo Engine
•Worldwide Network

1. SAFETY REGULATIONS
1.1. General Notes
Handling diesel engines and the necessary resources is no problem when the personnel
commissioned 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. In addition to these regulations those dictated by the type of
engine and its site are to be observed also.
IMPORTANT : If despite all precautions, an accident occurs, in particular through contact with
caustic acids, fuel penetrating the skin, scalding from oil, antifreeze being
splashed in the eyes etc, consult a doctor immediately.
1.2. Regulations Designed to Prevent Accidents
1.2.1. During commissioning, starting and operation
•
Before putting the engine into operation for the first time, read the operating instructions
carefully and familiarize yourself with the “critical” points, If you are unsure, ask your DHI
representative.
•
For reasons of safety we recommend you attach a notice to the door of the engine room
prohibiting the access of unauthorized persons and that you draw the attention of the
operating personal to the fact that they are responsible for the safety of persons who
enter the engine room.
•
The engine must be started and operated only by authorized personnel. Ensure that the
engine cannot be started by unauthorized persons.
•
When the engine is running, do not get too close to the rotating parts. Wear close-fitting
clothing.
•
Do not touch the engine with bare hands when it is warm from operation risk of bums.
•
Exhaust gases are toxic. Comply with the instructions for the installation of DHI Diesel
engines which are to be operated in enclosed spaces. Ensure that there is adequate
ventilation and air extraction.
•
Keep vicinity of engine, ladders and stairways free of oil and grease. Accidents caused by
slipping can have serious consequences.
- 1 -

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.
•
Change the oil when the engine is warm from operation.
CAUTION : There is a rise of burns and scalding. Do not touch oil drain plug 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 “Maintenance and
Care”.
•
Neither tighten up nor open pipes and hoses (lube oil circuit, coolant circuit and any
additional hydraulic oil circuit) during the operation. The fluids 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.
•
When using compressed air, e.g. for cleaning the radiator, wear goggles.
•
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.
1.2.3 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. Worn open-end wrench slip. which 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 working on parts which contain asbestos, comply with the notes at the end of this
chapter.
•
When checking injectors do not put your hands under the jet of fuel. Do not inhale atomized
fuel.
•
When working on the electrical system disconnect the battery earth cable first. Connect it
up again last in prevent short circuits.
- 2 -

1.3. Regulations Designed to Prevent Damage to Engine and Premature Wear
1) Never demand more of the engine than it was designed to yield for its intended purpose.
•
Detailed information on this can be found in the sales literature. The injection pump must
not be adjusted without prior written permission of DHI.
2) If faults occur, find the cause immediately and have it eliminated in order to prevent more
serious of damage.
3) Use only genuine DHI spare parts. DHI will accept no responsibility for damage resulting from
the installation of other parts which are supposedly “just as good”.
4) In addition to the above, note the following points.
•
Never let the engine run when dry, i.e. without lube oil or coolant.
•
Use only DHI-approved service products (engine oil , anti-freeze and anticorrosion agent).
•
Pay attention to cleanliness. The Diesel fuel must be free of water. See “Maintenance and
care”
•
Have the engine maintained at the specified intervals.
•
Do not switch off the engine immediately when it is warm, but let it run without load for
about 5 minutes so that temperature equalization can take place.
•
Never put cold coolant into an overheated engine. See “Maintenance and care”.
•
Do not add so much engine oil that the oil level rises above the max. marking on the
dipstick. Do not exceed the maximum permissible tilt of the engine. Serious damage to the
engine may result if these instructions are not adhered to.
•
Always ensure that the testing and monitoring equipment (for battery charge, oil pressure,
coolant temperature) function satisfactorily.
•
Comply with instructions for operation of the alternator. See “Commissioning and
operation”.
•
Do not let the raw water pump run dry, If there is a risk of frost, drain the pump when the
engine is switched off.
1.4. Regulations Designed to Prevent Pollution
1.4.1. Engine oil, filter elements, fuel filters
•
Take old oil only to an oil collection point.
•
Take strict precautions to ensure that oil does not get into the drains or into the ground. The
drinking water supply could be contaminated.
•
Filter elements are classed as dangerous waste and must be treated as such.
1.4.2. Coolant
•
Treat undiluted anti-corrosion agent and / or antifreeze as dangerous waste.
•
When disposing of spent coolant comply with the regulations of the relevant local
authorities.
- 3 -

1.5. Notes on Safety in Handling Used Engine Oil
Prolonged or repeated contact between the skin and any kind of engine oil decreases the skin.
Drying, irritation or inflammation of the skin may therefore occur. Used engine oil also contains
dangerous substances which have caused skin cancer in animal experiments. If the basic
rules of hygiene and health and safety at work are observed, health risks are not to the
expected as a result of handling used engine oil
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.
- 4 -

2. GENERAL INFORMATION
2.1. Engine Assembly
2.1.1. Engine sectional view (Longitudinal)
- 5 -
9
8
712 3 4 5 6
12 13 14 15
16
17
18
19
1110
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. Flywheel housing
7. Piston pin 17. Flywheel
8. Thermostat 18. Oil seal
9. Cooling fan 19. Crank shaft
10. Crank shaft pulley

2.1.2. Engine sectional view (Cross)
- 6 -
12
8
9
10
12
13
14
11
34567
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. Injection pipe 13. Cylinder liner
7. Oil filler cap 14. Starter

2.1.3. Engine assembly views
1) P158LE
- 7 -
EA6O1001
151
14
910 1817
23
16
22
12
11
16 13
19
16
20
22
21
2 3 4
1. Cooling fan 9. Exhaust manifold 17. Cooling water outlet
2. Air pipe 10. 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. Exhaust elbow (Turbocharger to inter cooler)
7. Starter 15. Air pipe 21. Idle pulley
8. Flywheel housing (Air cleaner to turbocharger) 22. Engine mounting bracket
16. Oil filter 23. Water pump

2) P180LE
- 8 -
123
5
910
11
12 16 13
18 17 19 20
21
22
23
16
22
67 8
415
14
16
EA6O1002
1. Cooling fan 9. Exhaust manifold 17. Cooling water outlet
2. Air pipe 10. 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. Exhaust elbow (Turbocharger to inter cooler)
7. Starter 15. Air pipe 21. Idle pulley
8. Flywheel housing (Air cleaner to turbocharger) 22. Engine mounting bracket
16. Oil filter 23. Water pump

3) P222LE
- 9 -
22
21
123
56 7 8
910 1817 1920
11
12 13
23
16
22
415
16
14
EA6O1003
1. Cooling fan 9. Exhaust manifold 17. Cooling water outlet
2. Air pipe 10. 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. Exhaust elbow (Turbocharger to inter cooler)
7. Starter 15. Air pipe 21. Idle pulley
8. Flywheel housing (Air cleaner to turbocharger) 22. Engine mounting bracket
16. Oil filter 23. Water pump

2.2. Engine Specification
2.2.1. Specification
- 10 -
Engine Model
Items P158LE P180LE P222LE
Engine type Water-cooled, 4 cycle Vee type
Turbo charged & intercooled
Combustion chamber type Direct injection type
Cylinder liner type Wet type, chromated or casting liner
Timing gear system Gear driven type
No. of piston ring Compression ring 2, oil ring 1
No. of cylinder-bore X stroke (mm) 8 - 128 x
142 10 - 128 x 142 12 - 128 x 142
Total piston displacement (cc) 14,618 18,273 21,927
Compression ratio 15 : 1
Engine dimension
(length X width X height) (mm)
1,484 x 1,389 x 1,161.5 1,557 x 1,389 x 1,248 1,717 x 1,389 x 1,288
Engine weight (kg) 950 1,175 1,575
Fuel injection order 1-5-7-2-6-3-4-8
1-6-5-10-2-7-3-8-4-9 1-12-5-8-3-10-6-7-2-11-4-9
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 pressure (kg/cm2) 285
Compression pressure (kg/cm2) 25 ~ 28 (at 200 rpm)
Intake and exhaust valve clearance (at cold) (mm) 0.25/0.35
Intake valve Open at 24
˚C (B.T.D.C)
Close at 36
˚C (A.B.D.C)
Exhaust valve Open at 63
˚C (B.B.D.C)
Close at 27 ˚C
(A.T.D.C)
Lubrication method Pressurized circulation
Oil pump type Gear type
Oil filter type Full-flow, cartridge type
Lubricating oil capacity (max./min.) (lit) 28/26 35/28 40/33
Oil cooler type Water cooled
Water pump Belt driven centrifugal type
Cooling Method Pressurized circulation
Cooling water capacity (engine only) (lit) 20 21 23
Thermostat type Wax pallet type (71 ~ 85 ˚C )
Alternator voltage - capacity (V - A) 24 - 45
Starting Motor voltage - output (V - kW) 24 - 7.0
Battery capacity (V - AH) 24 - 200

2.2.2. Engine power
Production tolerance : ±5%
Note : All data are based on operation without cooling fan at ISO 3046.
- 11 -
Engine model Condition
Continuous Prime Stand by
50 HZ 438 PS 494 PS 563 PS
(1,500 rpm) (322 kW) (363 kW) (414 kW)
Standard 60 HZ 497 PS 547 PS 602 PS
(1,800 rpm) (366 kW) (402 kW) (443 kW)
50 HZ 444 PS 492 PS
P158LE (1,500 rpm) -(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) (398 kW) (443 kW) (496 kW)
Standard 60 HZ 614 PS 676 PS 734 PS
P180LE (1,800 rpm) (452 kW) (497 kW) (540 kW)
50 HZ -548 PS 601 PS
(1,500 rpm) (403 kW) (442 kW)
P180LE-1 60 HZ -617 PS 677 PS
(1,800 rpm) (454 kW) (498 kW)
50 HZ 643 PS 723 PS 781 PS
P222LE (1,500 rpm) (473 kW) (532 kW) (574 kW)
Standard 60 HZ 730 PS 803 PS 883 PS
(1,800 rpm) (537 kW) (591 kW) (649 kW)

2.3. Engine Model and Serial Number
The engine model and serial number is
located on the engine as illustrated. These
numbers are required when requesting
warranty and ordering parts. They are
also referred to as engine model and
serial number because of their location.
•
Engine serial No. (example 1 : P158LE)
EAZOA300001
•
Engine serial No. (example 2 : P180LE)
EASOA300001
•
Engine serial No. (example 3 : P222LE)
EAYOA300001
- 12 -
Engine
number
EA6O1006
Serial No.
Production Year(2003)
Engine Model Suffix
Serial No.
Production Year(2003)
Engine Model Suffix
Serial No.
Production Year(2003)
Engine Model Suffix

3. TECHNICAL INFORMATION
3.1. Engines
The engines P158LE/ P180LE/ P222LE POLUS Series are V-type liquid-cooled 8/ 10/ 12-
cylinder four-stroke Diesel engines with direct injection.
1) Engine block
The cylinder block is a single piece of alloy cast iron. To increase its stiffness, it is extended
to a level below the crankshaft center line. The engine has replaceable wet cylinder liners
and individual cylinder heads with strung-in valve seat rings and replaceable valve guides.
2) Piston/ Connecting rod/ Crank assembly
The forged crankshaft has screwed-on counterweights. Radial seals with replaceable
wearing rings 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 pistons. Crankshaft and connecting rods run in steel-backed
lead bronze ready-to fit type bearings.
3) Engine timing
Camshaft, oil pump and injection pump are driven by a gear train arranged at the flywheel
end.
4) Valves
The overhead valves are actuated via chilled cast iron tappets, push rods and rocker arms
from the camshaft.
- 13 -
5
2
6
1
3
4
EA6O3
1. Crankshaft gear
2. Oil pump drive gear
3. Oil pump impeller gears
4. Camshaft drive gear
5. Injection pump drive gear
1. Crankshaft gear
2. Oil pump drive gear
3. Oil pump impeller gears
4. Camshaft drive gear
5. Idler gear
6. Injection pump drive gear
EA6O3001

3.2. Engine Lubrication
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 flywheel end.
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.
- 14 -
1. Oil suction pipes
2. Oil pumps
3. Oil relief valves
4. Oil cooler
5. Oil filter
6. Bypass valve
7. Main oil galleries
8. Oil gallery to crankshaft
9. Ports for main bearing lubrication
10. Ports for big end bearing
lubrication
11. Small end bearing lubrication
12. Camshaft bearing lubrication
13. Rocker arm lubrication
14. Jets for piston cooling and cam
lubrication
15. Injection pump lubrication
16. Oil drain plug
17. Lube oil pipes to turbochargers
18. Oil return from turbochargers

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.
Depending on the agreed extent 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 loss of pressure.
1) Oil cooler
An oil cooler is provided between the oil filter and the crankcase. This cooler is of the flat tube
type with turbulence inserts and operated by the coolant.
3.3. Engine Cooling System
- 15 -
EA6M1001
Coolant pipe
Coolant pipe
Thermostat
Water pump
Cylinder head
Oil cooler
Radiator

3.4. Fuel System
The fuel is delivered by the fuel lift pump via the fuel filter to the injection pump and from there
to the injectors.
The fuel is sprayed into the cylinder through nozzles fitted in screw-fit injections 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
3. Fuel Filter 7. Injector
4. Fuel filter ass’y 8. Fuel pressure relief valve
4a. Fuel water drain plug 9. Fuel return pipe
4b. Air bleeding plug 10. Fuel feed pump
(for fuel filter)
4
5
4b
4a
7
7
10 1
9
682
EA6O3003