Daewoo POLUS P126TI User manual

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 instruc-
tions.
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 : [phone]~8), FAX: [phone])
Or to your local DEALER or DISTRIBUTOR.
DAEWOO Heavy Industries LTD.
July. 1999

CONTENTS
1. General information................................................................................................................... 1
1.1. Engine specification 1.2. Engine assembly
2. Safety regulations...................................................................................................................... 6
2.1. General notes 2.4. Regulations designed to prevent pollution
2.2. Regulations designed to prevent accidents 2.5.
Notes on safety in handling used engine oil
2.3. Regulations designed to prevent damage
3. Technical information.............................................................................................................. 10
3.1. Engine model and serial number 3.7. Intercooler
3.2. Engine type 3.8. Fuel system
3.3. Engine timing 3.9. Cooling system
3.4. Valves 3.10. V-belt tension check and adjust
3.5. Lubrication system 3.11. Turbocharger
3.6. Air cleaner 3.12. Electrical equipment
4. Commissioning and operation............................................................................................... 26
4.1. Preparation 4.4. Operation in winter
4.2. Breaking-in 4.5. Tuning the engine
4.3. Inspection after starting
5. Inspection and maintenance .................................................................................................. 30
5.1. Periodical inspection and maintenance 5.5. Fuel system
5.2. Lubrication system 5.6. Injection nozzle maintenance
5.3. Cooling system 5.7. Turbocharger
5.4. Air intake system
6. Checking and setting .............................................................................................................. 42
6.1. Adjustment of valve clearance 6.4. Cylinder compression pressure
6.2. Adjustment of injection timing 6.5. V-belts
6.3. Tightening the cylinder head bolts
• Appendix....................................................................................................................................
49
• WORLDWIDE NETWORK

Engine Model
Items DE12T P126TI P126TI-I
Engine type
Water-cooled, 4 cycle in-line
Water-cooled, 4 cycle in-line
type
type Turbo charged
Turbo charged & intercooled
Combustion chamber type Direct injection type
Cylinder liner type Replaceable dry liner
Timing gear system Gear driven type
No. of piston ring Compression ring 2, oil ring 1
No. of cylinder-bore x stroke (mm) 4 - 123 x 155
Total piston displacement (cc) 11,051
Compression ratio 17.1 : 1
Engine dimension (length x width x height) (mm) 1,365.5 x 870 x 1,046 1,383 x 870 x 1,207
Engine weight (kg) 910
Rotating direction (from flywheel) Counter clockwise
Fuel injection order 1 - 5 - 3 - 6 - 2 - 4
Fuel injection timing (B.T.D.C static) 12 °
Injection pump type Zexel in-line “P” type
Governor type Mechanical governor type(RSV) Electric governor type(GAC)
Injection nozzle type Multi-hole type (5 hole) Multi-hole type (5 hole)
Fuel injection pressure (kg/cm2) 220 1st : 160, 2nd : 220
Compression pressure (kg/cm2) 28 (at 200 rpm)
Condition 50Hz 60Hz 50Hz 60Hz 60Hz
(1,500rpm) (1,800rpm) (1,500rpm) (1,800rpm) (1,800rpm)
Continuous --
280PS 336PS -
Power (ISO 3046) (206kW) (247kW)
Prime 205PS 245PS 328PS 378PS 356PS
(151kW) (180kW) (241kW) (278kW) (262kW)
Stand by 226PS 270PS 370PS 405PS 392PS
(166kW) (199kW) (272kW) (298kW) (288kW)
I ntake and exhaust valve clearance (at cold) (mm) 0.3
Intake valve Open at 18
° (B.T.D.C)
Close at 34 ° (A.B.D.C)
Exhaust valve Open at 46
° (B.B.D.C)
Close at 14 ° (A.T.D.C)
Lubrication method Full forced pressure feed type
Oil pump type Gear type driven by crankshaft
Oil filter type Full-flow, Cartridge type
Lubricating oil capacity (max./min.) (lit) 23/20
Oil cooler type Water cooled
Water pump Gear driven impeller type
Cooling Method Pressurized circulation
Cooling water capacity (engine only) (lit) 19
Thermostat type Wax pallet type (83 ~ 95 ° C)
Alternator voltage - capacity (V - A) 24 - 45
Starting Motor voltage - output (V - kW) 24 - 6.0
1. General information
1.1. Engine specification
- 1 -

1.2. Engine assembly
1.2.1. Engine sectional view (Longitudinal)
- 2 -
EA8M1002
1
2
10 11 12 13 14 15 16 17 18
3 4 56789
1. Cooling fan
2. Exhaust valve
3. Valve spring
4. Oil filter
5. Tappet
6. Push rod
7. Piston pin
8. Piston
9. Combustion chamber
10. Crankshaft pulley
11. Vibration damper
12. Oil pump
13. Crankshaft
14. Oil pan
15. Connecting rod
16. Camshaft
17. Flywheel housing
18. Flywheel

1.2.2. Engine sectional view (Cross)
- 3 -
EA8M1003
1
2
10
11
12
3
4
5
6
789
1. Intake manifold
2. Fuel filter
3. Oil cooler
4. Injection pump
5. Cylinder block
6. Oil filter
7. Injection nozzle assembly
8. Rocker arm
9. Cylinder head cover
10. Exhaust manifold
11. Piston ring
12. Turbocharger

- 4 -
EA8M1004
1 2 3 12 4 27 13 18
5
22
23
16
14 20 21 26
25
24
17 15 197 11 10869
1. Cooling fan
2. Cooling water pipe
3. Oil filler cap
4. Cylinder head cover
5. Turbocharger
6. Oil drain valve
7. Alternator
8. Oil pan
9. Starter
10. Flywheel housing
11. Flywheel
12. Exhaust manifold
13. Injection nozzle assembly
14. Oil filter
15. Fuel filter
16. Oil cooler
17. Intake manifold
18. Injection pipe
19. Thermostat
20. Injection pump
21. Oil level gauge
22. Mounting bracket
23. Vibration damper
24. Water pump
25. Fan drive
26. Crankshaft pulley
27. Breather
1.2.3. Engine assembly views
1) DE12T

2) P126TI
- 5 -
EA8M1005
12
768910
14 15 16 17 18 19
20 21
22
23
24
25
11
345 12 13
1. Cooling fan
2. Cooling water pipe
3. Air pipe
(Intercooler Intake manifold)
4. Air pipe
(Air cleaner Turbocharger)
5. Turbocharger
6. Oil drain valve
7. Air pipe
(Intercooler Intake manifold)
8. Oil pan
9. Starter
10. Flywheel housing
11. Flywheel
12. Exhaust manifold
13. Injection nozzle assembly
14. Oil filter
15. Breather hose
16. Oil cooler
17. Intake manifold
18. Injection pipe
19. Thermostat
20. Injection pump
21. Oil level gauge
22. Mounting bracket
23. Vibration damper
24. Water pump
25. Fan drive

2. Safety regulations
2.1. General notes
Day-to-day use of power engines and the service products necessary for running them
presents no problems if the persons occupied with their operation, maintenance and care are
given suitable training and think as they work.
This summary is a compilation of the most important regulations. These are broken down into
main sections which contain the information necessary for preventing injury to persons,
damage to property and pollution. In addition to these regulations those dictated by the type of
engine and its site are to be observed also.
Important :
If, despite all precautions, an accident occurs, in particular through contact with caustic
acids, fuel penetrating the skin, scalding from oil, antifreeze being splashed in the eyes
etc., consult a doctor immediately.
2.2. Regulations designed to prevent accidents
2.2.1. During commissioning, starting and operation
Before putting the engine into operation for the first time, read the operating instructions
carefully and familiarize yourself with the “critical” points, If you are unsure, ask your
DAEWOO representative.
•
For reasons of safety we recommend you attach a notice to the door of the engine room
prohibiting the access of unauthorized persons and that you draw the attention of the
operating personal to the fact that they are responsible for the safety of persons who enter
the engine room.
•
The engine must be started and operated only by authorized personnel. Ensure that the
engine cannot be started by unauthorized persons.
•
When the engine is running, do not get too close to the rotating parts. Wear close-fitting
clothing.
•
Do not touch the engine with bare hands when it is warm from operation risk of burns.
•
Exhaust gases are toxic. Comply with the installation instructions for the installation of
DAEWOO generator diesel engines which are to be operated in enclosed spaces. Ensure
that there is adequate ventilation and air extraction.
•
Keep vicinity of engine, ladders and stairways free of oil and grease.
Accidents caused by slipping can have serious consequences.
- 6 -

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 -