Daewoo DDA80 User manual

Manufactured under license of Daewoo International Corporation, Korea
USER´S MANUAL
DDA80-DDA50-DDA100LE-DPH50L
DIESEL WATER PUMP

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INDEX
1. SAFETY
2. KNOWING YOUR DIESEL DISPLACEMENT PUMP
3. PRE-OPERATION PREPARATION
4. STARTING THE ENGINE
5. OPERATION
6. MAINTENANCE
7. TRANSPORTING AND STORAGE
8. TROUBLESHOOTING
9. EXPLOSION VIEWS
10.SPECIFICATIONS

1. SAFETY PRECAUTIONS
2. KNOWING YOUR DIESEL DISPLACEMENT PUMP
• Do not smoke or allow flames or sparks to get near fuel．
• Always refuel your engine in a well-ventilated place．
• Do not overfill the tank and always close the filler cap securely．
• Never run the pump indoors as the engine emits poisonous carbon monoxide．
• Do not touch the mufflerduring orjust after operation；as the engine and muffler get hot．Always let the
engine fully cool before touching and storing the pump indoors．
• Always keep the pump at least 1 meter (3 feet) away from buildings and other equipment during opera-
tion• • Do not place flammable objects or liquids close to the pump．
• Before operating your displacement pump，please check your local laws and requlations before operating
your pump．It is illegal in some areas to operate an engine without a spark arrester；therefore，a spark arres-
ter is available as an optional part for this pump．
• Know all the pumps controls and know how to stop the pump quickly in the event of an emergency．Do
not let anyone without proper instructions operate the pump．
• Always keep children and pets away from the pump．
• Do not pump flammable or corrosive liquids such as gasoline or acid．In order to prolong the life of your
pump，avoid pumping corrosive liquids such as seawater，chemical solutions，used oil, or acidic liquids．
• Always operate your pump on a level surface．If the pump is tilted，fuel may spill and rapid wear might
occur as a result of inadequate lubrication．
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Suction Hose
The first step in preparing the pump for operation is to install the suction hose．For the suction hose，use a
reinforced-wall or wire braided hose to prevent suction collapse．A short hose is recommended over a long
hose．The pumps have standard National Pipe Threads on them；therefore，any standard hose set will fit
with the pump．If your hoses are metric threads or any other standard，please give our company a call we
carry a full line of adapters or provide you with a possible solution．
NOTE：Always install the provided strainer on the end of the suction hose before pumping If gravel or debris
enters the pump，the impeller can be seriously damaged．
Shown below is the pump hose wtilizing a barbed connection and hose clamp．If you already have speciali-
zed hose，disregard the following diagram．When using the barbed conection setup，make sure to use a
hose clamp to properly secure the hose to the barh connector
3. PRE-OPERATION PREPARATION
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Discharge hose
The second step is to install the discharge hose．The discharge hose can be fabric，just make sure to use
ahose clamp to secure the hose to the barb．This will prevent the hose from disconnecting under high pressure．
Note: A short and large-diameter hose is preferred over any other．A short and large diameter will provide
lower fluid friction and improve efficiency．
Engine oil
Engine oil is an important factor in determining the performance and life of your engine．Always make sure
the oil level is within the upper and lower limits specified on the oil dipstick．Make sure to check the engine
oil on a level surface or incorrect readings will result．
•To check the engine oil，first，remove the oil dipstick by turning counterclockwise．
•Wipe the dipstick clean and insert the dipstick back into the oil filler neck．Do not screw it in．Please refer
to Fig 2-1．
•If the level is low．fill engine oil to the top of the oil filler neck with the recommended oil below．
Below is a table of recommended oil grades for the engine in various weather conditions.
Please use the proper oil according to the Table 2-1．
Fig 2-1．Illustration of checking the engine oil
Fig 2-1．Illustration of checking the engine oil
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Note：For diesel engines，we highly recommend the use of 15W-40 engine oil．Some other
grades are comparable，but 15W-40 is the preferred oil grade．
Fuel
Remove the fuel cap and fill the fuel tank with diesel fuel．The preferred fuel for diesel engines is diesel
number 2．which can be easily obtained from a gas station.Do not use other fuels until consulting with your
local dealer or our company．
The capacity of your fuel tank is 3.3 US gallons．
Do not smoke or allow flames or sparks to get near fuel．Always refuel your engine in a wellventilated place
Do not overfill the tank and always close the filler cap securely
Air Cleaner
Before starting your displacement pump，remove your air cleaner cover and verify that the
air filter is clean and free of debris．Clean the air filter if necessary．
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Priming water
The pump chamber should be completely filled before operating．
Note：Never operate the pump without priming water or the pump will overheat．Prolonged operation of
the pump under these dry conditions will damage and destroy the seal．
Follow these guidelines to fill the pump with priming water．
1．Remove plug  2．Fill water 3．Install plug
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4. STARTING THE ENGINE
Recoil Starting
Note：When the engine is running，do not pull the recoil handle，otherwise the engine maybe damaged．
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8

Diesel engine with electric starter system
Starting
The preparation of the diesel engine for the electric starting system is the same as the manual recoil type．
a. Open the fuel cock．
b. Set the speed governor lever to the start position.
c. Turn the start switch clockwise to the“Start”position．
d. If the engine is started，immediately remove your hand away from the key switch．
e. If the engine does not start after 10 seconds，wait awhile (about 15 seconds) before tying to start the
engine again．
If you run the starter motor to long，the voltage of the accumulator will drop and the motor may be damaged．
Keep the key switch in the “ON” position
Battery
a. Always check the liquid level of the battery every month，if the level is lower than the low limit mark，refill
the battery with distilled water till you reach the upper limit mark．
If the liquid level in the battery is to low，the electric starter will not function to its best potential．Always keep
the level of the liquid in the baaery between the upper and lower linits．If there is too much liquid，the liquid
will splash onto other neary parts thereby mining the battery．
Cold starting
If the engine is difficult to start in winter,take off the rubber seal plug and put 2cc of machine oil into
the hole．
Notice：Engines supplied to the Torrid Zone will not contain the rubber plug．A solid plug is provided instead．
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Warning
Never use flammable liquids as fuel，as gasoline etc．Also，never take away the air cleaner for easy starting of
the engine doing so may cause explosions from the intake gases.
Never take the oil plug unless you’re planning on filling the oil．If the plug is not in place，rain，dust，and other
impurities may be sucked into the engine causing serious damage to the engine parts．
5. OPERATION
Stopping the pump
First，bring down the speed of the engine by using the speed governor．Let it run for 3 minutes at no load before
stopping it．
Then stop the engine．
Sudden stops to the engine will cause abnormal temperature increases in the block of the engine．Decrease the
load gradually when stopping the engine．Also，never stop the engine with the decompression lever．
Set the fuel cock at“S”(stop position)
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If the engine comes with an electric starter,turn the starting switch to the“Off”position.
Pull the recoil handle slowly until pressure is felt by your hand，this means the piston is on the compression
stroke；where the intake and exhaust valves are closed and then let the handle recoil back into the engine．This
natural position will prevent rust from occurring when the engine is being stored for long periods of time．Perform
these steps only when the engine is off；doing so otherwise will damage the engine．
6. MAINTENANCE
Oil check
During operation，it is a good idea to check the oil every morning to ensure the engine has sufficient oil．
Oil change
Engine oil is a critical factor in determining the life of your engine．Change the engine oil on time.Change the
engine oil more frequently if the engine is used in dusty areas．
Changing the oil while the engine is still warrfl will yield best results for the engine．When the oil is still warm，you
get rapid and complete draining of the oil．
Oil change procedures
•Remove the oil filler cap and drain plug to drain the oil
•Install the drain plug，and tighten it securely．
•Refill with the recommended oil and check the oil level．
•Install the oil filler cap．
The engine oil capacity is .60 liters or .63 US quarts
SAWl0W.30 0R
EQUIVALENT
MOTOR ASAE
10W-30
CHANGE THE OIL AFTER THE
FIRST MONTH 0R AFTER 20
HOURS，WHICHEVER COMES
FIRST．AFTER THIS．EVERY 6
MONTHS OR 100 HOURS．
WHICHEVER COMES FIRST．
DRAIN FILL 0.6L 0IL
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Note:Do not touch motor oil for long periods of time．Used motor oil can cause skin cancer if it comes in contact
with the skin for prolongd periods of time．Getting cancer from used motor oil is unlikely unless you handle used
motor oil on a daily basis．To be safe always wash your hands thoroughly with soap and water as soon as possi-
ble after handling used oil．
Below a maintenance schedule table is provided.
Time
Item Daily
After 20
hours
or 1 month
100 Hours or
Every 3 month
500 Hours
Every 6
month
1000 Hours or
Every year
Check and tighten the nut and screw ○
Check and fill machine oil ○
Change machine oil (First
time)
(Second
time and
later)
Clean and change oil filter ○●
(Change)
Check oil-leakage ○
Change the core of air filter
Cycle of check and main-tenance
will be shoaened at dusty
place.
○
Cleanfueltank Every month
Clean or change fuel filter ○
(Clean)
○
(Change)
Check nozzle ●
Check injection pump ●
Check pipeline of fuel
○
(Change if
necessary)
Adjust valve clearance of inlet
and exhaust
●
(First
time)
●
Grind valve holder 0f inlet and
exhaust
●
Change piston ring ●
Check accumulator liquid each month
Clean the core of air filter
○
(Clean)
every month or 50 hours
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Note：“●”mark indicates that it needs special wrench，please contact with dealer．
Air filter service
A dirty or clogged air filter will prevent air from flowing freely into the carburetor assembly．
Always keep the air filter clean or replace if necessary．Also,if the air filter is dirty or clogged，the performance of
the engine goes down．If operating the engine in a dusty area，service the air filter more frequently as dust parti-
cles will clog the filter at a faster rate．Never run the engine without an air filter，dust particles may get into the
intake system and damage the engine．Rapid engine wear will occur if the engine is run without the air filter．Do
not wash the air filter if it is the paper type．Also，never use gasoline to wash air filter elements because gasoline is
highly flammable and dangerous．A fire or explosion could occurfilter．Do not wash the air filter if it is the paper type
．Also，never use gasoline to wash air filter elements because gasoline is highly flammable and dangerous．A fire or
explosion could occur．
Instructions on changing the air filter
•Take the wing nut off and remove the air filter cover．Remove the elements and sepa- rate them．Check the
elements for tears and holes．If holes or tears are present，replace the air filter elements．
•The foam elemment can be washed．Warm water and household detergent will work fine for washing the
foam filter element．After washing，rinse it thoroughly with water and allow the element to dry．Soak the
element in clean engine oil and squeeze the oil out．If there is too much oil left in foam element，the engine will
smoke during startup．Tap lightly several times on a hard surface to remove excess dirt from the paper filter．
•Never brush on the paper element as this just forces more dirt into the paper element．Use compressed air to
blow from the inside out to remove the excess dirt．
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1．Drain screw
2．Inlet pipe connector
3．Tightening flange
4．Inlet pipe
5．Door valve
6．Water addition port
7．0utlet elbow
8．Pump case
9．Shaft seal
10．Impeller
11．Flow guidance
12．Pump cover
DISPLACEMENT PUMP DIMENSIONS
Note：When changing the seal on the pump，be sure to apply adhesive to the seal and the pump housing．
This will prevent future leaks．Also while installing the seal，do not hit or apply force，as this will damage the seal
．Slowly ease the seal into place．Please refer to Figure 2-3 for a cross sectional view of the housing and shaft．
Type H1 H2 H3 H4 L1
AT2C 348 297 151 106 248
AT3C 410 348 17l 106 325
Type H1 H2 H3 H4 L1
AT2C 13.47 11.7 5.9 4.2 9.8
AT3C 16.1 13.7 6.7 4.2 12.8
UNITS MM
1．Sealing ring
2．Ceramic ring
3．Fixed graphite ring
4．Corrugated pipe
5．Washer
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Note:After operation of the pump during winter．be sure to drain all the liquid out of the pump to prevent damage
t0 the pump．The pump may be damaged if left over liquid in the pump freezes．
7. TRANSPORTING AND STORAGE
A few guidelines need to be followed before transporting the pump．Below is a list of in- structions to be followed
during transportation．
•When transporting the pump,turn the fuel valve off and keep the pump on a level surface to prevent fuel
spillage．
•Secure the pump unit to a fixed object when transporting to prevent the pump from bouncing around．Conti-
nuous bouncing around can damage the pumps internals．
Before storing the pump for long periods of time，please follow the guidelines below．
•Clean the pump interior before stopping the pump．Remove the pump drain plug and empty all fluids from the
pump．Leaving fluid in the pump will cause rapid corrosion to the impeller．
•Turn the fuel valve to the “Off” position and empty all ofthe fuel out ofthe gas tank．
Note：While dealing with diesel，do not smoke or allow flames to come near the fuel as
accidents may occur．Failing to do so will lead to serious injuries and death．
•Chage the engine oil
•Remove the cold start oil fill plug and pour about a tablespoon of oil into the cylinder．Crank the engine several
times．
•Pull the starter rope until resistance is felt．Doing this will put the cylinder on the compression stroke；where
both intake and exhaust valves are closed．Having these two valves closed will prevent moisture from getting
into the combustion chamber and causing corrosion．
•Cover the engine and pump and store in a dry place．
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8. TROUBLESHOOTING
Problem Cause Remedy
Pump not pumping liquid
Not enough fill water．Refill the pump with water．
Leaking inlet pipe．
Check the inlet pipe and connector
of pipe，change pipe or tighten the
clipper joint screw．
Low pump speed．Adjust the engine speed accordingly
or find cause within the engine
The filter net is clogged．Check and clean the filter net．
Capacity of the pump has been
exceeded．
Check the position of the pump and
fix the operating conditions as
specified．
Seal wear and leakage．Change the seal．
Not enough water flow
The filter net，pipeline，or
impeller is clogged．Clean out the clogging matter．
Speed is low．Increase speed．
Impeller or seal is seriously
worn and gap is too large．
Adjust the gap or change the impe-
ller and seal．
Leaking inlet pipe．
Check the inlet pipe and connec-tor
of pipe，change pipe or tighten the
clipper joint screw．
Impeller damage and or serious
leakage．Change the impeller to a new one．
Flow of water is
not steady or
constant
The total lift is too high．Check for the cause of the problem
and adjust if necessary．
There is air in the pump or the
inlet pipe and seal are
leaking．
Taketheairdraincapoffandrelease the
air．Check the pipeline and or
change the pump seals．
Engine speed is not stable or
constant Adjust the speed of the engine
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Problem Cause Remedy
Power consumption
of pump is too
large
The impeller and flow guidance
are rubbing each other．
Listen to the sound of the pump
carefully．If there are rubbing
noises，adjust the impeller until
the noise is gone．
The impeller i s clogged with
weeds or foreign matter．Check and clean the pump.
No flow suddenly
The connector of the inlet pipe
is loose or is leaking．
Check the inlet pipeline and fix
accordingly．
Suction head has been exceeded. Check the suction head and lower
the position of the pump.
Vibrational noises
Suction head is too high and
causing cavitation．
Check the suction head and lower
the position of the pump.
Large water output. Decrease the output of the water.
Inlet pipe is clogged with
foreign matter,so the resistance
is too large．
Check the inlet pipe and filter net
and clean if necessary．
Rotary part is loose.
Listen carefully and inspect the
part that causes the noise then
stop the machine and adjust as
necessary．
Pump unit is loose or not
installed properly．
Stop the machine and adjust the
pump and engine．
Air inside the pump unit or air
inside the pipeline．
Remove the air drain screw and
elim- inate the air．
Impeller damaged Stop the machine and replace the
impeller．
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9. EXPLOSION VIEWS
AT2C(E)-4/AT3C(E)-4
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No. Description Qty. Part Number
1 Drain Plug 2 2C1／3C1
2 Rubber seal 2 2C2／3C2
3 M8×25 bolt 15 2C3／3C3
4 Wsher 8 16 2C4／3C4
5 Waterpump case 1 2C5／3C5
6 Seal 1 2C6／3C6
7 Flow guidance plate 1 2C7／3C7
8 Impeller 1 2C8／3C8
9 Shaft seal 1 2C9／3C9
10 M6×50 bolt 2 2C10／3ClO
11 Water pump seal ring 1 2C11／3Cll
12 Water pump cover 1 2C12／3C12
13 M6×55 bolt 1 2C13／3C13
14 M6bolt 3 2C14／3C14
15 Discharge elbow 1 2C15／3C15
16 O-ring Gasket(optional) 2 2C16／3C16
17 Flange(optional) 2 2C17／3C17
18 Barb connector(optional) 2 2C18／3C18
19 Rubber Gasket 1 2C19／3C19
20 One way valve 1 2C20／3C20
21 Suction flange 1 2C21／3C2l
22 M6×25 bolt 4 2C22／3C22
23 Strainer 1 2C23／3C23
24 Connecting flange 1 2C24／3C24
25 Washer 6 4 2C25／3C25
26 M6 nut 4 2C26／3C26
27 Throat clip 3 2C27／3C27
28 Diesel engine 1 2C28／3C28
29 Frame 1 2C29／3C29
30 Rubber mount 4 2C30／3C30
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