PETROLEUM TANK LORRY OWNER’ S MANUAL Vg PAEWOOWe would like to take this opportunity to thank you for choosing a DAEWOO UTILITY TRUCK. This manual has been prepared to inform you about the operation, main- tenance, and adjustments of your new DAEWOO UTILITY TRUCK, excluding the chassis. You are urged to read this manual carefully and to follow the instructions end safety rules in order to maintain the best performance and to prevent accidents and trouble. When it comes to service, remember that your DAEWOO dealer knows your vehicle best and is ir ‘erested in your full satisfaction. For any other information about the engine and chassis excluding spe- cial equipment, please refer to OWNER'S. MANUAL for HEAVY TRUCK which has been issued separately. {YZ DAEWOO COMMERCIAL VEHICLE * Allinformation, illustrations and specifications contained in this manual are based on the latest product information available at the time of Publication. The right is reserved to make changes at any time with- out notice.CONTENTS 4. MAJOR PART NAME . PIPING DIAGRAM |. OPERATION PRECAUTIONS |. MAJOR COMPONENT PARTS . DIAGNOSTICS AND CORRECTIVE ACTIONS. . PERIODIC INSPECTION CHART 7. SPECIFICATIONS 6.} PETROLEUM TANK LORRY 1. MAJOR PART NAME eS . a j Bottom valve hanc Manhole cover Safety bracket Ladder Side protector Tenk Hose box Emergency lever (010070PETROLEUM TANK LORRY 2. PIPING DIAGRAM 10/16/18KL Tank Lorry, 20KL Aluminum Tank Lorry ¥ — Emergency lever No. | Signal Name 1 Bottom Valve Open, Close Tank Pte +6 © _¥ 2 ah 4-way Valve | f Discharge ~~~ Svetion 3 | EE | c6arPume 4 %& Relief Valve 5 ¥ 2.way Valve 6 | > | steiner ‘010080PETROLEUM TANK LORRY 20/22KL Tank Lorry Emergency lever No. | Signal Name 1 Bottom Valve Open “Fe Close —Discharge | 2 4-way Valve ~~ Suction 3 Gear Pump 4 Relief Valve 5 2-way Valve 6 Strainer ‘010080PETROLEUM TANK LORRY 3. OPERATION PRECAUTIONS extinguisher § if ww WA | [ e ak —t 2 ) y Cotton clothes: Precautions before operating the pump (1) Keep flame or hazards away from the pump. (2) Check for operation of fire extinguishers. (3) Never allow flames near or smoke while operating. (4) The operator should always wear cotton clothes when operating. (To prevent static electricity) 10PETROLEUM TANK LORRY MEAG300 ® ®@@® © ® © @O®© MoBo020) ‘Other structures 010149] Checks before operating the pump (1) Ensure that the parking brake lever is pulled back- ward. (2) Ensure again that the gearshift lever is in the NEUTRAL(N) position. (3) Ensue thet the earth reel wires are connected to the other fitings on the vehicle. ‘When transporting gasoline (aviation gas) Caution For gesoiine (aviation gas) tank lorry, never operate the pump when filing or discharging the tank. If operating the pump, static electricity, or sparks or fictional heat can be cenerated by the gears engaging with each other and rotating, and consequently resulting in the fire haz~ ard. WPETROLEUM TANK LORRY 210190 (4) Ensure that earth bands are fastened to the flange Part of each valve. (5) Ensure that the set bolts are not loosened. (6) Check the conditions of the pump, PTO shaft, vari- ous valves, and piping. (For oil leak, bolt fasten- ing, cracks on welded parts) How to check for frost when using the tank lorry first in cold seaso (1) When using the tank lorry first in cold season since taking it over, open the drain plug on the gear pump to check for frost int. If frostis found visibly, warm up the gear pump area with hot water and drain residual water through the drain plug. (2) Using a drive shaft or pipe wrench, be sure to check, before actuating the PTO switch, that the inside of the gear pump has been frozen. If unusual sound is heard or the drive shaft does not rotate smoothly, it means that the inside of the gear pump has been frozen. Warm up the gear pump slowly with hot water. 12PETROLEUM TANK LORRY Caution 1. Do not actuate the PTO switch if the ‘gear pump is frozen. (Crack may result on gear pump) 2, Do not apply excessive force to the 2- way valve and 4-way valve if various valves and piping have been frozen. (Lever may be broken.) 3. Neveruse a torch nearthe vehicle with gasoline or inflammables loaded, or rear inflammatles. 4-way valve 20200] 0210] 210220) (3) After warming up the gear pump, pour hot water through the suction valve to make warm the inside of piping and various valves. Atter they become warm enough, inject oil inside to prevent conden- sates from freezing, How to drain the pump (1) With the 2-way valve lever placed in CLOSE posi- tion, remove the cam lock mechanism on the 2- way valve adapter, fasten the hose (3"), and se- cure the hose end so that it may not interfere with other receptacles. (2) Disconnect the earth reel wire and secure it to the drain receptacle for grounding. (To prevent static, electricity) (3) Ensure that the 4-way valve lever is placed in the "STOP" position. (4) Climb to the top of the tank and open the manhole to prevent the inside of the tank from form a vacuum. (Relieve gas and tank pressure.) (5) Turn open the OPEN/CLOSE handle on the bot- tom valve to make the oil of the tank flow into all the piping. 13PETROLEUM TANK LORRY Emergency lever DISCHARGE (PUMPING) way valve ovves0) Ke PTO él ‘TA72O (6) Ensure that the emergency lever position is pushed in, (7) Place the 4-way valve lever in the "DISCHARGE (PUMPING)" position. (8) Let the operator get in the cab, start the engine, and ensure that the gear is in NEUTRAL position, then depress the clutch pedal and press the PTO switch "ON". (9) Release the clutch pedal slowly. Then, ensure that the PTO shaft drives the pump. 14PETROLEUM TANK LORRY olozor L0260 PTO switch ASN] saa A Idling speed control knob otoe70) (10) Once the PTO shatt is activated, turn the idling ‘speed control knob until engine revolution reaches 600-700 rpm to adjust the engine rpm. (11) Let the operator get off the vehicle and check the 2-way valve and hoses for conditions, and vari ous valves for oll leaks. If no abnormality found, move the 2-way valve lever in the OPEN direc- tion. (12) The operator should stay near the emergency lever on the rear of the vehicle to prevent pos- sible accidents. (13) Stop the pump immediately after discharging oil ‘completely. (To stop the pump, depress the clutch pedal, press the PTO switch "OFF", and then bring the idling speed control knob back to its original Position, 15PETROLEUM TANK LORRY oo eeeeFFFSSSFSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSS Caution 1. Ifyou operate the gear pump when dis- charging inflammables such as gaso- line or aviation gas, inflammables may be exploded by static electricity or tric- tional heat inside the pump. 2. Be sure to connect the earth reel wires to the mating components so that static lectricity or frictional heat can be grounded. ‘ot0220 *to290 way valve SUCTION caer voz (14) All the valves should be placed in the CLOSE position and the manhole cover should be se- _ cured. How to actuate the suction pump (1) Keep the manhole open. (2) Turn open the bottom valve handle. (3) Ensure that the emergency lever position is pushed in, (3) Place the 4-way valve lever in the "SUCTION" po- 16PETROLEUM TANK LORRY 2eway valve (5) Fasten securely the hose to the 2-way valve adapter to connect to other receptacle and place the 2-way valve lever in (6) Let the operator get in the cab, start the engine, and ensure that the gear is in NEUTRAL position, then depress the clutch pedal and press the PTO switch "ON", (7) Release the foot from the cepressed clutch pedal slowly and, using the idling speed control lever, maintain the engine revoluton at 600-700 rpm. (8) Let the operator get off the vehicle and check the 2-way valve and hoses for conditions, and various valves for oil leaks. If no abnormality found, move the 2-way valve lever in the OPEN direction. 7PETROLEUM TANK LORRY — sao 010260) Idling speed | contret knob oucer0) Ci aution 1. I'you operate the gearpump when dis- charging inflammables such as gaso- line or aviation gas, inflammables may be exploded by static electricity or frle- tional heat inside the pump. 2, Be sure to connect the earth reel! wires to the mating components so that static electricity or frictional heat can be grounded. (9) The operator should stay near the emergency le- ver on the rear of the vehicle to prevent possible accidents, (10) Stop the pump immediately after sucking oll com- pletely. (To stop the pump, depress the clutch Pedal, press the PTO switch "OFF", and then bring the idling speed control knob back to its original position, (11) All the valves should be placed in the CLOSE Position and the manhole cover should be se- cured, 18PETROLEUM TANK LORRY 4, MAJOR COMPONENT PARTS a Manhole Salety device Satety bracket Battle plate 210200] TANK The tank is of a steel plate structure processed with electric welding. Its exterior is composed of a protec. tion frame on top for manhole and safety devices, safely bracket (on the front, rear, left, and right) for Preventing the tank from rolling down in case of ve. hicle overturn, and @ hose storage box. Its inside is Partitioned into completely isolated compartments; each compartment has an battle plate designed to pre. vent oils from surging when stopping the vehicle or changing direction abruptly, On the top ofthe tank, @ round manhole for receiving cil Is installed on each compartment. The manhole cover is. mounted with a hatch type inlet por, a safety valve, and a disc type cil level gauge. Undemeath the tank, a bot- tom valve having an emergency closing device is installed on each compartment, and these valves can be opened ‘or closed easily by using the ON/OFF handle on the bottom valve on the top of the tank. PIPING Piping is composed of bottom valves (1) having emer- gency closing device for each compartment, main pip- ing (2) connected to these valves, piping (3) connect- ing the suction and discharge circuits, pump (4), 4-way valve (5) having 4 functions of suction, discharge (pumping), discharge (natural), and stop, and 2-way valve (6) mounted on both sides of the tank front to Perform function as suction and discharge ports, In ad- dition, at the pump suction side, there is a strainer (7) altached to extend the pump service fe by filtering contaminants. At the pump discharge side, there is a bypass valve (8) mounted to prevent pressure in- crease, (1) Strainer The strainer filters contaminants from oils and the inside of pipes to extend the service life of the pump and valves. 19PETROLEUM TANK LORRY 2way valve ‘SUCTION DISCHARGE (NATURAL) Aeway valve. ea Riot valve (2) 2-way valve This valve allows oil passing through the 4-way valve to be descharged through the discharge hose or shuts off oil flow. (8) 4-way valve This valve is used for suction, discharge(pumping), stop, and discharge(natural) of oil flow, and each function is as follows: SUCTION: DISCHARGE: (PUMPING) DISCHARGE: (NATURAL) STOP: Forcing oil to flow into the pump from the 2-way valve Discharging oil flow, which has passed the pump from the tank, to the 2-way valve Discharging oil directly to the 2-way valve, not through the pump Allowing oil to circulate in the piping and pump without being discharged outside - Bypass valve operation (4) Relief valve (Bypass valve) This valve feed oll back to the pump if internal pres- sure of piping reaches 2kgl/em? or more at pump ‘operation for oil suction or discharge. (5) Emergency valve If emergencies occur outside or when oil is being discharged, use this valve (located underneath the tank) to shut off oil flow within the tank. This emer- gency valve is mounted in each compartment and connected to the rod, and consequently, can be operated as a whole by the emergency lever in- stalled on the rear part of the vehicle. 20PETROLEUM TANK LORRY BASSES Bottom vaive hi BE RIE 2EEEES REG ESE Bee ea GIS ISE BEEEES EGER BEE SAR BARASR BREE ESSE FESSSS SASS AAAS: 010380) Drive shaft Gear pump ot0320] (6) Bottom valve ‘This valve is installed underneath the tank and de- livers oil of the tank to the 4-way valve and piping Itis mounted for each compartment and integrated with the emergency valve as one set. The open/ close part of the bottom valve is connected to the rod and opened or closed by using the handle lo- cated on the top of the tank. Disc type oil level gauge The disc type oil level gauge Is installed in the center, of each compartment. Using this gauge enables check- ing for proper oil flow on the top of the tank. Safety valve Gas is produced if the oil in the tank is surged while the vehicle is running. If internal pressure in the tank rises (0.3kg/em?), this valve is actuated automatically to reduce internal pressure. Gear pump This is a system where the power generated in the transmission is transferred through the PTO drive shaft to the gear pump. As the pump takes in the oil in the tank, the gear in the pump is actuated to increase delivery pressure, with the result that the into the piping. 24PETROLEUM TANK LORRY 5. DIAGNOSTICS AND CORRECTIVE ACTIONS Complaint Cause Correction Gear pump does not rotate. PTO switch malfunctioning Diive shatt broken . Gear pump coupling damaged Gear pump damaged Check the switches and fuses. Replace the drive shaft. Replace the coupling, Repair the pump. Materials fall to be discharged. 2-way valve faulty 4-way valve faulty Bottom valve malfunctioning Bottom valve shut-off lever linkage faulty Relief valve faulty Gear pump faulty Repair/replace 2-way valve. Repait/replace 4-way valve. Repait/replace bottom valve. Repair the linkage, Replace the relie! valve. Repair the pump. Leaks of oil in the tank Bottom valve opened or defective 2-way valve opened or defective Relief valve opened or defective Bottom valve emergency lever link- age defective Various defective packing Hose coupling poorly connected Lock up, repair, or replace. Lock up, repair, or replace. Replace relief valve. Repair the linkage, Replace packing. Correct contacting condition. 226. PERIODIC INSPECTION CHART PETROLEUM TANK LORRY Check Items Service Intervals Daily, Every 5 hours Weekly, Every 4,000km or 30 hours operation Biweekly, 2,000km or 60 hours loperation| Monthly, 4,000km or 120 hours operation Halt. yearly, 24,000km| or 1720 hours Check for connections Check for open circuit Wiring Check for grommet and clips Check for fire extinguisher charge level Fire extinguisher| Check for fire extinguisher mount Check for delivery output during the pump operation Check for vibration or unusual sound during the pump operation © Check for oil leaks the pump operation © Check for damage or wear on the pump adapter and coupling Check for open/close conditions of the bottom valve Pump, and Piping ‘Check for oil leak from the bottom valve Check for oil leaks from pipe connections and flanges Check for oil leaks from valves ©|9|/O|/o Check for bolt fastening Tank 23PETROLEUM TANK LORRY 7. SPECIFICATIONS AOKL/16KL/18KL Tank Lorry eet iia 410KL Tank Lorry | 16KL Tank Lorry | 18KL Tank Lorry (Light oil) {Heavy duty cttight cil} (Light of) General Length (mm) 7,120 9,853 + Sescrptions gi (mm) 2,490 « e Height (mm) 3,100 | att 3,180 Tread (mm) | Front 2,050 « « Rear 1,855 e © Wheel base | ist 1,480 4,500 « ol 2nd 4,030 1,800 © 3rd - - Battery PT150 © © Engine Name DEI2 DEt2T © Number of cylinder 6 . « Total displacement (co) 11,051 « e Max. torque (kg-m/rpm) | 81.5/1,400 196/1,260 « Clutch Type metas i . . Transmission | Changeover positions | Forward level 5, | Forward level 6, « Backward level 1 | Backward level 1 Tank Loading capacity (L) 10,000 16,000 18,000 ‘Shape Oval e « Compartment 3 (6: option) 5 Material S841, SUS « « Cit gauge | Type Disc type/Ruler type e e Gear pump | Specifications 3 inch 4 inch « 600 41,000 te 24PETROLEUM TANK LORRY 18KU/20KL Aluminum Tank Lorry reat tt 8KL Aluminum Tank Lorryl20KL Aluminum Tank Lorry] jection em (Heavy duty oil) (Light oi!) General Length (mm) 9,853 co descriptions ‘Width (mm) 2,490 oe Height (mm) 3,195 e Tread (mm) | Front 2,050 + Rear 1,855 © Wheelbase | ist 4,500 « (mm) 2nd 1,800 = ord ~ om Battery PT150 Engine Name DE12Ti e Number of cylinder 6 | « Total cisplacement (ce) 11,051 « Max, torque (kg-m/rpm) 135/1,260 | & Clutch Type Discftiction, dry single plete, coil spring — ‘Transmission | Changeover positions Forward level 6, - Backward level 1 Tank Loading capacity (L) 18,000 20,000 Shape. Oval - Compartment 5 « Material (A5454-0 Sal Oilgauge | Type Disc type/Ruler type « Gear pump | Specifications 4 inch + Delivery output (Umin) 1,000 — 25PETROLEUM TANK LORRY aS 20KL/22KL Tank Lorry Section Hem ‘envy auy cera General Length (mm) 11,435 + desereions Tat (mm) 2,490 = Height (mm) 3,110 . 3,140 Tread (mm) | Front 2,050 - Rear 1,855 © Wheel base | tst 1,630 - ia 2nd 4,080 « 8rd 1,300 - Battery PT150 . Engine Name | oVvisT = Number of cylinder 8 & Total displacement (cc) | 14,618 Max. torque (kg:m/rpm) 870/2,800 © Clutch Type Discfriction, dry single plate, diaphragm © Transmission | Changeover positions Forward level 16, bes Backward level 2 Tank Loading capacity (L) 20,000 22,000 Shape Oval « Compartment 5 Material SS41,SUS « Oil gauge | Type Disc type/Ruler type « Gear pump | Specifications 4 inch 6 Delivery output (Uimin) 1,000 e 26