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Doosan AD158TI, Operation & Maintenance Manual

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Doosan AD158TI Operation & Maintenance Manual Download Page 122

Main parts maintenance

- 116 -

7.2. Cooling System

7.2.1. Fresh water pump assembly

7.3. Fuel System

7.3.1. Injection pump

The components relating to the injection pump should be serviced at regular intervals as the plunger and
delivery valve may be worn after a given length of time for use and cause the deterioration of the engine.

Make sure that servicing should be performed at the professional maintenance
shop as authorized by Bosch or Zexel Company. 

For adjustment of fuel injection volume, refer to the 

′

Specifications of fuel injection pump

′

 described as fol-

lows.

EDV2218164

þ

137

Hub

Rubber seal

Pump housing

Impeller

Cover

Spline shaft

Oppression

Mechanical seal

Summary of Contents for AD158TI

Page 1: ...950106 038007EN V158TI V180TI V222TI AD158TI AD180TI AD222TI MARINE ENGINE Operation Maintenance Manual...

Page 2: ......

Page 3: ...CE is 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 Import...

Page 4: ...red at a designated dealer or center or resulting from the use of non genuine parts Malfunctions resulting from unauthorized modifications changes or external hardware Malfunctions resulting from inco...

Page 5: ...ng 22 3 3 Engine Break in 23 3 4 Inspections after Starting 25 3 5 Check after Initial 50 Hours Operation 26 3 6 Operation In Winter 26 3 7 Tuning the Engine 27 4 GENERAL INFORMATION 29 4 1 General Re...

Page 6: ...7 MAIN PARTS MAINTENANCE 114 7 1 Lubricating System 114 7 2 Cooling System 115 7 3 Fuel System 115 7 4 Turbo charger 139 8 TROUBLE SHOOTING 166 Appendix...

Page 7: ...ection pump Mechanical variable speed R Q V Fuel consumption g PS h 155 163 185 liter h 90 106 152 Injection timing B T D C deg 15 1 16 1 18 1 Fuel inj nozzle opening pressure kg cm2 286 Starting syst...

Page 8: ...of injection pump Mechanical variable speed R Q V Fuel consumption g PS h 153 156 185 liter h 111 122 183 Injection timing B T D C deg 16 1 18 1 18 1 Fuel inj nozzle opening pressure kg cm2 286 Starti...

Page 9: ...ype of injection pump Mechanical variable speed R Q V Fuel consumption g PS h 152 160 190 liter h 132 154 229 Injection timing B T D C deg 17 1 18 1 19 1 Fuel inj nozzle opening pressure kg cm2 286 St...

Page 10: ...ylinder kg cm2 130 130 130 Com press at 200 rpm kg cm2 24 Initial condition Governor type of inj pump Electric governor Fuel consumption g PS h 148 153 152 153 151 150 liter h 73 88 89 111 110 130 Inj...

Page 11: ...wn represent the standard model they do not include all models 1 2 1 Engine sectional view Longitudinal V222TI EB2M1001 2 3 4 5 6 7 8 9 1 1 Cylinder head 4 Tappet 7 Oil pump 2 Cylinder head cover 5 Ca...

Page 12: ...3 4 1 1 14 6 9 7 13 12 11 5 6 7 8 9 10 1 Intake manifold 6 Exhaust manifold 11 Oil cooler 2 Breather assembly 7 Piston 12 Oil level gauge 3 Injection pump 8 Connecting rod 13 Oil filter 4 Injection p...

Page 13: ...1 Crank pulley 7 Fresh water filler cap 13 Exhaust manifold 2 Fuel filter 8 Sea water pump 14 Turbocharger wet 3 Intercooler 9 Heat exchange ass y 15 Sea water inlet pipe 4 Oil drain pump 10 Starter...

Page 14: ...avy Duty Engine Speed rpm Output PS 300 400 500 600 700 800 900 1000 150 160 170 g PS h 1000 1500 2000 Full Consumption Full Load Propulsion Curve O p e r a t i o n R a n g e Medium Duty Engine Speed...

Page 15: ...red when requesting warranty and ordering parts It is also referred to as engine model and serial number because of their location Note The engine model name V222TI is described in the name plate on t...

Page 16: ...Specification 10...

Page 17: ...putting the engine into operation for the first time read the operating instructions carefully and famil iarize yourself with the critical points If you are unsure ask your DOOSAN representative For...

Page 18: ...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 When using compressed air e g f...

Page 19: ...l or coolant Use only DOOSAN approved service products engine oil anti freeze and anti corrosion agent Pay attention to cleanliness The diesel fuel must be free of water See 4 6 Fuel System Have the e...

Page 20: ...mal 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...

Page 21: ...level of the cooling water in tank Caution If the installation angle of the engine exceeds 6 degrees please remark the maximum and minimum level of the oil dipstick by engraving on the lube oil capac...

Page 22: ...e exhaust Line Make sure that intake exhaust piping lines are properly designed and air filter element is fouled and worn severely If so correct and clean or replace it 3 1 5 Fuel line Check the fuel...

Page 23: ...t 1 Analog gauge panel Deluxe panel Dutch panel 2 3 4 5 11 1 10 9 6 7 EDV2218013 8 1 Volt meter 5 Clutch oil press gauge 9 Stop button 2 Water temp gauge 6 Rotary switch 10 Key switch 3 Tachometer 7 P...

Page 24: ...ch 2 Water temp gauge 6 Push button 10 Panel 3 Oil pressure gauge 7 Rotary switch 4 Clutch oil press gauge 8 Stop button 10 3 2 8 6 12 1 9 7 4 11 5 EDV2218016 1 Pyrometer 5 Volt meter 9 Select switch...

Page 25: ...Commissioning and operation 19 2 Digital gauge panel Circuit diagram EDV2218035...

Page 26: ...Front Rear 2 2 4 3 1 EDX1218005 1 LCD 3 Key switch 2 Function Keys 4 Start stop button 1 2 7 8 9 6 3 4 5 EDX1218006 1 Power connector 6 Fuse 2 Signal connector 7 CCTV Optional 3 CAN 8 GPS TBD 4 Ext b...

Page 27: ...horn will sound when the ignition is turned on and continue to sound until the key switch is shifted into OFF position or minimum oil pressure is obtained This provides a functional test of warning sy...

Page 28: ...rst restart the engine after waiting for 30 seconds at least to pre vent the circuit malfunction of the starter 3 2 2 Operation 2 Digital panel Digital panel system boot shutdown and the engine stop f...

Page 29: ...l until 20 hours break in is completed 3 3 2 Initial two hours of break in For the first five to ten minutes of operation operate engine at a fast idle below 1 300 rpm During the remaining first two h...

Page 30: ...equently Maintain oil level in the safe range between the min and max marks on dipstick Watch the oil pressure warning lamp If the lamp blinks whenever the boat attitude i e turning climbing on plane...

Page 31: ...nnect the battery or pole terminals or the cables If during operation the battery charge lamp suddenly lights up stop the engine immediately and remedy the fault in the electrical system Engine should...

Page 32: ...ing water and the viscosity of lubricating oil 3 6 1 Prevention against the freeze of cooling water When not using anti freeze completely discharge the whole cooling water after engine running The fre...

Page 33: ...thorough procedure of analysis and correction of all items affecting power and perfor mance Economical trouble free operation can better be ensured if a complete tune up is performed once every year...

Page 34: ...Commissioning and operation 28...

Page 35: ...nd rubber coated seal ring etc should be discarded New ones should be used for re assembled parts If these are reused normal perfor mance can not be maintained 7 To facilitate reassembling keep disass...

Page 36: ...ger and water cooling line cleaning 1 200 hr V belt check and adjustment 2 000 hrs change Thermostat check 2 years Impeller of sea water pump check 2 000 hrs change Lubrication system Oil level check...

Page 37: ...of the water lines or the upper plug of wet turbocharger open and fill the coolant about three forth of the expansion tank slowly until the air bubbles in water do not come out through the plug hole T...

Page 38: ...he expansion tank or overflow system The collected sample is less contaminated so it can not be substituted for the quality of whole coolant 2 Shake the bottle filled with sample coolant to mix well a...

Page 39: ...resh water instead The content of the anti freeze and anti corrosion agent can be regulated by this way Every year coolant must be replaced It is essential the coolant should be mixture of fresh water...

Page 40: ...urred a Remove the heat exchanger both left and right side covers b Remove the clogged small pieces and clean the heat exchanger tubes When the heat exchanger tubes do cleaning clean outside and inner...

Page 41: ...pply to DOOSAN genuine parts every replacement 4 3 6 Thermostat The thermostat maintains a constant tempera ture of coolant 71 85 C and improves ther mal efficiency of the engine by preventing heat lo...

Page 42: ...the engine sufficiently before running it In cold weather do not run the engine at overload or overspeed it immediately after starting off 2 When draining out or replenishing coolant do it slowly so t...

Page 43: ...mum marking on the dipstick Over filling will result in damage to the engine like a excessive blow by gas How to re mark the oil dipstick Since the inclination angle of marine engine may differ greatl...

Page 44: ...the oil level gauge indicates the vicinity of its maxi mum level For a few minutes operate the engine at idling in order to circulate oil through lubrication system Thereafter shut down the engine Af...

Page 45: ...l filter cartridge can be seated properly Note It is strongly advisable to use DOOSAN genuine oil filter cartridge for replacement Lightly oil the O ring and turn the oil filter until sealing face is...

Page 46: ...apply to API Service SAE 30 for reduction gear oil Change the reduction gear oil at 100 hours of operation at first and next exchange will be performed every 600 hours 4 4 6 Cylinder compression press...

Page 47: ...eased engine output finally leads to shorten the engine life The air filter element should clean periodically as follow Cleaning of the air filter element Every 100 hours Exchange of the air filter el...

Page 48: ...efully before installing the gaskets Observe the specified pressure when making the hydraulic test Observe the specified pressure when making the hydraulic test Cleaning of inter cooler Every 1 000 ho...

Page 49: ...ated Water in fuel can seriously affect engine performance and may cause engine damage 4 6 1 Priming pump strainer cleaning Clean the priming pump strainer every 100 hours operation The strainer is in...

Page 50: ...xhaust emission levels DOOSAN engines are designed to operate on most diesel fuels mar keted today In general fuels meeting the properties of ASTM designation D975 grades 1 D and 2 D have provided sat...

Page 51: ...38 125 52 131 55 Viscosity kinematic CST 100 F 40 C D 445 1 3 2 4 1 9 4 1 1 8 10 Cloud point F D 2 500 See note 1 See note 1 See note 1 Sulfur content wt Max D 129 0 5 0 5 0 15 Carbon residue on 10 w...

Page 52: ...If another fuel water separator is to be used it must be sized for the engine s fuel supply flow rate 4 6 4 Fuel filter exchanging a Loosen the fuel filter by turning it counter clockwise with the fil...

Page 53: ...lace it with a new one Otherwise fuel leaks from the fuel filter joints causing a critical fault in engine performance 4 6 5 Checking the fuel injection timing by authorized specialist personnel Check...

Page 54: ...of the cold engine are as follows Intake valves 0 25 0 05 mm Exhaust valves 0 35 0 05 mm 4 8 1 When the engine is not used long time In case of the engine is not used long time preserve the engine fr...

Page 55: ...ries need not And apply the grease on the surface of the wire terminals to protect corrosion Loosen the V belt to prevent its tension and push the paper sheet in the pulley homes under the V belts Run...

Page 56: ...General information 50...

Page 57: ...jor components such as input shaft gear shaft output shaft and housing The clutch for forward and reverse movements is composed of a hydraulic wet type and multi plate type and the construction and po...

Page 58: ...nusual sound temperature etc while idling the engine While checking the clutch pressure increase the engine rpm 3 Driving and stopping Check to see that the specified pressure is obtained when engagin...

Page 59: ...internal splines on the pressure plate 7 With double and triple plate PTO there are intermediate pressure plates 8 which also slide on the body Between the body and pressure plates are the friction f...

Page 60: ...engine and run until sufficiently warmed up to maintain normal engine idle speed With the engine running at or slightly above idle speed but not in excess of 1 200 rpm push handle firmly and quickly w...

Page 61: ...ult in excessive wear and or burn out which in not warrantable Do not adjust the PTO too tightly Loads above the maximum quoted can cause PTO component failure 3 PTO adjustment Do not attempt to adjus...

Page 62: ...ted or contaminated with lubricant they must be replaced Severe discol oration of facings often indicates the PTO has been operating in a slipping condition possibly due to faulty adjustment In cases...

Page 63: ...st above the bearings Internal drillings in the housing carry the grease to the bearings Do not over grease Excess lubrication at any of the points can result in contamination of the friction facings...

Page 64: ...Main accessory parts 58 5 2 3 Exploded view of typical 11 1 2 14 twin clutch EB4O5002 PIVOT PIN PLAIN WASHERS SPLIT PINS OR CIRCLIPS SPLIT PINS...

Page 65: ...owable horsepower as specified for each model in figure below Torque represents when there is no pro peller load 2 For small power The right figure is applicable to the drive arrangement in which the...

Page 66: ...ange use a propeller with less pitch to increase the RPM Should the engine s full throttle RPM want to exceed the specified range B the engine RPM is limited by the governor Use a propeller of higher...

Page 67: ...ator should be operated with the regulator and battery con nected in circuit to avoid the damage of the rectifier and regulator The alternator is maintenance free but it must be protected against dust...

Page 68: ...off fuse because the excessive current might flow into the parts to damage when fuse is cut off after resolving the problem locating the cause replace it with new fuse Since battery has a danger of ex...

Page 69: ...the starting key switch should be released immediately Otherwise the starter motor may be damaged or burned out In case of repairing the engine dip the pinion of the starter and ring gear into the fue...

Page 70: ...Main accessory parts 64...

Page 71: ...the pressure cap of heat exchanger tank to remove the air pressure Loosen the drain plugs as follows and then drain out the cooling water into a container 1 Below the right wet turbocharger elbow 2 Be...

Page 72: ...olts for crankshaft pulley in reverse order of assembly and disassemble the crankshaft pulley and vibration damper 6 1 8 Oil filter assembly This filter is change over type that is the ser vicing proc...

Page 73: ...mble the thermostat Loosen the water pump fixing bolts and detach the cooling water pump 6 1 10 Starting motor Loosen the starting motor fixing nuts and dis mantle the starting motor 6 1 11 Fuel filte...

Page 74: ...ction pipe from the nozzle holder and fuel injection pump Disassemble various fuel pipe and hose 6 1 13 Oil cooler assembly By removing the plug screw of cooling water discharge port the cooling water...

Page 75: ...turbo charger inlet outlet pipe for lubricating and tear the pipes down Loosen the turbocharger fixing nuts and detach the turbocharger from the exhaust manifold elbow 6 1 15 Inter cooler Tear down th...

Page 76: ...ove the cover bolts Remove the 4 fixing bolts from the lower plate Pull out the heat exchanger tube bundle Clean the tubes 6 1 19 Flywheel housing cover Detach the side cover Disassemble the flywheel...

Page 77: ...t out 6 1 23 Rocker arm Remove the rocker arm bracket fixing bolts and take the rocker arm assembly out Pull out the push rod 6 1 24 Cylinder head Loosen the cylinder head fixing bolts in the reverse...

Page 78: ...cting rod cap bolts in the reverse order of assembling and follow the similar method as in the cylinder head bolt removal Tapping the upper and lower connecting rod caps lightly with a non steel hamme...

Page 79: ...the order of disassembling and detach the fly wheel Remove the flywheel ring gear Heat the ring gear evenly with a gas burner up to 200 C to invite volumetric expansion Tapping around the edges of the...

Page 80: ...the shaft with a rope Note Do not mingle with the metal bearings and bearing caps randomly To prevent mixing temporarily assemble the metal bearings to the corresponding bearing caps in turn 6 1 32 C...

Page 81: ...t 5 kg cm2 against the inlet ports then immerse the cylinder block in water for about 1 minute to check any leaks Water temperature 70 C 6 2 2 Cylinder liner measurement Assemble the cylinder liner at...

Page 82: ...damage Eliminate the carbon residue and gasket piece from the cylinder head lower face thoroughly Then be careful for the valve seat not to be damaged For cracks or damages to search difficult may be...

Page 83: ...ne the wears and when the wear limit is more than limit replace the valves inspect the scratch and wear of valve stem seal contacting face and if nec essary correct with the grinding paper but if seve...

Page 84: ...en in guide reamer process c Valve seat Visual inspection Check if the exterior of the valve spring is damaged with the naked eye Replace it with a new one if required Valve seat thickness and angle A...

Page 85: ...contacting face of valve seat and after executing a sufficient lapping operation with the rotating and grinding motion of valve wipe off the grinding agent thor oughly d Valve spring Visual inspection...

Page 86: ...lve spring Marine Marine marine generator Items Free length Intake Exhaust Inside 72 43 mm Outside 67 17 mm Items Free length Intake Exhaust Outside 61 9 mm EA0M4056 Spring tester Items Length P1 P2 m...

Page 87: ...alve stem seals not to be damaged Install the valve spring washer to valve guide Put in the valve spring and then attach the valve spring plate on the springs Note Install the valve spring seat with T...

Page 88: ...outer diameter of rocker arm bracket with outside micrometer at the position that the rocker arm is installed and in case that it exceeds the limit value replace b Rocker arm Inspect the rocker arm su...

Page 89: ...and rolling it Inspect the curv ing degree with a clearance gauge and if abnormal replace it Run out d Rocker arm reassembling Inspect the oil passages of rocker arm and rocker arm bracket for any cl...

Page 90: ...asure the cam lobe height and journal diameter If the measured number is less than the spec ified limit the camshaft must replaced Cam bearing diameter Measure the camshaft bush inside diameter with a...

Page 91: ...he 2 ea of V blocks and inspect the run out of the camshaft adjust or replace the severe one Cam lobe height Use a micrometer to measure the cam lobe height and journal diameter If the measured number...

Page 92: ...in at the direction and position of the figure shown and take the wear Crankshaft journal outside diameter Crankshaft pin outside diameter In case that the lopsided wear is more than the limit value g...

Page 93: ...arse surface b Run out of crankshaft Place the crankshaft on the V block Place the dial gauge on the surface plate and measure the run out of crankshaft rotating the crankshaft 2 Inspection on cranksh...

Page 94: ...to utilize plastic gauge Install the crankshaft in the cylinder block and place the plastic gauge on the crankshaft journal and pin at axial direction and then after tightening the bearing cap at the...

Page 95: ...disassembling Pull out the snap ring for piston pin and with a pair of snap ring pliers With a round bar the piston pin With a pair of pliers remove the piston rings Clean the piston thoroughly 2 Ins...

Page 96: ...y 45 interval and calculate the average values after eliminating the maximum and minimum values Measure the clearance between the cyl inder liner bore and the piston outer diameter if it is more than...

Page 97: ...is same as the use limit value or less replace it Piston pin connecting rod bush clear ance Inspect the clearance between the piston pin and the connecting rod bush if it is more than the use limit va...

Page 98: ...arance of these parts If it is more than the use limit value replace the connecting rod 6 Piston reassembling After heating the piston at the piston heater for about 5 min 120 150 C by aligning the pi...

Page 99: ...et it in the injection pressure measuring tester By manipulating the tester handle inspect the injection pressure and atomizing state Operating pressure In case of low or high injection pressure adjus...

Page 100: ...r being reassembled Check the bolts for looseness after preliminary re assembly After completing the engine re assembly operation check if there is missing parts or shortage of parts Keep your hands c...

Page 101: ...f the cylinder block 6 3 6 Crankshaft Put the wear ring into the heater to heat it up to 150 200 C level push it over the crankshaft by means of a jig Assemble the main bearing to the cylinder block a...

Page 102: ...s tightening order 1 First step screw down 1 2 threads 2 Second step tighten with a bout 15 kg m by wrench 3 Third step tighten with a bout 25 kg m by torque wrench 4 Fourth step tighten with 30 kg m...

Page 103: ...n the cylinder block surface Temporarily assemble 2ea of guide bolts for installing the flywheel housing to the cylin der block After fitting the flywheel housing holes to the guide pins and engage te...

Page 104: ...he crankshaft After letting the guide pin insert through the flywheel holes and engaging the fixing bolts by 2 3 threads temporarily tighten them to the specified torque according to lightening order...

Page 105: ...e bolt holes on the fly wheel housing for installing the starter Insert the starter into the flywheel housing and tighten the fixing bolts 6 3 14 Piston Coat the pistons and connecting rod bear ings s...

Page 106: ...tightening order tighten them step by step Standard length of bolt and use limit from head seat to bolt tip By moving the connecting rod bearing cap by hands make sure if there is any play in left and...

Page 107: ...lock Attach the gasket at the surface of oil pump where the pressure regulating valve is to be installed and place the regulating valve on the gasket Assemble the oil pump by tightening the fixing bol...

Page 108: ...to damage the head gasket Tighten the cylinder head bolts to the specified torque according to step by step However prior to tightening the bolts with a long steel rule the parallel between the cylin...

Page 109: ...ozzle outer part with the stuck pre venting agents and assemble it 6 3 21 Rocker arm Coat the push rod with engine oil and put it into the push rod hole Make a position the rocker arm assembly on the...

Page 110: ...mpression TDC Top dead center 2 Loosen the lock nut of the 1 cylinder rocker arm 3 Push the feeler gauge between a rocker arm and a valve stem 4 Adjust the clearance screw respectively and then tighte...

Page 111: ...new gasket on the surface of cylinder head where the cover is to be installed Assemble the cylinder head cover by tight ening the fixing bolts Insert the oil filler cap Valve overlap cylinder No 1 5...

Page 112: ...pointer Fit the injection pump in the appropriate position using a special tool Special tool No EF120 189 After fixing the jig hole on the limit cap of the injection pump rotate the jig counter clock...

Page 113: ...ection pump drive gear Some cases are needed to remove cover assembly And turn the crank pulley so that the mark on pointer provided on injection pump coincides with matching mark FB on the flange sur...

Page 114: ...FB on the flange surface of the drive gear by turning the flange in the oblong holes of the drive gear 4 Tighten the bolt M8 to specified torque 2 2 kg m not to move the drive gear 5 After confirmati...

Page 115: ...ater pump by tighten ing the fixing bolts zigzag method Insert the thermostat of fresh water pump Insert the O ring to the thermostat and assemble the cooling water pipes by tight ening the fixing bol...

Page 116: ...o the exhaust manifold and assemble the elbow by tighten the nuts for connection Be careful not to drop the manifold because it is very heavy 6 3 32 Inter cooler After assembling the inter cooler fixi...

Page 117: ...fuel inlet and outlet hoses Check the fuel adjusting cock whether its position is placed as figure in order to use both filters all the time 6 3 36 Alternator Assemble the alternator bracket to the l...

Page 118: ...ut 10 mm 15 mm or so pushing with a thumb 6 3 38 Sea water pump Assemble the sea water pump Assemble the sea water filter on the inlet flange of sea water pump Adjust the V belt tension 6 3 39 Heat Ex...

Page 119: ...wing things must be obeyed by all means Refer to 3 3 Up to the first 50 hours Engine should be run at fast idling 1 000 1 200 rpm until the temperature of the engine becomes nor mal operating conditio...

Page 120: ...Disassembly and assembly of major components 114...

Page 121: ...arger etc also in order to ensure normal engine performance 7 1 1 Specifications 7 1 2 Oil pump Item Specifications Item Specifications Lubricating system Forced pressure circulation Adjusting valve f...

Page 122: ...alve may be worn after a given length of time for use and cause the deterioration of the engine Make sure that servicing should be performed at the professional maintenance shop as authorized by Bosch...

Page 123: ...nt Rack position mm Pump speed rpm Injection Q ty on RIG mm3 1 000st Press mmHg A Test condition for inj pump Remarks V1 11 20 0 05 900 235 4 3 0 Max power 1 500 V2 11 20 0 10 700 230 4 3 0 1 500 VS 8...

Page 124: ...8 3 Rack diagram 4 Boost compensator pressure 12 10 8 6 4 2 0 200 400 600 800 1000 1200 0 LQ VS V2 V1 A3 ENGINE SPEED rpm RACK POSITION mm EB2M5001 200 400 600 800 1000 1200 0 RACK POSITION mm 12 10 8...

Page 125: ...ck position mm Pump speed rpm Injection Q ty on RIG mm3 1 000st Press mmHg A Test condition for inj pump Remarks V1 12 00 0 05 1 050 266 0 3 0 Max power 1 500 V2 12 00 0 10 800 266 0 3 0 1 500 VS 8 96...

Page 126: ...ack diagram 4 Boost compensator pressure EB2M5003 XY X XW _ Y W YWW WW WW _WW XWWW XYWW X WW W sx z Y X hZ ENGINE SPEED rpm RACK POSITION mm RACK POSITION mm P3 P4 P2 P1 8 200 400 600 800 1000 1200 14...

Page 127: ...50 mm Rack diagram and setting valve at each point Refer to 3 rack diagram Check point Rack position mm Pump speed rpm Injection Q ty on RIG mm3 1 000st Press mmHg A Test condition for inj pump Remark...

Page 128: ...rts maintenance 122 3 Rack diagram 4 Boost compensator pressure EDV2218074 0 2 4 6 8 10 12 14 16 0 500 1000 1500 RP ZBT LS HS ABT EDV2218075 6 7 8 9 10 11 12 13 14 15 16 P4 P3 P2 P1 500 1000 1500 2000...

Page 129: ...diagram Check point Rack position mm Pump speed rpm Injection Q ty on RIG mm3 1 000st Press mmHg A Test condition for inj pump Remarks V1 11 55 0 05 900 244 3 0 Max power 1 500 V2 11 55 0 10 700 242 3...

Page 130: ...3 Rack diagram 4 Boost compensator pressure EDV2218058 V2 VS LQ V1 A3 12 10 8 6 4 2 0 200 400 600 800 1000 1200 0 ENGINE SPEED rpm RACK POSITION mm 200 400 600 800 1000 1200 0 RACK POSITION mm 12 10 8...

Page 131: ...Rack position mm Pump speed rpm Injection Q ty on RIG mm3 1 000st Press mmHg A Test condition for inj pump Remarks V1 11 55 0 05 1 050 243 0 3 0 Max power 1 500 V2 11 55 0 10 800 240 4 3 0 1 500 VS 8...

Page 132: ...ack diagram 4 Boost compensator pressure EDV2218077 12 10 8 6 4 2 0 LQ VS V2 V1 A3 ENGINE SPEED rpm RACK POSITION mm 200 400 600 800 1000 1200 1400 0 200 400 600 800 1000 1200 0 RACK POSITION mm 12 10...

Page 133: ...x 750 mm Rack diagram and setting valve at each point Refer to 3 rack diagram Check point Rack position mm Pump speed rpm Injection Q ty on RIG mm3 1 000st Press mmHg A Test condition for inj pump Rem...

Page 134: ...rts maintenance 128 3 Rack diagram 4 Boost compensator pressure 0 2 4 6 8 10 12 14 16 0 500 1000 1500 RP ZBT LS HS ABT EDV2218078 EDV2218079 6 7 8 9 10 11 12 13 14 15 16 500 1000 1500 2000 2500 0 P4 P...

Page 135: ...agram Check point Rack position mm Pump speed rpm Injection Q ty on RIG mm3 1 000st Press mmHg A Test condition for inj pump Remarks V1 11 55 0 05 900 244 3 0 Max power 1 500 V2 11 55 0 10 700 242 3 0...

Page 136: ...3 Rack diagram 4 Boost compensator pressure EDV2218076 V2 VS LQ V1 A3 12 10 8 6 4 2 0 200 400 600 800 1000 1200 0 ENGINE SPEED rpm RACK POSITION mm 200 400 600 800 1000 1200 0 RACK POSITION mm 12 10 8...

Page 137: ...iagram Check point Rack position mm Pump speed rpm Injection Q ty on RIG mm3 1 000st Press mmHg A Test condition for inj pump Remarks V1 12 00 0 05 1 050 266 0 3 0 Max power 1 500 V2 12 00 0 10 800 26...

Page 138: ...k diagram 4 Boost compensator pressure EDV2218072 XY X XW _ Y W YWW WW WW _WW XWWW XYWW X WW W sx z Y X hZ ENGINE SPEED rpm RACK POSITION mm RACK POSITION mm P3 P4 P2 P1 8 200 400 600 800 1000 1200 14...

Page 139: ...114A 2 0 x 6 35 x 850 mm Rack diagram and setting valve at each point Refer to 3 rack diagram Check point Rack position mm Pump speed rpm Injection Q ty on RIG mm3 1 000st Press mmHg A Test condition...

Page 140: ...rts maintenance 134 3 Rack diagram 4 Boost compensator pressure EDV2218074 0 2 4 6 8 10 12 14 16 0 500 1000 1500 RP ZBT LS HS ABT EDV2218081 6 7 8 9 10 11 12 13 14 15 16 500 1000 1500 2000 2500 0 P4 P...

Page 141: ...n the inlet side The fuel pressurized as the cam rotates on flows through the check valve on the outlet side as shown in B If feeding pressure increases abnormally the spring is compressed resulting i...

Page 142: ...14 Take off the plug 7 gasket 8 spring 6 and piston 5 on the piston side Pull out the snap ring 20 holding the tappet 10 Disassemble the snap ring then take off the tappet 10 and push rod 1 3 Inspect...

Page 143: ...ate the tappet at the rate of 100 rpm and check to see if fuel is drawn in and delivered for 40 seconds or so Delivery test Make a test with the feed pump mounted on a pump tester as illustrated Opera...

Page 144: ...ustion period will prevent the high speedy operation of the engine and can cause serious engine knocking 1 Structure A copper seal fitted to the injector ensures gas tight seating and good heat dissip...

Page 145: ...low or high injection pressure adjust by adding or reducing the spring tension adjusting shims In case that atomizing state is not good it should be replaced After adjusting the injection pressure ti...

Page 146: ...ystem Forced oil supply Model V158TIM V180TIM V222TIM Engine output PS rpm 540 2 100 650 2 100 800 2 100 Turbo charger model HX35M HX40M HX50M Maximum allowable exhaust gas temperature Turbine inlet 7...

Page 147: ...7 1 Turbine housing 11 Bearing 21 Nut 2 V vent 12 Thrust collar 22 Bolt 3 Wheel 13 Screw 23 Clamp 4 Piston ring 14 Thrust bearing 24 Compressor housing 5 Wheel shroud 15 Thrust spacer 25 Elbow 6 Cente...

Page 148: ...itions the turbocharger should be replaced or repaired 2 Checking of the rotor end play The radial and axial clearances of the rotor should check after every 2 000 hours operation This precau tion wil...

Page 149: ...damage or foreign matters Assemble each joint on oil pipes securely to prevent oil leaks 2 Intake system Check the inside of the intake system for foreign matters Assemble each joint on the intake du...

Page 150: ...If you turbo is fitted with the new nut it indicated that this turbo charger may have been built using the core balance process at point of manufacture rather than the traditional rotor balance pro c...

Page 151: ...shown before removing the compressor wheel lock nut Always check balance the rotor before rebuild 7 4 5 Disassembly Before disassembling the turbocharger scribe the parts listed below to help in align...

Page 152: ...fitted remove the O ring seal 41 Caution The compressor wheel blades can be easily damaged when the compressor housing is removed Loosen and remove the 6 bolts 57 and clamp plates 88 Or remove v band...

Page 153: ...have alignment marks before disassembly of the CHRA If no marks exist scribe the shaft and compressor wheel as shown before removing the compressor wheel lock nut refer to 4 3 4 Remove the compressor...

Page 154: ...ion Care should be taken not to score the assembly turbine wheel shaft Remove the heat shield 38 Place the bearing housing on a flat surface and using circlip pliers remove the insert retaining ring 6...

Page 155: ...Main parts maintenance 149 HX50 Using two flat screwdrivers Remove the oil slinger 31 HX35 HX50 Remove and discard the piston ring seal 16 EDV2218108 EDV2218055 EDV2218109 EDV2218110...

Page 156: ...maintenance 150 HX35 Remove and discard the oil baffle 33 Remove and discard the O ring seal 32 Remove the thrust bearing 12 HX50 Remove and discard the O ring seal 32 EDV2218111 EDV2218112 EDV2218113...

Page 157: ...discard the oil baffle 33 Remove the thrust bearing 12 Remove the thrust collar 36 Using circlip pliers remove and discard the two circlips 64 and the journal bearing 11 from the compressor end EDV221...

Page 158: ...tures Turbine Wheel In the event of carbon build up it may be necessary so carefully blast the Piston Ring Groove area of the turbine wheel using low grade shot medium Caution Shot blasting specific a...

Page 159: ...housing 5 Inspect the profile for damage caused by possible contact with the rotor Check all threads for damage Inspect the outer and internal walls for cracks or flaking caused by overheating also ch...

Page 160: ...e clean and free from dirt Replace with new if any damage is found HX35 V158TI Compressor wheel 7 Inspect carefully for cracked bent or dam aged blades but DO NOT ATTEMPT TO STRAIGHTEN BLADES Replace...

Page 161: ...he circlips are always fitted with the bevelled edge facing the journal bearing Caution Circlips 64 Premature failure will result if the circlips are fitted incorrectly Rotor balance Before assembly a...

Page 162: ...nner circlip 64 with the bevelled edge facing upwards Lubricate the journal bearing 11 and install into position Fit the outer circlip 64 with the bevelled edge facing the bearing Turn the bearing hou...

Page 163: ...an engine oil Caution Align the piston ring seals 16 so the gaps are positioned 180 from the oil drain hole Gently press down on the turbine wheel a slight rotation of the wheel will assist in properl...

Page 164: ...ion Align the balance mark on the thrust collar with that on the shaft Using clean engine oil lubricate the thrust bearing 12 Install the thrust bearing HX35 HX50 Fit the new piston ring seal 13 to th...

Page 165: ...oil seal plate 43 Install the oil baffle 33 into the oil seal plate 43 Apply a small amount of engine oil to the oil seal plate 43 and place the O ring seal 32 into position HX50 Apply a small amount...

Page 166: ...the oil slinger 31 and install into the oil seal plate 43 Install the oil seal plate 43 into the bearing housing 4 Caution Align the balance marks on the oil slinger 31 with that on the shaft end Gen...

Page 167: ...e Left hand thread Caution Ensure that the balance marks are aligned on the compressor wheel and the shaft HX35 Carefully slide the retainer ring 91 over the assembly turbine wheel 6 Locate the C H R...

Page 168: ...be marks are aligned Secure the turbine housing and check the trust clearance using a dial gauge HX50 V180TI V222TI Secure the turbine housing and check the trust clearance using a dial gauge HX50 V18...

Page 169: ...s very important to maintain the engine in accordance with the specified maintenance procedure and pay particular attention to checking oil air leaks unusual sound on running 1 Checking of the rotor f...

Page 170: ...otor axial play and radial play 1 When disassembling the turbocharger be sure to plug the oil inlet and outlet ports 2 If the measured axial and radial plays are beyond the limit of wear replace or re...

Page 171: ...ot only the pipes installed between the engine and oil inlet port but also the oil outlet pipe and check them for damage or foreign matters Assemble each joint on oil pipes securely to prevent oil lea...

Page 172: ...Main parts maintenance 166...

Page 173: ...ype No Service or replace fuel injection valves Check service or adjust Check whether a proper voltage continuously occurs in low temperature starting aid circuit while switch is turned ON When glow p...

Page 174: ...valve Worn plunger barrel Fuel system failure Governor Improper adjustment Lever link malfunction Reduced compression pressure Improper clearance of intake exhaust valves Defective intake exhaust valv...

Page 175: ...Improper valve clearance Seizure likeliness Clogged intake air pipe Clogged cylinder head exhaust outlet Clogged exhaust pipe Cracked cylinder head Defective fuel injection valve Improper fuel inject...

Page 176: ...ce White smoke is produced Fuel Lube oil Clogged air cleaner Damaged or worn valve stem Flaws or wear of piston Damaged or worn valve guide Flaws or wear of liner Leakage through cylinder head gasket...

Page 177: ...sh Burnt coil Short circuited Damaged battery Damaged switch Grounding termainal Disconnected Coupler connection Repair Charging Replace or repair Replace or repair Replace or repair Replace or repair...

Page 178: ...h inner contactor Short circuited or disconnected lead wire Faulty IC regulator Battery Key switch Electric appliance Battery terminal Battery terminal ON Alternator Sagged fan belt Damaged diode Defe...

Page 179: ...ylinder head Cylinder head cover Fuel injection nozzle holder Fuel injection pipe M15 2 M8 M28 M14 1 5 12 9 8 8 CK60 8 kg m 15 kg m angle 90 angle 90 2 2 7 0 5 2 5 Cam shaft timer Rocker arm bracket L...

Page 180: ...30 0 45 0 4 0 55 0 47 0 77 0 85 0 9 1 25 0 5 M7 0 43 0 46 0 7 0 63 0 83 0 78 1 2 1 3 1 4 1 95 2 35 M8 0 7 0 75 1 1 1 1 4 1 25 1 9 2 1 2 2 3 1 3 8 M8 1 0 73 0 8 1 2 1 1 1 5 1 34 2 1 2 3 2 4 3 35 4 1 M...

Page 181: ...ve compon ents Pistons Piston O D 110 801 110 959 Replace the liner Measure at a spot 13 mm from the bottom surface of the piston Clearance between the piston and liner 0 041 0 221 0 3 Replace if the...

Page 182: ...0 025 Allowable concentricity of journal and pin 0 01 0 03 Allowable inclination of journal and pin 0 01 0 03 Crankshaft and bearing clearance 0 052 0 122 0 25 Replace the valve spring Measure on crow...

Page 183: ...earing cap and loosen one stud bolt for measurement Lateral clearance of big end and small end 0 50 Replace connecting rod Allowable weight difference among connecting rods 18 g Connecting rod bearing...

Page 184: ...29 5 kg 1 0 kg 2 5 kg Exhaust Free length of outside spring 68 17 mm Exhaust Set length of outside spring P1 P2 46 3 mm 32 8 mm Exhaust Load on inside spring P1 P2 39 0 kg 71 5 kg 2 0 kg 5 0 kg Exhaus...

Page 185: ...030 69 192 Replace the bushing Camshaft bearing diameter 69 910 69 940 Camshaft bearing oil gap thrust 0 060 0 120 0 24 Replace the cam or bushing Camshaft bearing oil gap middle 0 130 0 180 0 24 Repl...

Page 186: ...4 Replace the bushing or cover Gear shaft O D 16 950 16 968 Replace the gear shaft 17e7 Drive gear bushing O D kg cm2 28 000 28 033 Replace the bushing 28e7 Valve opening pressure Oil pressure adjustm...

Page 187: ...Governor Actuator Controller...

Page 188: ......

Page 189: ...reaches the set speed In terms of operating the vehicle the driver monitors the speedometer and if there is a desired speed this cor responds to the governor s speed input while the governor s output...

Page 190: ...nt C 1 5 A 2 0 A Max operating current C 4 5 A 3 1 A Rack operating power C 58 7 N 27 5 N Rack operating range ASTM 20 mm 21 mm Engine injection pump specs Right rack type Right rack type Item GN11 DW...

Page 191: ...the frame of the static core and the assem bly and then fixed in place with an epoxy resin 5 Moving core assembly A welded assembly composed of several layers of pure iron When the gover nor controll...

Page 192: ...ith the 25 turn potentiometer This speed setting output value becomes the input value traveling to the dynamic control section With the help of this dynamic control circuit most of the engine and fuel...

Page 193: ...es when terminals G and H are connected The engine speed controller includes functions for protecting the actuator and the engine as well as addi tional functions For example the controller circuit in...

Page 194: ...Clockwise 1 200 Hz or less Idle Adjustment Counterclockwise 4 100 Hz or less Droop Range Adjustable between 1 5 Max Droop Adjustment With Terminals K L Connected Fluctuation of 875 75 Hz 1 0 A Min Dro...

Page 195: ...Pick up BATTERY OPTIONAL ACTUATOR CABLE SHIELDING TO MEET CE DIRECTIVE ADD JUMPER FOR 12V BATTERY OR ACTUATOR CURRENTS ABOVE 5A AUX 10V POWER FUSE 15A MAX SPEED TRIM CONTROL 5K CLOSE FOR IDLE CLOSE FO...

Page 196: ...UP BATTERY 6 00 152 6 05 165 6 00 152 5 25 133 O 0 27 7 1 A B C D E F G H J K L N P M CAUTION GA C 2 3 OVERSPEED OVERSPEED SPEED SPEED RAMPING GAIN DROOP STABILITY DEAD TIME COMPENSATION JUMPER RESET...

Page 197: ...When rotated clockwise the engine rpm rises 7 Overspeed Adjusts the engine overspeed rpm When rotated clockwise the maximum rpm rises 8 Droop rpm Used when running the generator in parallel 9 Reset Us...

Page 198: ...ls G and M To maintain the idle rpm after starting the engine 2 After starting the engine Once the engine is started move the actuator to the maximum fuel supply position then maintain the idle rpm af...

Page 199: ...terminals M and G Turn the speed potentiometer counter clockwise to adjust the engine rpm But if excessive exhaust smoke is produced while accelerating the engine adjust the starting fuel potentiomet...

Page 200: ...nal G is short circuited the engine speed controller may be damaged 10 Remote speed adjustment A speed adjustment potentiometer is required in order to continuously adjust the engine speed remotely ov...

Page 201: ...e 3 Faulty wiring connection 2 C D 1 0V AC when starting the engine 1 Large gap between magnetic pick up sensor and ring gear Check gap 2 Faulty wiring in magnetic pick up sensor Check whether the res...

Page 202: ...g device is restricted when the voltage exceeds 2 0V DC 3 When the voltage is less than 1 0V DC 1 There is a fault in the speed controller 4 The gain value is too low The actuator Is not working prope...

Page 203: ...H J F E D C B A Battery Actuator Pick up Speed Trim N M L K Droop AUX P 10V Idle 6 5 4 3 2 1 OFF D1 D2 ON Crank Run Over speed Power Pick up Crank Run Over speed Test Starting Fuel Speed Ramping Idle...

Page 204: ...ntroller due to unnecessary nearby electromagnetic waves either mount the controller on a grounded metal surface or use a shielded metal case All wires should be shielded and the shielded part should...

Page 205: ...is not enough fuel which may cause faulty starting In the 5 o clock or higher direction fuel efficiency worsens during starting and the amount of exhaust gas may increase 2 Adjust the speed ramping po...

Page 206: ...t be adjusted regardless of whether or not idle mode is used 6 Adjusting the Governor Characteristics 1 After disconnecting the G M terminal initial speed switch OFF adjust it when the engine reaches...

Page 207: ...until the engine overspeed lamp turns on and the engine shuts off It will be set to a speed around 15 higher than the engine operating speed IMPORTANT After all adjustments are complete restart the e...

Page 208: ...lem is not resolved There may be a problem with the controller hardware so replace the controller 9 8 ON OFF 5 OFF ON 4 5 6 7 1 5 2C 1 5 2C 10 1 2 3 Idle Droop G H J F E D C B A N M L K AUX P 10V OFF...

Page 209: ...em be sure to check whether the voltage between the terminals is DC 24V 4 V Also ground terminal E to the frame Wiring connection no 10 4 Connect a 5 kW resistor externally as shown in the picture to...

Page 210: ...engine speed remotely and externally within a certain speed range Refer to the chart to set the resistance value accord ing to the required speed range 2 When the engine speed is set to the minimum s...

Page 211: ...peed Ramping Facing 9 o clock Droop Full CCW Minimum E M Speed Adjustment 160 gear teeth Speed Adjustment 4 000 Hz 1 500 rpm Idle Adjustment 2 133 Hz 800 rpm 300611 00684 Overspeed 1 725 rpm based on...

Page 212: ...ck Droop Full Full CCW Minimum E M Speed Adjustment 152 gear teeth Speed Adjustment 3 800 Hz 1 500 rpm Idle Adjustment 2 026 Hz 800 rpm 300611 00686 Overspeed 2 070 rpm based on 160 gear teeth Run lam...

Page 213: ...erminal N receives signals from the load sharing unit auto synchronizer or other accessories in the governor system Use shielded wires when connecting wiring The engine speed drops when an accessory i...

Page 214: ...h measures readjust the gain and stability again in order to optimize the system This will help to reduce and eliminate instability 2 Instability at slow intervals hunting The main factors involved in...

Page 215: ...stopped 300 1 200 using test ohm meter Defective speed sensor Damaged or incorrectly connected speed sensor wiring Check sensor line Replace speed sen sor 4 C D E G starting 1 5V or higher when measu...

Page 216: ...a black box function that manages engine operation records when faults are detected for users to have more convenience in operating this precise digital speed controller Product features Rigid and sta...

Page 217: ...of the front side for easy connection to external devices Over speed run and crank signals are displayed on the front LED and contact points a or b are also available for outputs on external controlle...

Page 218: ...cation RS232 57600 bps CAN J1939 250 kbps 8 Rated Power DC 24V 12V 30V 9 Current Consumption 120 mA 10 Operating Temperature 20 70 C 11 Storing Temperature 30 80 C 12 Operating Humidity 0 95 3 2 D SUB...

Page 219: ...Terminal D should be connected to the ground in connection with the shield cable Gap between the RPM sensor and the gear tooth should be adjusted between 0 9 and 1 1 mm sensor inputs should be at leas...

Page 220: ...oint is a shared terminal while ter minals 7 and 8 are for the contact point b and terminals 8 and 9 for the contact point a The contact point a starts to operate when the engine reaches its designate...

Page 221: ...33 6 Product dimension 170 130 140 153 165 6 19 4 6 EDL11160004...

Page 222: ...external devices using crank run and over speed functions RS232 and CAN port allow communication with PCs or external host computers for data transfer and monitoring functions 1 Connecting to the engi...

Page 223: ...up sensor and the gear tooth should be adjusted between 0 9 and 1 1 mm 5 Operating sequence for digital speed controller Power On Off It means that DC 24V power is either supplied or terminated throug...

Page 224: ...s G H and J Terminal G should be connected to the ground and it is recommended to use shielded cables Terminal H is connected to G depending on the current consumption of the actuator for actuators wi...

Page 225: ...e idle function Inputs can be done by toggle or converting switches 5 Connecting to aux AUX is a terminal for control signal inputs from load sharing devices or synchronization devices through termina...

Page 226: ...crank output contact point and the contact point will be in opera tion when the controller activates the crank function The second crank contact point is a shared termi nal while terminals 1 and 2 ar...

Page 227: ...ontroller activates the over speed function The eighth over speed contact point is a shared terminal while terminals 7 and 8 are for the contact point b and terminals 8 and 9 for the contact point a C...

Page 228: ...d Right Each key as respective functions as follows LCD LCD key turns on and off the display Mode Mode key switches the display to either operation mode or wave form display Menu Menu key lets users c...

Page 229: ...CD Menu Tree Diagram EDL11160049 Overall LCD Menu Tree Diagram Logo Display RPM Display Main Display Menu Display MENU MENU UP LEFT RIGHT DOWN MENU MENU MODE MENU Low Battery RPM Display Main Display...

Page 230: ...s tem errors occur the LCD display will show such errors and processing messages Step 1 DC 24V power supply to the terminals E and F When DC 24V power is supplied to the terminals E and F the controll...

Page 231: ...he engine PID control Date Time setup It offers function for users to move to the screen for designating year month day and hour Alarm list It offers function for users to move to the alarm display fo...

Page 232: ...s for STARTING FUEL SPEED RAMPING ACTUA TOR MAX LOW BATTERY Set run rpm Users can designate normal speed target RPM of the engine Users need to input different normal speed values depending on the spe...

Page 233: ...es of speed changes when the speed increases or decreases in the idle condition of the engine Max current Users can designate the maximum operating current for the actuator of the engine Low battery I...

Page 234: ...setting with YES or NO option If you select YES the controller will repeatedly change the RPM to automatically calculate the optimized P I and D values If the controller identifies the optimized P I a...

Page 235: ...ler this menu offers the most common parameter setting values For default setup select YES and then press Enter button If you don t want to implement this function press No but ton If you press YES al...

Page 236: ...rpm 60 Hz 102T 1 800 rpm 2 070 rpm 102 65 Optimal Value 5 DE08 1 500 rpm 50 Hz 140T 1 500 rpm 1 725 rpm 140 65 Optimal Value 6 DE08 1 800 rpm 60 Hz 140T 1 800 rpm 2 070 rpm 140 65 Optimal Value 7 DE0...

Page 237: ...ain setting items of the controller includes GEAR NUMBER CRANKING RPM and SET RUN RPM You need to designate setting values to these items Other system setup items are optional and there fore you can d...

Page 238: ...o increase or decrease the idle operating speed of the engine and then press Enter button Configuring set over speed Step 1 Press Menu button of the controller and then you can see DRIVE UNIT MENU Ste...

Page 239: ...alues at which the controller starts to con trol the actuator when the engine starts to operate and then press Enter button Configuring gear number Step 1 Press Menu button of the controller and then...

Page 240: ...nt of fuel sprayed when the engine starts and then press Enter button Configuring speed ramping Step 1 Press Menu button of the controller and then you can see DRIVE UNIT MENU Step 2 Select System set...

Page 241: ...rease the limit of the maximum current con sumption of the actuator and then press Enter button Max 10 A Configuring low battery Step 1 Press Menu button of the controller and then you can see DRIVE U...

Page 242: ...n press Enter button Droop Function Droop function is indicated in percentages as follows RPM with no load is subtracted by RPM with maximum load and then divided by RPM with no load Example for 3 dro...

Page 243: ...DRIVE UNIT MENU Step 2 Select System setup menu in DRIVE UNIT MENU using Up Down Left and Right buttons and then press Enter button Step 3 Select F LOAD CURR in SYSTEM SETUP menu and then press Enter...

Page 244: ...ns to input the operating current values of the actuator for the generator with no load and then press Enter button 3 PID gain setup configuration Configuring PID gain Kp Ki and Kd values Step 1 Press...

Page 245: ...1 Select your type in Engine Type menu and then start the engine with the preset configuration values maintaining it with no load Step 2 During the normal operation press Menu button of the controller...

Page 246: ...mal operation window and the auto tuned values will apply to the normal operation that will be continued Step 6 If auto tuning failed to identify optimized P I and D values within 4 to 6 minutes the s...

Page 247: ...more than 5 seconds LCD alarm message Error LED lamp E03 Pick up Error Problems in sensor signals when the engine starts Engine RPM lower than 600 LCD alarm message Error LED lamp E04 Pick up Error P...

Page 248: ...and Right buttons to select either YES or NO in System Message and then press Enter button Default setup will change the configuration values of the engine to the default values In order to initi ate...

Page 249: ...for adjustment and then press Enter button Use Up and Down buttons to input set ting values and then press Enter button 11 System monitor Functions Step 1 Press Menu button of the controller and then...

Page 250: ...attery Fault message you need to charge the battery or replace it with the one having normal voltage before starting the controller Step 2 Configure parameter values required for selection of the engi...

Page 251: ...up Error Problems in sensor sig nals when the engine starts Engine RPM lower than 600 Alarm message pop up on LCD Check the RPM sensor and connecting circuits Error LED on Replace the RPM sensor Actu...

Page 252: ...oller and contact our A S center for service request Step 3 Check whether the power LED turns on or not after supplying power to DC 24V input terminals E F of the battery If the LED does not turn on c...

Page 253: ...HY DP MANUAL 001 Digital Panel for Marine Engines Service Manual Ver 1 0 Doosan Infracore...

Page 254: ...3 3 3 CAN Communication Connector 11 3 3 4 External Buzzer Connector 11 3 3 5 CCTV Connector 11 3 3 6 USB Connector 12 3 4 Fuse and Internal Buzzer 12 3 4 1 Fuse 12 3 4 2 Internal Buzzer 12 3 5 Key Sw...

Page 255: ...munication Connection 26 5 3 Software Installation and Execution 27 5 4 Display Structure and Detailed Functions 29 5 4 1 Menu Structure 29 5 4 2 Operation Record Files 30 5 4 3 Setting Functions by P...

Page 256: ...problems of existing analog panels and allow users to check engine controls and conditions by means of a digital visualization product It provides information in analog graphic gauges and digital disp...

Page 257: ...4 Flash Memory 256MB Flash 8GB MicroSD card 5 RAM 512MB 6 Operating Voltage DC 24V 16 to 30V 7 USB USB 2 0 1 Port 8 Operating Temperature 20 to 70 9 Internal Buzzer Piezo Buzzer 98dB 10 Communication...

Page 258: ...he product before operation Do not disassemble the product cover at discretion warranty does not cover unauthorized disassembly Excessive impact may damage the display although a reinforced display is...

Page 259: ...engine harness wiring Use the mounting hole to fix the bracket in a place within reach of the engine harness wiring Place the product inside the bracket connected with the rotation lock to connect it...

Page 260: ...th sides of the panel Check the location within reach of the engine harness wiring and the mounting location and then mount the panel using proper bolts Finish gaps between the product and the structu...

Page 261: ...2 Start Stop Button Page 13 No Name Reference Power Connector Page 9 Signal Connector Page 10 CAN Page 11 External Buzzer Page 11 USB Page 12 Fuse Page 12 CCTV Optional Page 11 GPS TBC Internal Buzzer...

Page 262: ...alve Battery 7 8 Starter Signal 9 Starter Signal 10 DC 12V Out 11 DC 5V Out 12 GND Power 13 GND 14 Battery DC 24V Fuse Input Power connector supplies power and power signals Table 3 3 Fig 3 3 3 3 1 Po...

Page 263: ...24 Valve Out Valve Control Signal 7 Spare Analog Input 2 25 Exhaust Gas Temperature Sensor 2 8 Spare Analog Input 4 26 Exhaust Gas Temperature Sensor 2 9 Spare Digital Input 1 27 10 28 11 Fuel Leakag...

Page 264: ...on Connector CAN harness optional connection CAN1 CAN2 for multi panels CAN3 PC communication firmware download Table 3 5 3 3 4 External Buzzer Connector Additional connection for external buzzer harn...

Page 265: ...key contained in the product to insert it and rotate to the right by 90 ON when the key is ON the key should remain inserted 2 When the key is ON the product will boot and the gauge display will appe...

Page 266: ...he engine will start the button LED will flash when pressing the button 2 Press the button for more than 3 seconds while the key is ON and the engine is in operation to stop the engine You can reduce...

Page 267: ...t saving when pressing it in page mode Configuration Engine Model setting Master Slave setting and ON OFF setting to start the slave ON OFF setting for over speed testing ON OFF setting for spare sens...

Page 268: ...OFF setting for over speed 1 400RPM or faster test 5 Spare Sensor Alarm ON OFF setting for spare check sensor light 6 USB Back Up USB backup for event save files 7 Date Setup Date and time setting 3...

Page 269: ...ox oil pressure charging coolant level fuel leak and overspeed alarm Fig 3 16 Gauge Display 3 8 1 Engine Speed Tachometer It shows engine RPM in gauge and digital values and counts accumulated engine...

Page 270: ...ngine will stop Fig 3 18 Engine Water Temperature Gauge 1 It shows the pressure indicated by the gauge hand in digital values blue for better accuracy however it is available when the DIGIT button is...

Page 271: ...essure indicated by the gauge hand in digital values blue for better accuracy however it is available when the DIGIT button is on 2 It shows the open short diagnosis for sensor problems Open Short Pow...

Page 272: ...arm The alarm will be activated with buzzer beeping when problems for coolant temperature engine oil pressure gearbox oil pressure charging coolant level fuel leakage and over speed are detected Fig 3...

Page 273: ...Engine Oil Over Heat Alarm will be activated when the engine oil temperature is 150 or higher Battery Voltage Current voltage Exhaust Air Temperature High Alarm will be activated when the exhaust air...

Page 274: ...age Switch Low Boost Air Pressure Over Speed High Boost Air Pressure Low Voltage Abnormal Engine Shutdown Low Water Level Low Engine Speed It shows the numbers of normal operations normal stops emerge...

Page 275: ...each gauge hand is within the normal range and ERROR or is displayed on the screen Where ERROR or is displayed on the screen Check the harness connection Function keys check whether each function key...

Page 276: ...be installed up to 4 units except Master in the ship and you can check the ship conditions and control those panels at any places of installation Fig 4 1 Master Fig 4 2 Slave 1 Fig 4 3 Slave 3 Fig 4 4...

Page 277: ...shown in 2 panels Master and Slave 1 connection completed 2 Connect Slave 1 CAN2 and Slave 2 CAN1 as shown in while maintaining connection as described in 3 panels Master Slave 1 and Slave 2 connectio...

Page 278: ...guration between Master and Slave 4 Configure the Master panel as described above Notes Master mode is available for one panel only and Slave mode is available up to 4 units You can permit Slaves to s...

Page 279: ...u can configure sensor values of each sensor engine model and over speed conditions Fig 5 1 Digital Panel Manager Initial Screen Before using Digital Panel Manager prepare CAN RS232 cables optional fo...

Page 280: ...tings You can also find them in Configuration Menu at the top left corner Fig 5 4 Main Screen of the Program Click Communication Settings 5 Digital Panel Manager 3 Permission Cert Manufacturer or rese...

Page 281: ...ected at the bottom right corner will turn on in green When the product is connected to Digital Panel Manager ON LINE will turn on in green PC Communication Connection Status Product Connection Status...

Page 282: ...the product Read Device Data Transmit data settings in all tabs to the product Hour Meter Settings Configure the operation hours of the product Open Operation Record Files Open the operation record f...

Page 283: ...d files saved in the product users are not allowed to use this function Fig 5 8 Advanced Menu 1 Menu Advanced Click Open Operation Record Files 2 Click ODX files with dates that you want to check and...

Page 284: ...ta as Excel Files Convert current data to Excel files and save them 3 The window in which you can check the operation records will be activated You can see Files and Advanced Menu at the top left corn...

Page 285: ...ion window Click Fig 5 13 Activate Operation Record Window 5 Digital Panel Manager 5 The list of each sensor will be activated In order to check the records of the sensor that you want to click on the...

Page 286: ...e in the same folder the former will have the priority Manufacturer research institute cert activates all tabs 5 Digital Panel Manager 6 When clicking the date of operation records by each sensor you...

Page 287: ...nactive Deactivate all tabs except event settings Fig 5 17 Service Authentication Deactivate 5 Digital Panel Manager Fig 5 18 General User Authentication Deactivate End User Authentication Deactivate...

Page 288: ...ine stop conditions against engine over speed Configure CAN communication speed Configure criteria for starter off RPM 300 to 600RPM when staring the engine Monitor the engine conditions in real time...

Page 289: ...ON OFF check for engine stop by reduced engine oil pressure ON OFF check for engine stop by fuel leakage Default off ON OFF check for engine stop for engine over speed ON OFF for engine stop by lack o...

Page 290: ...ou can only check the settings with other permissions Fig 5 21 Sensor Tab Fig 5 23 Exhaust Gas Temperature Fig 5 24 Engine Oil Pressure Fig 5 25 Gearbox Oil Pressure Fig 5 26 Engine Oil Temperature Fi...

Page 291: ...ts 1 The device is not turned on 1 Check whether harness cables at the back of the product are properly connected 2 Where harness cables have too much dust or moisture remove them and clean the dust o...

Page 292: ...operty damages caused by the following reasons Where you use the product for purposes other than the ones described in this manual Where you alter the product or its components at discretion Where you...

Page 293: ...152 2 000 115 2 300 DE12TIB L126TIH 152 2 000 115 2 300 L126TIM 152 2 100 115 2 415 D2848LB V158TIH 160 1 800 115 2 070 V158TIM 160 2 100 115 2 415 V158TIL 160 2 300 115 2 645 D2840LB V180TIH 160 1 80...

Page 294: ......

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