Doosan DP158LCF Page 10 Operation & Maintenance Manual Download

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4. Regular inspection

General information

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General Information

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Routine Inspection

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Regular inspection table

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General Conditions

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Use of Genuine Parts

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Cooling system

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General Information

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Coolant standards

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Capacity of coolant

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Checking the Coolant

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Measurement of Coolant Concentration

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Discharging the coolant

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Charging the Coolant

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Cleaning the cooling circuit

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Inter cooler

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Lubrication system

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General Information

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Engine oil standards

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Engine Oil Capacity

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Checking the Engine Oil

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Replacement of Engine Oil

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Replacement of Engine Filter

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Fuel system

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General Information

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Fuel Standards

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Water draining from fuel filter

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Replacing fuel filter

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Preventing fuel contamination

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Fuel injection pump

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Cleaning the fuel pre-filter

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Air bleeding in the fuel circuit

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Injector maintenance

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Fuel injection nozzle

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Removal of nozzle

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Installation nozzle

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Note for cleaning nozzle

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Checking the injection timing

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Adjusting injection timing

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Intake/exhaust system

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General Information

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Air Filter

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Summary of Contents for DP158LCF

Page 1: ...950106 01352 Operation Maintenance Manual GENERATOR DIESEL ENGINE DP158LCF LCS LDF LDS DP180LBS LAS LBF LAF DP222LAS LBF LBS LCF LCS Doosan lnfracore ...

Page 2: ...der 1 5 7 2 6 3 4 8 Injection timing BTDC 23 1 18 1 23 1 18 1 Dry weight kg 1 155 With fan Dimension L x W x H mm 1 274 X 1 138 X 1 207 With fan Flywheel housing SAE NO 1M Flywheel Clutch NO 14M No of teeth on flywheel 160 Cooling System Cooling method Fresh water forced circulation Coolant capac ity L Engine only Approx 20 With radiator Approx 79 Air on 43 C Approx 90 Air on 52 C Coolant flow rat...

Page 3: ...specification Oil class Above API CD SAE 15W 40 Fuel System Injection pump Bosch in line P type Governor Electric type Fuel feed pump Type Mechanical type injection pump Capacity L hr 315 Injection nozzle Type Multi hole type Opening pres sure MPa 28 Fuel filter Full flow Cartridge type with water drain valve Fuel Used Diesel fuel oil Intake Exhaust System Max back pressure kPa 5 9 Max intake air ...

Page 4: ...P180LBS DP180LBF DP180LAS DP180LAF General Information Engine types Water cooled 4cycle V type Turbo charger inter cooled air to air Cylinder liner type Wet type liner No of cylinder bore x stroke mm 10 128 X 142 Total displacement cc 18 273 Compression ratio 15 1 Rotation Counter clockwise viewed from flywheel Firing order 1 6 5 10 2 7 3 8 4 9 Injection timing BTDC 21 1 19 1 21 1 19 1 Dry weight ...

Page 5: ... 687 505 756 556 DP158LDF 50Hz 1 500rpm 630 464 693 510 180L DP180LBS 60Hz 1 800rpm 817 601 899 661 DP180LAS 60Hz 1 800rpm 760 559 836 615 DP180LBF 50Hz 1 500rpm 756 556 832 612 DP180LAF 50Hz 1 500rpm 682 502 750 552 DP222L DP222LCS 60Hz 1 800rpm 1 023 753 1 126 828 DP222LCF 50Hz 1 500rpm 894 657 983 723 DP222LBB 60Hz 1 800rpm 967 711 1 063 782 DP222LBF 50Hz 1 500rpm 821 604 903 664 DP222LAS 60Hz ...

Page 6: ...3001A 1 Fuel Filter 6 Crankshaft Pulley 11 Engine Oil Supply Pipe 2 Breather 7 Cooling Fan Pulley 12 Flywheel Housing 3 Coolant Pump 8 Idle Pulley 13 Flywheel 4 Alternator 9 Engine Oil Return Pipe 14 Oil Pan 5 Engine Oil Drain Plug 10 Turbocharger 15 Oil Filter 1 2 3 4 5 6 7 8 9 10 11 15 14 13 12 ...

Page 7: ...58L DV2213002A 1 Cooling Fan 6 Turbocharger 11 Flywheel Housing 2 Oil Pan 7 Breather 12 Oil Filter 3 Engine Oil Drain Plug 8 Fuel Filter 13 Alternator 4 Starter 9 Oil Cooler 14 Oil Cap 5 Exhaust Manifold 10 Tacho Sensor 1 8 7 5 4 2 14 13 12 11 10 9 3 6 ...

Page 8: ...ons http www brizmotors ru equipment ctm 400 Top DP158L DV2213003A 1 Injector 4 Fuel Injection Pump 7 Oil Filler Cap 2 Fuel Injection Pipe 5 Intake Manifold 8 Inlet Pipe 3 Fuel Pre Filter Priming Pump 6 Intake Stake 1 2 3 4 5 6 7 8 ...

Page 9: ...de and Manufacturing Number The engine code and manufacturing number are engraved in the position marked A in the drawing These numbers are necessary to request quality assur ance or to order parts DV2213007A Engine number engraving Type 1 Type 2 Type 3 Type 4 Type 5 Type 6 A ...

Page 10: ...eral Information 51 Engine oil standards 51 Engine Oil Capacity 52 Checking the Engine Oil 52 Replacement of Engine Oil 53 Replacement of Engine Filter 53 Fuel system 54 General Information 54 Fuel Standards 54 Water draining from fuel filter 55 Replacing fuel filter 55 Preventing fuel contamination 56 Fuel injection pump 56 Cleaning the fuel pre filter 56 Air bleeding in the fuel circuit 57 Injec...

Page 11: ...arger 63 Routine check and serving the turbocharger 63 Disassembly and cleaning a turbocharger 63 Cylinder block head 64 Valve Clearance 64 Adjusting the Valve Clearance 64 Tightening Cylinder Head Bolt 65 Cylinder Compression Pressure 66 Electric system 67 Battery 67 Starter 67 Others driving system 68 V Belt 68 ...

Page 12: ...y starts and the levels of fuel oil and coolant are within the normal range 2 Check if any discharged emissions are colored and if the exhaust contains toxic gas elements 3 Check whether abnormal noise occurs after starting an engine or not 4 Check whether oil or water is leaking DANGER Wait until the engine is sufficiently cooled before starting inspection after operating the engine Otherwise you...

Page 13: ...ear 2Year Coolant system Check of coolant level V belt tension adjusting if neces sary Check of coolant hose clamp Concentration of antifreeze solution Replace V belt Cleaning of water jacket and radia tor Change of coolant Replace of coolant hose clamp Lubrication system Check of engine oil level Engine exterior for loss of oil Oil Separator for oil leaks Change of Engine oila Change of Oil Filte...

Page 14: ...e held liable Fuel lines for leaks Drain Fuel filter Water separator Check of fuel stop lever Engine Clean fuel pre filter Replace Fuel filter Replace Water separator filter Drain Water Sediment from fuel tank Check of Injectors replace if nec essarya Replace Fuel Hoses Clamps Electrical system Engine alarms Check of battery charging Magnetic pick up and adjust Cylinder head Cylinder head valve an...

Page 15: ...n 3 Periodically check coolant to maintain the concentra tion of antifreeze and additives 4 The engine cylinder liner is of a wet type which specially requires good coolant flow 5 You can check the concentration of antifreeze and corrosion inhibitor using the coolant test sheet Ambient tem perature C Coolant C Antifreeze Above 10 85 15 10 80 20 15 73 27 20 67 33 25 60 40 30 56 44 40 50 50 Engine M...

Page 16: ...and the standard color table EDL022154A 1 Compare the changed pink color part A of the test sheet with the GLYOOL FREEZEPOINT End pad of the standard color table on top of the container and confirm the concentration The concentration indication has to be within the color scope of 33 50 2 The state of additives for anticorrosion is shown on the point where the color of MOLYBDATE Middle pad on the s...

Page 17: ...ler cover and then drain cooling water CAUTION If the color on the test sheet does not match the color of the standard color table find a middle color on the standard color table For example if the color of C of the test sheet matches D and F on the NITRITE of the standard color table select E To prevent corrosion inside of the engine cooling unit drain the coolant and replace it with new coolant ...

Page 18: ... minutes check if there is any leakage in the drain plug and coolant line If the coolant is insufficient replenish it DANGER Never open the radiator cap while the engine is overheated If the radiator cap is opened while the engine is overheated hot water will spurt out and may cause serious burns Open the radiator cap after ensuring that the engine has been cooled sufficiently Mark and separately ...

Page 19: ...y contaminate and clog the cooling pins This results in reduced engine power or engine failure So always check the intake system for air leak damage or contamination of air filter DV2213205B CAUTION To keep the optimum performance of the air cooler clean it regularly Air air intercooler with downstream radiator Combined radiator Cooling air Hot charge air from compressor Recooled charge air to int...

Page 20: ...low back into the oil pan The engine oil level should indicate between the upper limit and the lower limit of the oil level gauge Engine oil should be periodically replaced based on the regular inspection table and the oil filter and the cartridge should be replaced as the engine oil is replaced Engine oil standards Use the specified engine oil suitable for the environment and conditions of the si...

Page 21: ...the engine oil if required DV2213016A 1 Check the oil level everyday using an oil level gauge 2 Check if the oil is smeared between the upper limit A and the lower limit B of the oil level gauge 3 If engine oil is smeared below the lower limit B or not smeared on the gauge at all replenish engine oil 4 Check condition of engine oil If it is polluted replace it with new oil Engine Model Engine oil ...

Page 22: ...he oil filter head and cartridge contact thor oughly and make sure that the oil filter cartridge is positioned properly 3 Apply a little bit of oil to the o ring area of the cartridge assemble it until the O ring surface may contact and turn it 3 4 or 1 turn using a wrench to keep it air tight DANGER Prolonged and repeated contact of skin with engine oil may lead to shrinking dryness of skin and e...

Page 23: ...phur content is max 0 05wt Fuels with a sulphur content of 0 05wt are not permitted as they result in increased corrosion and hence greatly reduce the service life of engines The oil change intervals must be halves if the sulphur content is 0 02wt CAUTION Use clean certified and qualified fuel only Using irregular or unspecified fuel may cause critical damage and faults to the engine Replenish fue...

Page 24: ... the new cartridge adapter seal ring 4 6 Apply thin coat of clean oil to the O ring 5 area of the cartridge and fill the cartridge with fuel 7 Assemble the cartridge to the fuel filter head 8 Tighten the cartridge with hand until the O ring contacts the fuel filter head surface DANGER Fuel may be drained when water is drained from the fuel filter Fuel is highly inflammable Fire may occur when you ...

Page 25: ...should not modify the fuel injection pump if the sealing line is damaged such engine cannot receive compensation if the fuel injection pump is found abnormal autho rized personnel should handle it The adjustment and test of the fuel injection pump must be conducted using a tester Cleaning the fuel pre filter The fuel pre filter should be cleaned periodically through disassembly the fuel pre filter...

Page 26: ... of the nozzle is adjusted by means of shims at the compression spring DV2213022A Fuel injection nozzle 1 Install a nozzle to the nozzle tester DV2213023A 2 Check the fuel injection pressure If the pressure does not satisfy the reference value adjust the injection pressure of the nozzle using an adjustment shim DANGER Fuel is highly inflammable Fire may occur when you use fire near the engine when...

Page 27: ...213166B CAUTION As the nozzle injection nozzle is designed to operate under high pressure you should handle it with special care Do not hold your hands under the fuel jet as there is a rise of injury Do not inhale the atom ized oil fuel If possible work under an extraction system abnormal abnormal normal Engine Model Nozzle injec tion pressure Mpa DP158L DP158LCS 28 DP158LCF 28 DP158LDS 28 DP158LD...

Page 28: ...ve out the carbon by lightly tapping on the tool Before reassembly thoroughly wash nozzle body and needle in clean test oil Hold the needle at the pintle end only to avoid corro sion do not touch the lapped surfaces of the needle with you fingers Thoroughly clean all other parts of the nozzle holder with clean fuel Check nozzle discharge pressure in nozzle tester The edge type filter should not be...

Page 29: ...s aligned with the injection timing degree of the engine 3 Coincide the mark on pointer provided in injection pump with the matching mark FB on the flange surface of the drive gear by turning the flange in the oblonog holes of the drive gear 4 Tighten the bolt M8 to specified torque 2 2 kgf m not to move the drive gear 5 After confirmation that fastening bolts are completely tightened check the st...

Page 30: ... The dust should not exceed the half of the dust bucket capacity 2 You can disassemble the dust bucket by removing two clamps Remove the dust bucket cover and empty the dust inside 3 Assemble the cover and dust bucket accurately with care 4 For easy alignment the cover has dent and the dust collector has a protrusion Here is the position where a filter is mounted horizontally check the TOP mark on...

Page 31: ...d then dry it at room temperature Fully dry the element before reassembling it to the engine 3 In an emergency temporarily clean the element by using the following method 1 Tab the end plate of the element with the thumb to clean it temporarily EDL022157A Note Before reassembling the element make sure that the filter paper is not wrinkled the state of rubber sealing is good and there is no deforme...

Page 32: ...r should be carefully managed For a wet type air filter the intake resis tance should be small as possible 2 Exhaust system For the exhaust system when exhaust gas leaks from the exhaust pipe or turbocharger joint supercharging efficiency is lowered So you need to pay attention to prevent gas leakage and burn Heat resistant nuts are used for parts which are highly heated during opera tion such as ...

Page 33: ...of 8 12 cylinder engine 6 cylinder is posi tioned at the valve overlap when 1 cylinder is positioned at the compression TDC Top Dead Center Note In case of 10 cylinder engine 7 cylinder is posi tioned at the valve overlap when 1 cylinder is positoned at the compression 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 st...

Page 34: ...gure by a further 90 1 4 revolution Engine Model In valve Ex valve DP158L DP158LCS 0 25mm 0 35mm DP158LCF 0 25mm 0 35mm DP158LDS 0 25mm 0 35mm DP158LDF 0 25mm 0 35mm DP180L DP180LBS 0 25mm 0 35mm DP180LBF 0 25mm 0 35mm DP180LAS 0 25mm 0 35mm DP180LAF 0 25mm 0 35mm DP222L DP222LAS 0 25mm 0 35mm DP222LBS 0 25mm 0 35mm DP222LBF 0 25mm 0 35mm DP222LCS 0 25mm 0 35mm DP222LCF 0 25mm 0 35mm Valve overlap...

Page 35: ...fuel injection nozzle holder hole DV2213046A 4 Connect the compression pressure gauge to the adapter CAUTION If excessive torque may damage the cylinder head gasket cylinder liner flange and cylinder head bolt so keep the specified torque When tightening cylinder head bolts after a repair must always adjust the valve clearance CAUTION The cylinder head bolts to be retightened must not bolts loosen...

Page 36: ...pinion gear and ring gear in the fuel wash them completely and apply grease again When you clean the surrounding of engine be careful so that water may not enter the starter Viewing the gravity meter Liquid level indicating line liquid level upper limit liquid level lower limit lsotator UPPER LEVEL LOWER LEVEL CAUTION Starter should be protected from humidity all the time Before working on the ele...

Page 37: ...contact surface 2 is flush with the V belt DV2213049A 3 Slowly depress pad 3 until the spring can be heard to disengage This will cause the indicator 1 to move upwards Note If pressure is maintained after the spring has disen gaged a false reading will be obtained 4 Read the tension value at the point that the top surface of indicator arm 1 intersects with the scale 5 Before taking readings makes ...

Page 38: ...5 To replace the V belt loosen the fixing bolts 1 and the lock nut 2 and push the tension pulley inwards by turning the adjusting bolt 3 counter clockwise DV2213055A 6 Loosen the mounting bolts B 7 Loosen the lock nut A 8 Adjust the nut C until the belt tension has correct tensions 9 Retighten the lock nut A and the mounting bolt B 10 To replace the belt loosen the lock nut and push the alternator...

Page 39: ...4 Tightening Torque of Main Parts 74 Tightening Torque of General Bolts 75 Tightening torque of plug screw 77 Hollow Screw 4 Hole Tightening Torque 77 Special tool 78 Special Tool 78 Engine Disassembly 82 Procedure of Disassembling an Engine 82 Engine Assembly 95 Procedure of Assembling Engine 95 ...

Page 40: ...2 0 1550 cm2 in2 10 76391 m2 ft2 1 19599 m2 yd2 Weight 2 204623 kg lb 0 001 kg t ton Volume 0 061024 cc in3 0 061024 ml in3 0 061024 cm3 in3 61 023744 L in3 0 264172 L gal Forcea 2 204622 kgf lbf 0 2248089 N lbf Acceleration 3 28084 m s2 ft s2 39 37008 m s2 in s2 Torqueb 7 233014 kgf m ibf ft 86 79619 kgf m ibf in 0 7375621 N m ibf ft 8 850748 N m ibf in Power 1 340483 kw Hp Pressure 0 01 kPa bar ...

Page 41: ...5 12 9T 21 0 kgf m 1 0 kgf m Flywheel M16 X 1 5 12 9T 1st 10 0 kgf m 2nd 90 3rd 90 Angle Method Connecting Rod Cap M16 X 1 5 10 9T 1st 10 0 kgf m 2nd 90 Angle Method Cylinder Head M15 X 2 12 9T 1st 8 kgf m 2nd 15 kgf m 3rd 90 4th 90 5th 60 Angle Method Cylinder Head Cover M8 8 8T 2 2 kgf m 0 33 kgf m Fuel Injection Nozzle Holder M28 X 1 5 10 9T 7 0 kgf m 0 5 kgf m Fuel injection Pipe nut M14 X 1 5...

Page 42: ...rength Rank Tightening Torque Remarks Nomi nal Diame ter Pitch mm Strength Classification 3 6 4 6 4 8 5 6 5 8 6 6 6 8 6 9 8 8 10 9 12 9 4A 4D 4S 5D 5S 6D 6S 6G 8G 10K 12K Elastic Limit Value kg mm2 20 24 32 30 40 36 46 54 64 90 106 Tightening Torque kg m M5 0 15 0 16 0 25 0 22 0 31 0 28 0 43 0 48 0 5 0 75 0 9 M6 0 28 0 30 0 45 0 4 0 55 0 47 0 77 0 85 0 9 1 25 1 5 M7 0 43 0 46 0 7 0 63 0 83 0 78 1 ...

Page 43: ...12 5 18 5 16 7 24 5 27 5 28 41 49 M20 11 5 12 18 16 22 19 31 5 35 36 51 60 M20 x 1 5 12 8 13 5 20 5 18 25 22 5 35 39 5 41 58 68 M22 15 5 16 24 5 21 30 26 42 46 49 67 75 M22 x 1 5 17 18 5 28 24 34 29 47 52 56 75 85 M24 20 5 21 5 33 27 40 34 55 58 63 82 92 M24 x 1 5 23 25 37 31 45 38 61 67 74 93 103 Nomi nal Diame ter Pitch mm Strength Classification 3 6 4 6 4 8 5 6 5 8 6 6 6 8 6 9 8 8 10 9 12 9 4A ...

Page 44: ... M16 M18 M22 M24 M26 M30 5 0 5 0 8 0 8 0 10 0 10 0 12 0 12 0 15 0 Material Classifi cation M8 M10 M12 M14 M16 M18 M22 M26 M30 M38 SM25C 1 6 2 5 3 5 4 5 5 5 9 0 13 0 18 0 30 0 SUM22La a Applied to Doosan Engines 0 8 1 8 3 0 4 0 5 5 6 5 11 0 16 0 20 0 35 0 STS304 0 8 1 8 3 0 4 0 5 5 6 5 11 0 16 0 20 0 35 0 ...

Page 45: ...of the tool with hammer slightly 3 EF 120 262 Valve Spring Press First assemble the tool on the cylinder head porperly with a stud bolt and a nut Second compress the valve spring by pressing down the tool handle then detach the cotter pins and springs 4 EF 120 183 Valve Stem Seal Punch First join the valve stem seal to the valve stem Second place the tool onto the valve stem seal then install the ...

Page 46: ...e maximum com pression pressure is acquired 7 60 99901 0036 Jig for injection Nozzle Detach First link the tool to the nozzle with projection of the tool then connect it by tight ening the upper bolt of the tool with a spanner Second detach the nozzle by turning the lower large nut of the tool counter clockwise 8 EF 120 189 Injection Pump Alignment Jig First fix the jig s hole on the limit cap of ...

Page 47: ...through the tool until it is passed the tool completely 10 EF 123 365 Cyl inder Liner Puller First place the tool onto the cylinder block and insert T shape plate of the tool into the cylinder liner and hook it on the bottom of the cylinder liner Pull out the cylinder liner by turning the hexagonal nut of the tool 11 60 99901 0027 Feeler Gauge Determine the gaps of the valves or back lash of the g...

Page 48: ...hen remove the snap ring from the position pin 14 T7621010E Pis ton Ring Plier When disassemble or assemble the piston rings from piston use the piston ring plier in order not to be scratched the piston surface by ring s keen edge After expanding the both ends of piston ring as figure using special tool remove the piston rings No Product Num ber Shape Application Work Tips ...

Page 49: ... Loosen the drain valve A of the oil pan and then drain engine oil 5 Remove the V belt DV2213054A 1 Turn the adjusting nut A and then remove the V belt 2 Turn the adjusting nut B and then remove the V belt CAUTION Prepare tools and genuine parts necessary before disassembling engine Prepare a shelf for the storage of removed parts Perform repairs in a light and clean space Keep hands clean while p...

Page 50: ...A 1 Loosen the hose clamp A 2 Loosen the V clamp B 3 Remove the inlet elbow C 4 Remove the other side elbow as the same procedure 9 Remove the oil delivery pipe DV2213058A 1 Loosen the the fixing bracket bolts A of the oil delivery pipe 2 Loosen the fixing bolts B of the oil delivery pipe 3 Loosen the hollow screw C 4 Remove the oil delivery pipe D A B C C B A D CAUTION Be careful not to loss the ...

Page 51: ...sembly DV2213060A 1 Remove the heat screen 2 Loosen the fixing bolts A of the exhaust elbow bracket 3 Loosen 8 fixing bolts B and 4 fixing bolts C 4 Remove the exhaust manifold and elbow assembly D 5 Remove the other side exhaust manifold and elbow assembly as the same procedure 13 Remove the intake stake DV2213061A 1 Loosen the fixing bolt A 2 Loosen the hose clamp B 3 Loosen the V clamp C 4 Remo...

Page 52: ...the fixing bolts A 2 Loosen 12 fuel injection pipe nuts B connected the injector 3 Loosen 12 fuel injection pipe nuts C connected the fuel injection pump 4 Remove 3 fuel injection pipe asseblies 17 Remove the fuel pipe DV2213067A 1 Loosen the fixing bolts A 2 Loosen the hollow screw B CAUTION Be careful not to let dust inside the engine A B A B CAUTION Be careful not to damage the fuel injection p...

Page 53: ...move the oil filter with the chain plier EF 200 038 2 Loosen the fixing bolt B and C 3 Remove the oil filter housing 21 Remove the fuel pre filter DV2213065A 1 Loosen the hollow screws A 2 Loosen the fixing bolts B 3 Remove the fuel return pipe and fuel pre filter CAUTION Be careful not to loss the O ring Be careful not to damage the fuel pipes CAUTION Be careful not to damage the fuel pipes D B A...

Page 54: ...d cover and gasket as the same procedure 24 Remove the fuel return pipe DV2213069A 1 Remove the hollow screw and 6 seal rings A 2 Remove the fuel return pipe B 3 Remove the other side fuel return pipe as the same procedure 25 Remove the injectors DV2213073A 1 Remove the injector holer fixing nut B with the jig for injection nozzle detach 60 99901 0036 2 Remove the injector A 3 Remove 12 injectors ...

Page 55: ...ation direction 2 The injection timing pointer marking on the fuel injec tion punmp driven gear is aligned with marking on the cylindrical surface 28 Remove the fuel injection pump DV2213072A 1 Loosen 6 fixing bolts A 2 Remove the fuel injection pump B 29 Remove the rocker arm assembly DV2213075A 1 Loosen the fixing bolts A 2 Remove the rocker arm assembly B 3 Remove 12 rocker arm assemblies as th...

Page 56: ...32 Remove the cooling water pipe DV2213078A 1 Loosen the fixing bolts A and nuts B 2 Remove the cooling water pipe C 33 Remove the thermostat DV2213172A 1 Remove the O ring B 2 Remove the thermostat A 3 Remove the gasket C 4 Remove 3 thermostats as the same procedure 34 Remove the water pump assembly DV2213173A 1 Loosen 6 fixing bolts A 2 Remove the water pump assembly B A B A A B C CAUTION Be car...

Page 57: ...1 socket bolt 6 Remove the cooling fan assembly I 36 Remove the crankshaft pulley DV2213175A 1 Loosen 8 fixign bolts A in the order of 1 8 2 Remove the crankshaft pulley B 37 Remove the oil cooler cover DV2213083A 1 Loosen 20 fixing bolts A 2 Remove the oil cooler cover B 38 Remove the cooling water pipe DV2213084A 1 Loosen fixing bolts A 2 Remove the cooling water pipe B H E F G B I D A C A B 1 2...

Page 58: ... the oil pan DV2213086A 1 Loosen 20 fixing bolts A 2 Remove the oil pan B 42 Remove the oil suction pipe and the oil pump DV2213087A 1 Loosen 2 fixing bolts A 2 Loosen 2 fixing bolts B 3 Loosen the fixing bolt C 4 Remove the oil suction pipe and the oil pump D 43 Remove the connecting rod and piston assembly DV2213088A 1 Loosen 2 connecting rod bolts and then remove the connecting rod cap B 2 Push...

Page 59: ...ng rod bearing J from connecting rod cap H 45 Remove the cylinder liner DV2213089A 1 Remove the cylinder liner A from the cylinder block with the cylinder liner puller EF 123 365 2 Remove 12 cylinder liners as the same procedure 46 Change the engine position DV2213178A 1 Change the engine positon The crankshaft direction is upward 47 Remove the front oil seal DV2213090A CAUTION Be careful not to i...

Page 60: ...12 fixing bolts A 2 Remove the flywheel housing B 50 Remove the crankshaft DV2213093A 1 Loosen 2 side fixing bolts A and 2 bearing cap bolts B 2 Remove bearing cap C 3 Remove 12 bearing caps as the same procedure 4 Remove the crankshaft D 5 Remove the main bearing and the thrust bearing 51 Remove the camshaft DV2213094A 1 Remove the camshaft A from cylinder block C B A i h B A 1 2 3 4 5 6 7 8 CAUT...

Page 61: ...et and the spray nozzle DV2213095A 1 Loosen 2 fixing bolts A and 1 hollow screw B 2 Remove the oil spray nozzle C 3 Remove 12 oil spray nozzles as the same procedure 4 Remove the valve tapet D 5 Remove 24 valve tapets as the same procedure A B C D ...

Page 62: ...DV2213094A 1 Apply engine oil inside cam hole and outside cam journal of the cylinder block 2 Attach the camshaft A to the cylinder block 3 Align the cam gear marking to the crankshaft gear marking Timing mark Note The engraved marks is 1 CAUTION Cleanse all disassembled and disconnected parts Especially clean the oil and coolant path with compressed air and check if there is any resis tance Arran...

Page 63: ...ten M12 fixing bolts A at a tightening torque of 11 2kgf m 1 5kgf m and M10 fixing bolts A at a tight ening torque of 7 4kgf m 1 0kgf m 6 Attach the flywheel wearing DV2213182A 1 Apply LOCTITE 271 on the flywheel surface with the thickness 0 5mm 1 0mm 2 Heat the wearing at 150 C 10 C for above 5 minutes 3 Attatch the wearing A to the flywheel Align the wearing end with the fylweel end 7 Attach the...

Page 64: ... a rubber hammer 5 Pull off the front oil seal assembly jig 9 Attch the front oil seal cover DV2213090A 1 Attach the front oil seal cover B 2 Tighten 6 M8 fixing bolts A at a tightening torque 2 24 kgf m 10 Change the engine position DV2213184A 1 Change the engine positon The flywheel direction is downward 11 Attch the cylinder liner DV2213089A 1 Apply enfing oil on the surface of the cylinder lin...

Page 65: ...ng rod cap B 3 Tighten 2 M16X1 flange hex bolts A at a tightening torque 10 kgf m 90 by using the angle method CAUTION Ensure that the Y mark of the piston ring faces the top surface of the piston Make the piston ring position dislocated to 120 CAUTION The intake valve pocket is larger than the exhaust valve pocket Attach the engine as the same piston weight Place the Class of the piston weight on...

Page 66: ...A 1 Attach the oil pan B 2 Tighten 20 M8 fixing bolts A at a tightening torque 2 2 kgf m 0 33kgf m 16 Change the engine position DV2213185A 1 Change the engine positon The piston direction is upward 17 Adjust the fuel injection timing DV2213027A CAUTION Be careful to note the direction when attaching the connecting rods and the connecting rod caps Ensure that the number engraved on the connecting ...

Page 67: ...ft until the yellow mark of the camshaft gear is not shown 3 Adjust the fuel injection timing with rotating the flywheel to the engine rotating direction 18 Attach the fuel injection driven gear temporarily DV2213186A DV2213171A 1 Attach the driven gear A to the fuel injection pump temporarily 2 Attach the O ring B and C to the fuel injection pump 3 Align the injection timing pointer of the fuel i...

Page 68: ...njection pump driven gear 360 with rotating flywheel 3 Tighten 3 the other M8 fixing bolts A of the fuel injec tion pump driven gear at a tightening torque 3 1 kgf m 0 46kgf m 21 Attach the flywheel housing cover DV2213188A 1 Attach the flywheel housing cover A 2 Tighten 4 M8 fixing bolts B at a tightening torque 2 2 kgf m 0 3kgf m 22 Attach the cylinder head DV2213189A 1 Attach the inner washer C...

Page 69: ...e push rods DV2213076A 1 Attach 24 push rods A 25 Attach the rocker arm assembly DV2213075A 1 Attach the rocker arm assembly B 2 Tighten the fixing bolts A 3 Attach 12 rocker arms as the same procedure 26 Attach the injectors DV2213073A CAUTION Be careful to use the right valve without confusing the intake valve with the exhaust valve The intake valve is the mark I engraved on the head and the exh...

Page 70: ...8 Adjust the valve clearance Method 1 DV2213041A DV2213042A DV2213213A DV2213043A 1 Rotate the crankshaft so that 1 cylinder may be positioned at the compression TDC Top Dead Center Note 1 Cylinder is located at the side where cooling water pump was installed Note In case of 8 12 cylinder engine 6 cylinder is posi tioned at the valve overlap when 1 cylinder is positioned at the compression TDC Top...

Page 71: ...w 8 cylinder engine DP158L 10 cyliner engine DP180L 12cyliner engine DP222L 29 Adjust the valve clearance Method 2 DV2213041A DV2213208A Engine Model In valve Ex valve DP158L DP158LCS 0 25mm 0 35mm DP158LCF 0 25mm 0 35mm DP158LDS 0 25mm 0 35mm DP158LDF 0 25mm 0 35mm DP180L DP180LBS 0 25mm 0 35mm DP180LBF 0 25mm 0 35mm DP180LAS 0 25mm 0 35mm DP180LAF 0 25mm 0 35mm DP222L DP222LAS 0 25mm 0 35mm DP22...

Page 72: ...ad Center Note In case of 10 cylinder engine 7 cylinder is posi tioned at the valve overlap when 1 cylinder is positoned at the compression TDC Top Dead center 8 cylinder engine DP158L 10 cyliner engine DP180L 12 cyliner engine DP222L 6 7 8 9 10 1 2 3 4 5 10 9 8 7 6 5 4 3 2 1 10 Cylinder engine 6 7 8 9 10 1 2 3 4 5 10 9 8 7 6 5 4 3 2 1 10 Cylinder engine Engine Model In valve Ex valve DP158L DP158...

Page 73: ...ng bolts A by hand temporarily 3 Tighten thd fixing bolts A at a tightening torque 2 2kgf m 0 33kgf m 4 Attach the other intake manifold as the sameproce dure Cylinder No 1 2 3 4 Valve In Ex In Ex In Ex In Ex 1TDC 6TDC Cylinder No 5 6 7 8 Valve In Ex In Ex In Ex In Ex 1TDC 6TDC Cylinder No 9 10 11 12 Valve In Ex In Ex In Ex In Ex 1TDC 6TDC CAUTION 3 and 4 cylinder head covers have the breather 10 ...

Page 74: ...ghtening torque1 8kgf m 0 27kgf m 35 Attach the fuel pipe DV2213068A 1 Attach the fuel pipe D 2 Tighten the fixing nut B and C at a tightening torque 5 5kgf m 0 825kgf m 3 Tighten the fixing nut A at a tightening torque 5 5kgf m 0 825kgf m 36 Attach the fuel pipe DV2213067A 1 Attch the fuel pipe C 2 Tighten the hollow screw B at a tightening torque 1 2kgf m 0 14kgf m 3 Tighten the fixing bolt A at...

Page 75: ...t a tightening torque 4 4kgf m 0 66kgf m Note Tighten the fixing bolts to attach the inlet elbow and the inlet pipe at a tightening torque 2 2kgf m 0 33kgf m 39 Attach the fuel filter DV2213062A 1 Attach the fuel filter assembly B 2 Tighten the fixing bolt A at a tightening torque 7 5kgf m 1 12kgf m 40 Attach the intake stake DV2213061A 1 Attach the intake stake D 2 Tighten the V clamp C 3 Tighten...

Page 76: ...d and exhaust elbow assembly as the same procedure Note Tighten the fixing bolts to attach the exhaust mani fole and the elbow bracket at a tightening torque 8 0kgf m 0 5kgf m 42 Attach the turbocharger DV2213070A 1 Attach the turbocharger B 2 Tighten 4 fixing bolts A 3 Attach the other turbocharger as the same procedure 43 Attach the oil return pipe DV2213169A 1 Attach the oil return pipe C 2 Tig...

Page 77: ...tach the other inlet elbow as the same procedure 46 Attach the oil cooler housing DV2213085A 1 Attach the oil cooler housing C 2 Tighten 5 M10 outer fixing bolts B at a tightening torque 6 2kgf m 3 Apply LOCTITE 262 on the M10 inner socket bolts A 4 Tighten 5 M10 inner socket bolts A at a tightening torque 6 2kgf m 47 Attach the cooling water pipe DV2213084A 1 Attach the cooling water pipe B 2 Tig...

Page 78: ...n the stud head bolts in the order from 1 8 51 Attach the cooling fan pulley and the idle pulley DV2213174A 1 Attach the cooling fan pulley assembly I 2 Tighten 3 fixing bolts G and 1 socket bolt H at a tightening torque 4 4kgf m 0 33kgf m 3 Fix the cooling fan pulley using the jig 4 Tighten 1 cooling fan fixing bolt at a tightening torque 20kgf m 5 Attach the idle pulley bracket F 6 Tighten 3 fix...

Page 79: ...tach 3 thermostats as the same procedure 54 Attach the cooling water pipe DV2213078A 1 Attach the cooling water pipe C 2 Tighten the fixing bolts A and nuts B at a tightening torque 2 2kgf m 0 33kgf m 55 Attach the starter DV2213053A 1 Attach the starter B 2 Tighten 3 fixing bolts A at a tightening torque 4 4kgf m 1 2kgf m CAUTION Make sure that the cooling fan pulley can be rotated after attachin...

Page 80: ...htening torque 2 2kgf m 0 33kgf m 58 Adjust the tension after attaching the V belt DV2213054A 1 Attach the V belt and then adjust the tension with turning the adjusting nut B 2 Attach the V belt and then adjust the tension with turning the adjusting nut A 59 Attach the cooling fan DV2213052A 1 Attach the cooling fan B 2 Tighten 6 fixing bolts A 60 Inject the coolant 1 The mixing ratio for the engi...

Page 81: ...5 About the engine 114 61 Add the engine oil 1 Add our recommended genuine oil to replenish the oil level CAUTION Use genuine engine oil recommended by Doosan ...

Page 82: ...115 6 Cooling system General information 117 General Information 117 Specifications 117 Failure Diagnosis 120 Thermostat 121 General Information 121 Check of the thermostat 121 ...

Page 83: ...lant temperature is lower than the valve opening temperature of the water temperature controller the coolant flows into the coolant pump If higher it flows into the radiator The radiator releases the heat absorbed from the coolant and sends the coolant to the coolant pump again DV2213098A Specifications Detail of Jacket Heater Port M30 x 1 5 To Jacket Heater Detail of Jacket Heater Port M30 x 1 5 ...

Page 84: ...BS DP180LBF DP180LAS DP180LAF Cooling System Cooling method Fresh water forced circulation Coolant capac ity L Engine only Approx 21 With radiator Approx 79 Air on 43 C Approx 90 Air on 52 C Coolant flow rate L min 660 550 660 550 Pressure cap kPa Max 49 Water tempera ture C Max for stand by and prime 103 Before start of full load 40 Water pump Centrifugal type driven by belt Thermostat Type Wax p...

Page 85: ...x 23 With radiator Approx 114 Air on 43 C Approx 125 Air on 52 C Coolant flow rate L min 660 660 550 660 550 Pressure cap kPa Max 49 Water tem perature C Max for stand by and prime 103 Before start of full load 40 Water pump Centrifugal type driven by belt Thermostat Type Wax pellet type Opening temp C 71 Full open temp C 85 Cooling fan Type Blow Type Diameter blades 915mm 9 blades ...

Page 86: ...r head gasket Replace it Overcooled engine Bad water temperature controller operation Replace it Too low ambient temperature Heat the block Leaking coolant Damaged radiator Repair or replace it Loosened or damaged radiator connection Repair or replace the connection Defective radiator cap Replace it Badly mounted coolant pump Repair or replace it Bad or damaged coolant pump gasket Replace the gask...

Page 87: ... DV2213100A_E 4 Check if there is any foreign substance in the water temperature controller Note Clean the inside of the water temperature controller with an air gun 5 Check if there are any foreign substance or damage part inside and outside of the hose CAUTION The wax pellet type thermostat shows slower response to the change of cooling water than the bellows type thermostat This happens because...

Page 88: ...123 7 Lubrication system General information 125 General Information 125 Specifications 125 Failure Diagnosis 127 ...

Page 89: ...nder block oil is delivered to the crankshaft bearings camshaft bearings and rocker arm for lubrica tion In addition the turbocharger is connected to the engine lubrication circuit Around the cylinder block and the timing gear lubricating oil is dispersed Each cylinder has an oil injection nozzle for cooling the bottom of the piston Engine oil is filtered through the oil filter and purified DV2213...

Page 90: ...ype Driven by crankshaft gear Oil filter Full flow Cartridge type Oil capacity L Max 34 Min 23 Lubrication oil pressure kPa Idle speed Min 100 Governed speed Min 250 Max oil temperature 120 Oil specification Oil class Above API CD SAE 15W 40 Item DP222L Remarks DP222LAS DP222LBS DP222LBF DP222LCS DP222LCF Lubrication System Lubrication method Fully forced pressure feed type Oil pump Type Gear type...

Page 91: ... and piston ring Replace it Worn cylinder liner Replace it Burnt piston ring Replace it Worn valve guide oil seal valve guide or valve stem Replace it Low oil pressure Bad oil Replace oil with specified oil Burnt oil pump relief valve Replace it Clogged oil pump strainer Cleanse the strainer Worn oil pump gear Replace it Cracked oil delivery pipe of the oil pump Replace it Defect oil pump Repair o...

Page 92: ...ontroller system 138 DGC 2013 Governor Controller System 138 Description 138 Mounting Warning 138 EMC Electromagnetic Compatibility 139 Functions 139 Adjustments 139 External Wiring 142 Magnetic speed sensor connections 143 Remote speed adjustment 143 Droop parallel Operation mode Manual paralleling 144 Accessory Input Automatic Paralleling 144 Controller LAMP Display diagnosis 144 System Troubles...

Page 93: ...ar and well fastened to avoid vibrations It is important that there are no fuel leakages or air infil tration neither on the suction or return line installation Therefore securely fasten all the connections of fuel line The return line back to the fuel tank must not be adjoin the suction line In case of diesel fuel containing high water content due to insufficient fuel quality maintenance difficul...

Page 94: ... in line P type Governor Electric type Fuel feed pump Type Mechanical type injection pump Capacity L hr 315 Injection nozzle Type Multi hole type Opening pres sure MPa 28 Fuel filter Full flow Cartridge type with water drain valve Fuel Used Diesel fuel oil Item DP180L Remarks DP180LBS DP180LBF DP180LAS DP180LAF Fuel System Injection pump Bosch in line P type Governor Electric type Fuel feed pump T...

Page 95: ...ce Bleed Disassemble correct Defective installation of fuel injection pump bracket Defective adjustment of the fuel injection pump tappet Excessively worn cam of camshaft Inspect correct Inspect correct Replace Seizure of needle valve of nozzle Fuel leakage between nozzle and needle valve Improper fuel injection pressure Service or replace Service or replace Adjust 2 Engine starts but stops immedi...

Page 96: ...to fuel Defective plunger operation Defective actuator operation Defective nozzle Injection start pressure different between cylinders Defective controller Check feed pump Air bleeding Replace fuel Disassemble correct Disassemble correct Disassemble correct Adjust Adjust 7 Engine cannot reach the max speed Nozzle not working properly Defective operation of actuator or controller Disassemble correc...

Page 97: ...rankshaft gear It is connected to the forced lubrication system so sepa rate connection is not required The governor of electric fuel injection pump is consist of the actuator that is operated by the signal of the control system and the control system that maintain the engine RPM as the changing load ...

Page 98: ...uel stop plate The plate controls the increasing fuel as the preventing movement of adjusting screw 6 Operation lever It is the connecting lever to operate the fuel rack 7 Fuel rack It controls the fuel capacity of the fuel injec tion pump connected link lever Fuel injection Pump Emergency stop lever Upper control chamber oil lubrication Electronic control chamber Ghana Actuator Side view Operatin...

Page 99: ...14xT1 2 4 Stop Screw 1 M6xL25 5 Lock Nut 1 M6xP1 0 6 Allen Screw SEMS 6 M6x22L 7 Allen Screw SEMS 2 M6x30L or 18L 8 Mounting Bar 1 9 Spacer 2 Φ6 5x Φ16xT7 4 10 Pump Gasket 1 T 0 5 11 Front Cover 1 T 3 2 12 Front Gasket 1 T0 5 13 Allen Screw 8 Seal Screw 4 14 Top Cover 1 T 3 2 15 Top Gasket 1 T 0 5 16 Operating Lever 1 17 Stop Lever 1 18 Manual Stop Device ASS Y 1 No Title Amount Remarks ...

Page 100: ...abinet protected from the weather and high humidity and do not expose the controller unit to the source of radiant heat Prolonged exposure to mois ture for one month or longer or in case condensation forms can lead to change in the resistance of internal circuit and failure to reach rated torque Therefore make sure that the controller is dry before use 2 Do not rely exclusively on the governor sys...

Page 101: ...rank lamp is on and the relevant relay is activated 12 12 TB1 Terminal block for input and output 13 13 TB2 Relay terminal for overspeed mode capacity 2A 125VAC 14 14 TB3 Relay terminal for run mode capacity 2A 125VAC 15 15 TB4 Relay terminal for crank mode capacity 2A 125VAC Adjustments 1 The ranges of resistance indicated on the case are applicable only to DI engines 2 For potentiometer adjustme...

Page 102: ...Turn 2 Gain clockwise until instability develops at no load Note Gradually move 2 Gain counterclockwise until stability returns Note Move 2 Gain counterclockwise further by around 20 minutes 10 to ensure stable performance 3 Stability adjustment Note Turn 3 Stability clockwise at no load until insta bility develops Note Gradually move 3 Stability counterclockwise until stability returns Note Move ...

Page 103: ... 9 When the engine won t start 1 If there is no wrong wiring Return all adjustments to the factory set values Start up the engine again CAUTION On completion of all the adjustments start up the engine again to ensure the stable operation at engine startup at no load and at load operation respectively CAUTION In case the exhaust smoke is not thick It is recom mended to place 4 Starting Fuel at the ...

Page 104: ...tween battery and terminal F After the wiring work check the voltage between terminals which should be 24VDC 4V Ground the terminal E to the frame wiring 10 4 As illustrated in DV2213211A connecting the optional 5kΩ resistance enables fine adjustment of engine speed within the range of preset speed 210Hz range 5 In case of 12V system or of actuator with current consumption over 5 amp or above conn...

Page 105: ...m speed setting above a small amount of droop can be added by turning 7 Droop counterclockwise On the other hand at the maximum speed setting the governor performance will be near Isochronous regardless of the droop adjustment setting DV2213106A Potentiometer Value by Speed Range Factory set Value CAUTION Wrong or erroneous wiring and battery voltage can cause fatal damage to the controller G J K ...

Page 106: ...decrease and the speed adjustment must be reset When operating in the upper end of the control system frequency range a jumper wire or frequency trim control may be required between Terminals G and J This increases the frequency range of the speed control to over 7 000Hz Controller LAMP Display diagnosis Power When the battery power is connected and inner control power DC 12V is achieved the lap i...

Page 107: ...s case place the switch D1 to OFF position and readjust 2 Gain and 3 Stability 4 If instability should be still present placing D2 to OFF position may help stabilize the engine Again readjust 2 Gain and 3 Stability for optimum control 5 Slow instability Hunting Slow instability can have many causes most of which are due to wrong setting against the engine charac teristics Adjustment of 2 Gain and ...

Page 108: ... engine stopped 300 1200Ω tester ohmme ter 1 Defective speed sensor 1 Check sensor line 2 Improper or defective wiring to the speed sensor 2 Replace speed sen sor 4 C D When starting the engine 1 5V or above tester AC volt meter 1 The gap between speed sensor and gear teeth too great 1 Check sensor line 2 Defective speed sensor 2 Replace speed sen sor 5 A B When the engine stopped 3 8 4 5Ω tes ter...

Page 109: ...00454 5 Firing order 1 5 7 2 6 3 4 8 6 Fuel injection timing BTDC 23 Rack diagram and setting valve at each point A Test condition for injec tion pump Nozzle Holder Ass y 1688 901 019 Opening pressure 210 bar Injection pipe ID X OD L Ø3 0 x Ø8 0 1 000 mm Test oil ISO4113 Temperature 40 5 C B Engine standard parts Nozzle Holder Ass y 65 10101 7051 Nozzle 4 x Ø0 40 Opening pressure 280 bar Injection...

Page 110: ...order 1 5 7 2 6 3 4 8 6 Fuel injection timing BTDC 18 Rack diagram and setting valve at each point A Test condition for injec tion pump Nozzle Holder Ass y 1688 901 019 Opening pressure 210 bar Injection pipe ID X OD L Ø3 0 x Ø8 0 1 000 mm Test oil ISO4113 Temperature 40 5 C B Engine standard parts Nozzle Holder Ass y 65 10101 7051 Nozzle 4 x Ø0 40 Opening pressure 280 bar Injection pipe ID X OD L...

Page 111: ...0 5 Firing order 1 6 5 10 2 7 3 8 4 9 6 Fuel injection timing BTDC 21 Rack diagram and setting valve at each point A Test condition for injec tion pump Nozzle Holder Ass y 1688 901 015 Opening pressure 208 5 1 5 bar Injection pipe ID X OD L Ø3 0 x Ø8 0 600 mm Test oil ISO4113 Temperature 40 5 C B Engine standard parts Nozzle Holder Ass y 65 10101 7051 Nozzle 4 x Ø0 40 Opening pressure 280 bar Inje...

Page 112: ...400 5 Firing order 1 6 5 10 2 7 3 8 4 9 6 Fuel injection timing BTDC 19 Rack diagram and setting valve at each point A Test condition for injec tion pump Nozzle Holder Ass y 1688 901 019 Opening pressure 210 bar Injection pipe ID X OD L Ø3 0 x Ø8 0 1 000 mm Test oil ISO4113 Temperature 40 5 C B Engine standard parts Nozzle Holder Ass y 65 10101 7051 Nozzle 4 x Ø0 40 Opening pressure 280 bar Inject...

Page 113: ...iring order 1 12 5 8 3 10 6 7 2 11 4 9 6 Fuel injection timing BTDC 21 Rack diagram and setting valve at each point A Test condition for injec tion pump Nozzle Holder Ass y 1688 901 019 Opening pressure 210 bar Injection pipe ID X OD L Ø3 0 x Ø8 0 1 000 mm Test oil ISO4113 Temperature 40 5 C B Engine standard parts Nozzle Holder Ass y 65 10101 7051 Nozzle 4 x Ø0 40 Opening pressure 280 bar Injecti...

Page 114: ...iring order 1 12 5 8 3 10 6 7 2 11 4 9 6 Fuel injection timing BTDC 19 Rack diagram and setting valve at each point A Test condition for injec tion pump Nozzle Holder Ass y 1688 901 019 Opening pressure 210 bar Injection pipe ID X OD L Ø3 0 x Ø8 0 1 000 mm Test oil ISO4113 Temperature 40 5 C B Engine standard parts Nozzle Holder Ass y 65 10101 7051 Nozzle 4 x Ø0 40 Opening pressure 280 bar Injecti...

Page 115: ... system General information 155 General Information 155 Specifications 156 General information 155 Construction 157 Function 158 Failure Diagnosis 159 How to Maintain Turbocharger 162 Special inspection of turbocharger 163 ...

Page 116: ...supplied fuel burned completely to work for the engine efficiently the sufficient air should be delivered to the cylinder That is the enfine power is virtually determined by the size of cylinder If compressed air is delivered to the cylinder with a given capacity the air amount in the cylinder increases to burn more fuel thereby increasing the engine power The method of compressing the air to supp...

Page 117: ... air restriction kPa With clean filter element 2 16 With dirty filter element 6 23 Item DP222L Remarks DP222LAS DP222LBS DP222LBF DP222LCS DP222LCF Intake Exhaust System Max back pressure kPa 5 9 Max intake air restric tion kPa With clean filter element 2 16 With dirty fil ter element 6 23 Generator Engine DP158L DP180L DP222L Turbocharger Model Alied Signal T40E Alied Signal T45E Alied Signal TV5...

Page 118: ...pressor housing 3 Oil shut off 13 Bearing housing 23 Clamp 4 Fixing nut 14 Retainer ring 24 Bolt 5 Seal ring 15 Seal plate 27 Liquid gasket 6 Seal ring 16 Thrust bearing 30 Loctite 7 Seal ring 17 Journal bearing 31 Liquid anti burn angents 8 Compressor wing wheel 18 Screw 9 Turbine housing 19 Screw 22 23 25 15 19 14 18 16 17 13 21 11 10 27 30 31 7 4 8 6 2 5 9 1 3 ...

Page 119: ...rangement is made for the shaft not to shift 2 journal bearing floating bearing is adopted and it forms the double oil films at the in out surfaces in comparison to the general stationary type so that the bearing may be able to rotate independently and consequently the double layers of films act as the damper to make the slipping speed on the bearing surface less than the rotaing speed of shaft so...

Page 120: ...he gasket Leakage of gas from the exhaust manifold Replace the gasket or tighten the fixing nut Poor turbo actuator operation Replace the turbocharger Leakage from the engine block and the exhaust manifold Check the engine Contaminated blowby gas and abnormal oil amount Check the turbo impeller and the turbo intake outlet Large gap of the turbocharger wheel causing inter ference with the wall Chec...

Page 121: ...ount Check the turbo impeller and the turbo intake outlet Large gap of the turbocharger wheel causing inter ference with the wall Check if there is any sand or metallic for eign substance Damaged turbocharger wheel Check if there is any sand or metallic for eign substance Damaged wheel and shaft of the turbocharger Check if there is any sand or metallic for eign substance Poor rotating force of th...

Page 122: ...lic for eign substance Oil consumption Poor clamping state Adjust and tighten the clamp Leakage of coolant from the turbocharger or oil from the oil hose Replace the hose and the gasket Leakage from the engine block and the exhaust manifold Check the engine Contaminated blowby gas and abnormal oil amount Check the turbo impeller and the turbo intake outlet Large gap of the turbocharger wheel causi...

Page 123: ...ocharger wheel Check if there is any sand or metallic for eign substance Damaged wheel and shaft of the turbocharger Check if there is any sand or metallic for eign substance Poor rotating force of the turbocharger wheel Check if there is any sand or metallic for eign substance Blue emissions Leakage from the engine block and the exhaust manifold Check the engine Too much fog Oil leakage to the tu...

Page 124: ...d for a long period circulation of oil in the pipe gets poor After starting an engine 1 Operate the engine at idle for five minutes from starting it 1 When the engine is suddenly loaded while the engine and the turbocharger have not been smoothly rotated after starting the engine parts with insufficient oil may be burnt 2 Check if oil gas or air is leaked from each part If so take proper action 2 ...

Page 125: ...the bearing or the rotor assembly may be abnormal So you need to replace or repair the turbocharger 2 Checking the play of rotor assembly Remove a turbo charger from the engine and check the axial and radial play of the rotor assembly When you disas semble the turbocharger be sure to seal the oil inlet and outlet with a tape etc 1 Axial play of the rotor assembly DV2213036A DV2213037A_E 2 Radial c...

Page 126: ...A_E 3 In case that the end plays to axial and circumference directions replace or repair the turbocharger Dial indicator Magnetic stand Oil outlet Oil inlet Move turbine shaft at both right and left sides simultaneously in radial direction ...

Page 127: ...ssembly of Cylinder Head 172 Check of Cylinder Head 172 Valve 174 General Information 174 Check of Valve 174 Check of Valve Guide 174 Valve Seat 175 Valve Spring 175 Rocker arm 177 Disassembly Rocker Arm 177 Assembly Rocker Arm 177 Check of Rocker Arm 177 Tappet and push rod 178 Tappet Clearance 178 Visual inspection of tappet 178 Warpage of Push Rod 178 Camshaft 179 Camshaft End Play 179 Check of...

Page 128: ...ions Item DP158L Remarks DP158LCS DP158LCF DP158LDS DP158LDF10 Cylinder block head Valve system type Overhead valve type No of valve per cylinder Intake 1 Exhaust 1 Valve lashes at cold mm Intake 0 25 Exhaust 0 35 Intake valve Opening 24 BTDC Close 36 ABDC Exhaust valve Opening 63 BBDC Close 27 ATDC Item DP180L Remarks DP180LBS DP180LBF DP180LAS DP180LAF Cylinder block head Valve system type Overh...

Page 129: ... DP222LBF DP222LCS DP222LCF Cylinder block head Valve system type Overhead valve type No of valve per cylinder Intake 1 Exhaust 1 Valve lashes at cold mm Intake 0 25 Exhaust 0 35 Intake valve Opening 24 BTDC Close 36 ABDC Exhaust valve Opening 63 BBDC Close 27 ATDC ...

Page 130: ...kage 5 Block the discharging outlets of the cooling water path and the oil path of the cylinder block and put pressure of 4 kg cm2 on the inlet Then sink the cylinder block in the 70 C water for 1 minute and check if air leaks Measurement of Cylinder Liner 1 Assembly the cylinder liner at the cylinder block and measure inner diameter at upper middle lower that is 3 step by 45 interval DV2213111A 2...

Page 131: ...l tool 4 Attach the valve spring washer to valve guide 5 Put in the inner and outer spring and then attach the valve spring plate on the springs 6 Attach the valve cotter with the valve spring compress tool 7 Check if the valve cotters have been positioned correctly with the plastic hammer after completing attaching them DV2213114A Check of Cylinder Head 1 Checking cylinder head 1 Check cracks or ...

Page 132: ... testing Note Hydraulic test is same as for cylinder block 2 Distortion at the lower face DV2213115A DV2213116A 1 Measure the amount of distortion using a straight edge and a feeler gauge at six positions as shown in the figure 2 If the measured value exceeds the maximum allow able limit replace the cylinder head Standard Limit Below 0 05mm 0 2mm ...

Page 133: ... becomes less than limit replace the valve DV2213118A Check of Valve Guide 1 Inser the valve into valve guide and measure the clearance between valve and valve guide by the shaking degree of valve If the clearance is bigger measure the valve and then replace the more worn valve guide DV2213119A_E 2 If the valve guide has already been replaced measure the center with valve seat if it deviates or no...

Page 134: ...nd then press it into the cylinder head by means of a special tool 5 After coating the grinding powder paste on valve head 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 thoroughly Valve Spring 1 Visual inspection Check if the exterior of the valve spring is damaged with the naked eye Repla...

Page 135: ...lace the valve spring DV2213124A_E 4 Tension of valve spring Measure the tension of a valve spring by using a spring tester If the reading is below the tolerance limit replace the valve spring DV2213125A_E Item Standard Squareness of valve spring Below 1 0mm Item Standard Inside at weight condition 15 17kg 46 3mm Outside at weight condition 37 41kg 46 3mm Squareness Squareness Free length tape Spr...

Page 136: ...Measure the 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 DV2213127A_E 2 Rocker arm Inspect the rocker arm surface that contacts with the valve stem for any scratch step wear and correct the minor degree of wear with an oil stone or the fine grinding paper and replace if they are sev...

Page 137: ...ntacts the camshaft has damage like crack or scratch If the damage is small correct it with oil stone or fine grinding paper if excessive replace it DV2213128A_E Warpage of Push Rod Put the push rod on a surface plate and measure the warpage with a feeler gauge shile spinning it If the reading exceeds the tolerance limit replace it DV2213129A_E Standard Limit 0 035mm 0 077mm 0 25mm Limit Below 0 3...

Page 138: ...th naked eyes and correct any minor scratches by means of an oil stone grinding and if severe replace it 2 Cam lobe height Use a micrometer to measure the cam lobe height and journal diameter If the measured number is less than the specified limit the camshaft must replaced DV2213132A Check of camshaft 1 Camshaft bearing outer diameter Using an outer diameter micrometer measure the outer diameter ...

Page 139: ...ce If the reading exceeds the tolerance limit replace the camshaft bearing 4 Camshaft bearing replacement Replace the camshaft bearing with a special tool DV2213135A 5 Warpage of camshaft Place the camshaft on 2 V blocks and inspect the warpage of the camshaft by using a dial gauge to correct it if excessive replace the camshaft DV2213136A Item Standard Camshaft bearing inner diameter of cylinder ...

Page 140: ...5 Temperature Switch 185 Temperature Sensor 185 Pressure Sensor Switch 185 Magnetic Pick up 186 Starter 187 General Information 187 Specification 187 Views 188 Wiring Diagram 189 Resistance 189 Alternator 190 General Information 190 Views 190 Wiring Diagram 191 Specification 191 Performance 191 Abnormally Charging 191 ...

Page 141: ...ended Item DP180L Remarks DP180LBS DP180LBF DP180LAS DP180LAF Electrical System Alternator voltage capacity V A 27 5 45 Voltage regulator Built in type IC regulator Starting motor voltage capacity V kW 24 7 0 Battery capacity 2 200Ah recommended Item DP222L Remarks DP222LAS DP222LBS DP222LBF DP222LCS DP222LCF Electrical System Alternator voltage capac ity V A 27 5 45 Voltage regulator Built in typ...

Page 142: ...0A 2 0R 2 0R E 2 1 OFF RUN ON IDLE SWITCH ON OFF CONTROL UNIT IDLE RUN over speed St Alternator B 0 85B L R P S1 ACC 1 25W 0 5WB 0 85BrB S2 H6 0 5GY H7 0 5WR H9 0 5LY H8 Battery Starter Sensor Water temp Pick up Speed Bat Sensor Engine oil G G Pick up Speed Actuator Bat Bat D1 WK Water temp Switch 103 C T W D1 87a 30 2 0R 0 5 P bar B GND User Supply User Supply 5K J REGISTER SPEED TRIM K L OFF STA...

Page 143: ...e 30 bar momentary 2sec 4 Operating temperature 30 C 100 C Max 120 C 1h Operation Temperature ON 103 C 3 C OFF 96 C Current Capacity DC12V 9A TYPE Normal Open Insulation Resistance more than 10MΩ Temperature C 50 80 100 120 Resistance Ω 153 9 47 5 58 0 26 2 31 3 16 1 M16x1 5 M16x1 5 Pressure bar Resistance Ω 0 10 5 10 3 1 5 31 4 2 52 4 3 70 4 4 88 4 5 106 5 6 124 5 7 140 10 8 155 10 155 15 9 170 2...

Page 144: ...tance 1 8kΩ 15 4 Inductance 3 1H 25 5 Insulation Resistance 10MΩ or more at 500V DC 6 Resistance B Y 350Ω 10 above 14V above 7V Gear Module M 3 Teeth Z 32 M 3 Z 32 Clearance 1 0 0 1mm 1 0 0 1mm Revolution 1 000 20 RPM 1 000 20 RPM Load Open 5kΩ Resistive KET MG640322 5 SW 19 Lock Nut M16x1 5 0 5 B GND 0 5 Y SIGNAL ...

Page 145: ...rter should be protected from humidity all the time Before working on the electric system be sure to disconnect the ground wire minus wire of the battery Short circuit may occur while working on the electrical system Connect the ground wire last after completing all of work Specification NOMINAL OUTPUT 24V 7 0kW ENGAGEMENT SYSTEM AUXILIARY ROTATION SYSTEM SOFT START Max RATED TIME 30 SEC ROTATION ...

Page 146: ...11 Electric system 188 Views DV2213139A Ground Terminal M10X1 5 Switch Terminal Relay M5X0 8 Battery Terminal M10X1 25 Solenoid Relay Motor Switch Terminal Solenoid M Terminal ...

Page 147: ...89 Wiring Diagram DV2213140A Resistance Battery Terminal Relay Solenoid Motor M Ground Terminal Switch Terminal M Terminal Item Spec Relay Switch Terminal Relay Case 23 5kΩ 2 35 Solenoid Switch Terminal M Terminal 0 124Ω 5 ...

Page 148: ...uld not be operated except with the regulator and battery connected in circuit to avoid damage to the rectifier and regulator The alternator is maintenance free nevertheless it must be protected against dust and above all against moisture and water Views DV2213137A Type 3V 2 V Belt P Terminal KEY GP 890545 Frequncy RPM 10 Pulley ratio 244 85 L Terminal R Terminal B Terminal M6x1 0 Housing KET MG 6...

Page 149: ... condition needs only the terminal when the engine is stopped 1 During operation 0 5 MFD B P Termianl Regulator R L B R 150 250 OHM L Specification RATING Continuous rating ROTATION DIRECTION Clockwise BATTERY VOLTAGE 24V TURN ON RPM Max 1 050 RPM SPEED IN USE 1 000 8 000 RPM MAX INLET AIR TEMP 105 C POLARITY SET VOLT 27 5V TEMP GRAD 10 3mV C Performance Voltage V Output current A Speed RPM COLD H...

Page 150: ...value between the voltage regulators Position Voltage Terminal B Body About DC27V 29 5V Terminal L Body About DC27V 29 5V Terminal R Body About DC3V 5V Position Voltage Terminal B Body About DC22V 27V Terminal L Body About DC22V 27V Terminal R Body 0 Terminal Resistance L Body 4 4 5 kΩ R Body 110 180 kΩ Body R 110 180 kΩ L R 110 180 kΩ ...

Page 151: ...ement of Crankshaft 196 Measurement of Crankshaft Bearing and Connecting Rod Bearing 197 Piston 199 Disassembly of Piston 199 Assembly of Piston 199 Piston Inspection 199 Piston Ring and Ring Groove 200 Piston pin 200 Connecting rod 202 Inspecting the connecting rod 202 Others 203 Engine Timing 203 ...

Page 152: ... seals with replaceable wearing rings on crankshaft and flywheel are provided to seal the crankcase penetra tions The connecting rods are die forged diagonally split and can be removed through the top of the cylinders together with the pistons Crankshaft and connecting rods run in steel backed lead bronze ready to fit bearings ...

Page 153: ... size bearing 3 There are 4 kinds as below and the crankshaft also can be used by regrinding as below Standard 0 25 Inside diameter 0 25 mm less than standard 0 50 Inside diameter 0 50 mm less than standard 0 75 Inside diameter 0 75 mm less than standard 1 00 Inside diameter 1 00 mm less than standard 4 R part standard value Crank pin R 3 5 4 0 Crank journal R 3 5 4 0 DV2213149A_E 3 Warpage of cra...

Page 154: ... and bearing Method 2 Plastic gauge 1 Assemble the crankshaft to the cylinder block 2 Place the plastic gauge on the crankshaft journal and pan 3 Assemble the bearing cap and tighten the bolt to the specified torque 4 Loosen the bolt remove the bearing cap 5 Measure the width of the plastic gauge at the widest point using the ruler for plastic gauge measurement This is the oil clearance 6 Measure ...

Page 155: ...12 Others driving system 198 DV2213153A Item Standard Limit Axial end play 0 190 0 322mm 0 452mm ...

Page 156: ... plier inser the snap rings of the piston pin 4 With confirming the upper side indication of piston ring after assembling the ring in the piston ring groove inspect if the movement of ring is smooth Piston Inspection 1 Visual inspection 1 Visually check the piston for crack scratch wear etc Specially check the wear status of the ring groove 2 Piston outside diameter inspection 1 With the outside m...

Page 157: ... Piston pin 1 Wear 1 Measure the wear amount of the piston pin with a outside micrometer 2 If the reading exceeds the tolerance limit replace the pin DV2213160A 2 Clearance 1 Measure the clearance between the piston pin and connecting rod bush Item Standard Piston outside diameter Ø127 739 Ø127 757mm CAUTION By comparing the measured value of the piston outside diameter with the cylinder liner ins...

Page 158: ...12 Others driving system 201 2 If the reading exceeds the tolerance limit replace the one which are worn more DV2213161A Item Standard Clearance 0 003 0 015mm ...

Page 159: ...pecting the connecting rod 1 Measure the parallelism between the connecting rod small end s bush hole and the large end bearing hole Here use both the connecting rod measuring device and feeler gauge DV2213162A_E Item Standard Limit Degree of parallelization 0 02mm 0 2mm Piston Burners ...

Page 160: ...iving system http www brizmotors ru equipment ctm 400 Others Engine Timing DV2213204A 5 2 6 1 3 4 1 Crankshaft gear 2 Oil pump drive gear 3 Oil pump impeller gears 4 Camshaft drive gear 5 Injection pump drive gear ...

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