Doosan GV158TIC Operation & Maintenance Manual Download Page 1

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950106-058010EN

GV158TIC, GV180TIC, GV222TIC

GAS GENERATOR ENGINE

Operation &
Maintenance Manual

Summary of Contents for GV158TIC

Page 1: ...950106 058010EN GV158TIC GV180TIC GV222TIC GAS GENERATOR ENGINE Operation Maintenance Manual...

Page 2: ......

Page 3: ...on Important Reassembly Tighten to specified torque Align the marks Use special tools of manufacturer s Directional Indication Lubricate with oil Inspection Lubricate with grease Measurement During en...

Page 4: ...ed 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 incor...

Page 5: ...r Components 45 3 1 Engine Disassembly 45 3 2 Measurement and Inspection of Major Parts 56 3 3 Engine Reassembly 74 3 4 Starting and Trial Operation 93 3 5 Speed Controller Setting 95 3 6 Display Modu...

Page 6: ...6 Engine Installation 143 6 1 Installing 143 6 2 Inspection Prior to Installation 144 Appendix...

Page 7: ...particular through contact with caustic acids fuel penetrating the skin scalding from oil antifreeze being splashed in the eyes etc consult a doctor immediately 1 2 Handle Compressed Natural Gas Safe...

Page 8: ...enting procedure to relive the natural gas pressure downstream of the shutoff valve 1 Shut off manual valves on natural gas supply lines and main shutoff valve on natural gas fuel supply line 2 Start...

Page 9: ...nce work when the engine is switched off If the engine has to be main tained while it is running e g changing the elements of change over filters remember that there is a risk of scalding Do not get t...

Page 10: ...tion to the above note the following points Never let the engine run when dry i e without lube oil or coolant Use only DOOSAN approved service products engine oil anti freeze and anticorrosion agent H...

Page 11: ...key switch is turned to the ignition position the pre heater plug or air heater runs continuously to make starting the engine easier and reduce white exhaust gas If the coolant tem perature is over 25...

Page 12: ...pollution 3 Engine oil and anti freeze solution must be handled with reasonable care as they cause paint dam age 4 The use of proper tools and special tools where specified is important to efficient...

Page 13: ...er 1 5 7 2 6 3 4 8 1 6 5 10 2 7 3 8 4 9 1 12 5 8 3 10 6 7 2 11 4 9 Fuel ignition tim ing Adjust angle 40 B T D C 40 B T D C Operate angle 14 B T D C 12 B T D C Engine control system ECM engine control...

Page 14: ...3 0 4 Ignition coil Inductive coil pack Ignition timing adjustment Controlled by ESC and ICM Control system Control system On highway heavy duty Voltage V 24 Component ESC ICM sensor harness Turbo cha...

Page 15: ...IC 50 Hz 1 500 rpm 230 kW 313 PS 207 kW 281 PS 60 H z 1 800 rpm 270 kW 367 PS 243 kW 330 PS GV180TIR 50 Hz 1 500 rpm 319 kW 434 PS 290 kW 394 PS 261 kW 355 PS 60 Hz 1 800 rpm 375 kW 510 PS 340 kW 462...

Page 16: ...w longitudinal 1 Crank shaft pulley 11 Turbo charger 2 Connecting rod 12 Flywheel 3 Piston 13 Flywheel housing 4 Cylinder liner 14 Vibration damper 5 Valve 15 Oil spray nozzle 6 Rocker arm 16 Oil pan...

Page 17: ...iew cross 1 Oil level gauge 8 Intake manifold 2 Oil filter 9 Spark plug 3 Oil cooler 10 Cylinder head 4 Exhaust manifold 11 Cylinder block 5 Cylinder head cover 12 Oil drain pump 6 Throttle valve 13 S...

Page 18: ...ook 3 Cooling water pump 13 Inter cooler 4 Water outlet 14 Ignition coil 5 Gas pressure regulator 15 Intake manifold 6 Throttle valve 16 Turbo charger 7 Oil drain pump 17 Exhaust elbow 8 Mounting brac...

Page 19: ...water pump 13 Inter cooler 4 Water outlet 14 Ignition coil 5 Gas pressure regulator 15 Intake manifold 6 Throttle valve 16 Turbo charger 7 Oil drain pump 17 Exhaust elbow 8 Mounting bracket 18 Vibrati...

Page 20: ...ion coil 3 Cooling water pump 12 Turbo charger 4 Water outlet 13 Exhaust elbow 5 Gas pressure regulator 14 Crank shaft pulley 6 Throttle valve 15 Oil pan 7 Oil drain pump 16 Starting motor 8 Mounting...

Page 21: ...dering parts They are also referred to as engine model and serial number because of their loca tion Engine serial No example1 GV158TIC EEZOD 4 00001 Serial No Production year 2004 Engine model Engine...

Page 22: ...V22TIC natural gas engine is an overhead valve turbocharged water to air charge cooled electronically controlled engine 2 3 1 Design characteristic Spark ignited by the spark plug Electric engine cont...

Page 23: ...d controller ESC The Engine Speed Control is designed to provide basic isochronous speed control for gas engines using the Flo Tech Throttle Engines with mechanical loads and generator loads are handl...

Page 24: ...increase its stiffness it is extended to a level below the crankshaft center line The engine has replaceable wet cylinder liners and individual cylinder heads 2 3 7 Piston con rod and crankshaft The...

Page 25: ...raws the oil from the oil sump and delivers it through the oil filter and oil cooler to the main distributor gallery and from there to the main bearings big end bearings and camshaft bearings as well...

Page 26: ...if necessary Check the oil level with the engine cooled If the engine is warm allow time for 5 10 minutes for oil drain into the crankcase before checking oil level The oil level must be between Max...

Page 27: ...5 Engine oil capacity Engine model In oil pan Total lit Max lit Min lit GV158TIC 28 26 31 GV180TIC 35 28 38 GV222TIC 40 33 43 SAE 10W 40 SAE 5W 40 SAE 15W 40 SAE 5W 30 SAE 10W 30 SAE 15W 50 40 C 40 F...

Page 28: ...ter shut down the engine After waiting for about 10 minutes measure the quantity of oil and refill the additional oil if necessary 2 3 14 Replacement of oil filter cartridge Every time oil exchanges r...

Page 29: ...cted every 500 hours to maintain it properly Note The proper density control of antifreezing solution and rust preventing additive will be able to prevent the rusting effectively and maintain the stab...

Page 30: ...r which hue has changed with the color list of label on storage bottle 5 By comparing the hue changed into yellowish green or so with the green color indication of test paper storage bottle confirm th...

Page 31: ...untered Clogged air filters may cause black smoke and reduce power A check should be made from time to time to see that the fastening elements securing the air cleaner to the intake manifold seal the...

Page 32: ...8 12 cylinder engine 6 cylinder is positioned at the valve overlap when 1 cylinder is positioned at the compression TDC Top Dead Center In case of 10 cylinder engine 7 cylinder is positioned at the v...

Page 33: ...80TIC 12 Cylinder engine GV222TIC Specified value Measurement tolerance Intake valve Exhaust valve Intake valve Exhaust valve 0 30 mm 0 40 mm 0 05 mm Valve overlapping on cylinder Intake Exhaust valve...

Page 34: ...the spark plug Install the special tool compression gauge adapter at the spark plug hole and connect the compression pressure gauge there Condition water temperature 20 C engine rotation 200 rpm EFM10...

Page 35: ...deposits from electrode and Inspect insulator area Measure the spark plug distance at elec trode position A Replace spark plug if necessary Install spark plug A EB3O310I Standard Distance A 0 3 0 4 mm...

Page 36: ...on should be applied on the compressed air and exhaust gas pipes For leaking air will bring the over heat engine an immediate repair must be done During the operation that is surrounded by the dust an...

Page 37: ...against dust and above all against moisture and water Operate the alternator according to the instructions given in the chapter BAT Korea Delco Remy EE3OM019 Ignition terminal Indicator lamp terminal...

Page 38: ...of grease should be applied again Always protect starter motor against moisture Battery ground M10 X 1 5 Bolt Switch terminal M5 X 0 8 Bolt M10 X 1 25 Bolt Battery terminal EE3OM021 24V x 7 0kW 100 Vo...

Page 39: ...rear side of it without fail If the silver paper etc is used for connecting the cut off fuse because the excessive current might flow into the parts to damage when fuse is cut off after resolving the...

Page 40: ...Recharging Too low Starting motor revolution Starting motor operation poor Normal Normal Polluted Normal Normal Normal Adjust Replace Replace or clean element Inspect ignition timing Inspect ignition...

Page 41: ...Cooling system Operating state 1 Overload 2 Radiator core clogged Normal Check thermostat Normal Replace Normal Normal Inspect radiator Replenish Clean cooling water passage Normal Engine disassembly...

Page 42: ...Check valve clearance Repair Replace Normal Normal Normal Engine disassembly valve assembly Inspect cylinser head gasket for damage Retighten Replace Normal Inspect air leakage of intercooler Inspect...

Page 43: ...o low Use recommened oil replenish Normal Normal Check cooling temperature Check oil amount Retighten Replace Inspect oil quality Check oil relief valve Normal Water mixed in oil Disassemble engine Im...

Page 44: ...Retighten Replace Normal Normal Check valve clearance Adjust Inspect nature gas leakage Repair replace cylinder liner piston ring piston Disassemble engine valve assembly piston cylinder liner etc Ins...

Page 45: ...l quality Replace with specified oil Engine disassembly piston cylinder liner Internal External Clean Replace Disassemble cylinder head valve stem seal 7 Engine Knocking Too low Inspect combustion of...

Page 46: ...ring Switch Inspect cut wire shorts and loose connections Repair Replace Electrolytic liquid s standard Check fan belt tension damage Discharging Disassemble alternator Voltage regulator Replace Batte...

Page 47: ...ine Adjust Repair or replace Clean or replace air cleaner 4 Overheating Engine oil insufficient or poor Cooling water insufficient Fan belt loosened worn damaged Cooling water pump s function lowered...

Page 48: ...st washer Repair or replace Adjust valve clearance Replace tappet cam Repair or replace 6 Oil Consumption excessive 1 Oil level elevated Clearance between cylinder liner piston Wear of piston ring rin...

Page 49: ...e V belt tension Change the coolant water 1 year Lubrication system Check for leakage Check the oil level gauge Change the lubricating oil 1st Every 200hr Replace the oil filter cartridge 1st Every 20...

Page 50: ...th many parts only when the original parts that the manufacture recommends to use is used the engine trouble would be preventively maintained and capable to keep up the maximum performances For the an...

Page 51: ...d reassembly do the work with the naked and clean hand and also the working place must be maintained clean The torn parts after disassembly must be kept not to collide each other In disassembling torn...

Page 52: ...o the prepared ves sel 3 1 5 V belt Loosen the V belt tension adjusting bolts and remove the V belt 3 1 6 Ignition coil gas pressure regulator Remove the high voltage cable by hand from each cylinder...

Page 53: ...osen the gas hose and air cleaner hose for connecting the gas fuel mixer Loosen the clamp and fixing bolt for con necting the turbocharger and then tear down the air intake stake and gas fuel mixer Re...

Page 54: ...s and tear the throttle valve down from the intake stake Remove the manifold fixing bolts and tear the manifold down from the cylinder head 3 1 11 Alternator Remove the supporting guide piece for inst...

Page 55: ...ater pump fixing bolts and disassemble the cooling water pump 3 1 14 Oil cooler By removing the plug screw of cooling water discharge port the cooling water is discharged Remove the oil cooler cover f...

Page 56: ...motor fixing nuts and disassemble the starting motor 3 1 16 Timing drive sensor Remove the timing drive fixing bolts and disassemble the timing drive and timing sensor 3 1 17 Flywheel housing cover S...

Page 57: ...3 1 20 Rocker arm Remove the rocker arm bracket fixing bolts and take the rocker arm assembly out Pull out the push rod 3 1 21 Cylinder head Loosen the cylinder head fixing bolts in the reverse order...

Page 58: ...verse order of assembling and disassemble the crankshaft pulley and vibration damper 3 1 23 Oil pan Remove the oil pan fixing bolts and sepa rate the pan Remove the oil pan gasket and scrap it 3 1 24...

Page 59: ...ead s direction remove the piston Note Be careful for the removed pistons not to collide each other or with the other parts At the storage of pistons maintain them in the order of cylinders In order f...

Page 60: ...3 1 28 Flywheel housing Remove the flywheel housing fixing bolts and take them out Remove the oil seal from the flywheel housing 3 1 29 Crank shaft Remove the bolts from bearing caps Remove the main...

Page 61: ...nding bearing caps in turn 3 1 30 Camshaft and tappet Pull out the tappets from the cylinder block Remove the camshaft being careful not to damage the camshaft and its bearings 3 1 31 Oil spray nozzle...

Page 62: ...ck s camshaft bush to any damage and the alignment of oil supply holes and if abnormal replace it 3 2 2 Cylinder liner measurement Assemble the cylinder liner at the cylinder block and measure inner d...

Page 63: ...ead and measure distance B 3 2 5 Inspection and measurement of cylinder head 1 Damage check Inspect the cylinder head for any crack or damage Eliminate the carbon residue and gasket piece from the cyl...

Page 64: ...ection and measurement of valve and valve guide 1 Valve After cleaning the valves with clean diesel oil measure the valve stem s outside diameter at upper middle and lower to determine the wears and w...

Page 65: ...degree of valve If the clearance is bigger measure the valve and then replace the more worn cylinder head 3 Valve seat Assemble the valves at the cylinder head and using the measuring instru ment fro...

Page 66: ...spring perpendicularity regular Valve spring tension standard Squareness of valve spring Measure the sequareness of the valve spring with the surface plate and the right angle square If the reading ex...

Page 67: ...d Install the valve spring washer to valve gulde After putting on the inside outside spring Install the valve spring seat on them Note Install the valve spring seat with TOP painted in Yellow side up...

Page 68: ...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 Inspect the rocker arm surface that contacts with the va...

Page 69: ...ce them Place the push rod on the surface plate and rolling it Inspect the curving degree with a clearance gauge and if abnormal replace it Run out Inspect the oil passages of rocker arm and rocker ar...

Page 70: ...of an oil stone grinding and if severe replace it 3 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 ca...

Page 71: ...mshaft outside diameter and bush inner diameter of cylinder block mm 6 Camshaft bearing replacement Remover installer 7 Camshaft run out With placing the camshaft on the 2ea of V blocks and inspect th...

Page 72: ...take the wear Crankshaft journal outside diameter Crankshaft pin outside diameter In case that the lopsided wear is more than the limit value grind to the under size and use the undersized bearing Ma...

Page 73: ...any processed jaw or coarse surface 3 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...

Page 74: ...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 spe...

Page 75: ...play of crankshaft by pushing the crankshaft to axial direction 3 2 13 Piston 1 Piston disassembling Pull out the snap ring for piston pin and with a pair of snap ring pliers With a round bar remove t...

Page 76: ...direction By comparing the measured value of the piston outside diameter with the cylinder liner inside diameter the big ger clearance is replaced 3 Piston ring and ring groove In case of piston ring...

Page 77: ...meter and if the value is same as the use limit value or less replace it 6 Piston pin and connecting rod bush clearance Inspect the clearance between the piston pin and the connecting rod bush if it i...

Page 78: ...le With the snap ring plier insert the piston pin snap ring With confirming the upper side indication of piston ring after assembling the ring in the piston ring groove inspect if the movement of ring...

Page 79: ...3 Measure the valve opening temperature and the valve full opening temperature and inspect if the valve lift is more than 8 mm and if abnormal replace it No Opening temperature Full opening temperatur...

Page 80: ...ust be avoided Inspect if the movement of engine is smooth after assembling After completion of assembling whether various bolts are loose or not should necessarily be insured Make sure that there is...

Page 81: ...le of the cylinder block 3 3 5 Crank shaft 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 cylin der b...

Page 82: ...to the tightening order tighten the bearing cap bolts with 30 kg m and with rotating angle method 90 10 and tightening order are as follows Bearing cap bolt s tightening order 1 First step Tighten wit...

Page 83: ...rque Coat the oil seal P T F E with lubricat ing oil and assemble the oil seal carefully for it not to deviate or be damaged by means of special tool Mandrel for assembling Attach the gasket on the su...

Page 84: ...o not allow the temperature of the ring gear to exceed 200 C 390 F By means of mandrel assemble pilot bearing to the flywheel By means of mandrel press in the wear ring at the backward face Install tw...

Page 85: ...rt the oil seal by the crank shaft Note Without coating the oil seal with oil or lubricant assemble it in the dry state Tighten the fixing bolts in the zigzag method 3 3 10 Piston Line up the piston a...

Page 86: ...90 10 Connecting rod bolt tightening order 1 First step Engage 2 3 threads by hands 2 Second step Tighten to about 7 kg m with wrench 3 Third step By means of torque wrench tighten to 10 kg m 4 Fourt...

Page 87: ...f the oil pump where the oil suction pipe is to be installed and install the oil suction pipe by tightening the fixing bolts Assemble the pipe bracket on the cylin der block side with bolts 3 3 12 Vib...

Page 88: ...ify the marks of Gl and GE impressed on the valve head before assembling the valve with the valve head With a valve stem seal fitting jig assem ble the valve stem seal with the valve guide 3 3 15 Cyli...

Page 89: ...by hands 2 Second step Tighten to a bout 8 kg m with wrench 3 Third step Tighten to 15 kg m with a torque wrench 4 Fourth step Rotate 90 by rotation angle method 5 Fifth step Finally tighten addition...

Page 90: ...ing bolts to the specified tightening torque Adjust the valve clearance Regarding the adjustment refer to the regular main tenance part 3 3 18 Timing drive sensor Attach an O ring to the cylinder bloc...

Page 91: ...to the opposite direction about 30 in order to remove a back lash and then rotate in normal direction to set the flywheel timing angle and effect hole sensor magnet position If not aligned the start...

Page 92: ...tighten the fixing bolts by the zigzag method 3 3 21 Intake manifold gas regulator Attach a new gasket to the cylinder head side Assemble the intake manifold by tighten ing the fixing bolts Attach a g...

Page 93: ...g the bolts evenly as the right fig ure Attach new gaskets to the exhaust mani fold and then assemble the exhaust man ifold with the fixing bolts Caution Be careful not to drop the manifold because it...

Page 94: ...er Attach a gasket on the surface in the oil cooler housing where the oil cooler is installed Tighten the oil cooler with fixing bolts Install the oil cooler assembly by tighten ing the fixing bolts i...

Page 95: ...e and check for licks 3 3 27 Cooling water pump Attach a gasket at the cooling water pump at cylinder block side Assemble the cooling water pump by tightening the fixing bolts zigzag method Insert the...

Page 96: ...the turbocharger with fixing bolts Attach a gasket on the oil supply pipe and assemble the pipe with the fixing bolts Attack a gasket on the oil discharge pipe and assemble the pipe by tightening the...

Page 97: ...fuel line Open fuel line valve and check for leaks using soapy water or commercial leak detector 3 3 31 Inter cooler After assembling the intercooler fixing bracket on the intake manifold and then ass...

Page 98: ...semble the alternator bracket to the lower part of cylinder block by tightening the fixing bolts Install the alternator supporting plate belt tension plate to the oil pan by means of bolts Assemble th...

Page 99: ...overload or overspeed and the engine life time may be shortened Therefore the following things must be obeyed by all means Up to the first 50 hours Engine should be run at fast idling until the temper...

Page 100: ...ill generally show higher oil pressure for any specific RPM than hot oil Both of these conditions reflect normal engine operation c Watch the engine water temperature gauge and be sure there is proper...

Page 101: ...sition about 5Vdc slowly turn the rated speed potentiometer coun terclockwise until the signal just begins to move to minimum b If the output is at minimum slowly turn the rated speed potentiometer cl...

Page 102: ...before attempting to start the engine Interrelated problems can occur and an understanding of all possibilities is needed before using a control for the first time Caution To protect against possible...

Page 103: ...n the magnetic pick up and the control or a defective magnetic pick up 6 With the engine running and stable slowly increase the rated speed setting with the RATED SPEED pot until the desired rated spe...

Page 104: ...s speed is lowered 14 Dynamic adjustment a Gain is too high and stability too low There are secondary overshoots on transients and large overshoots on starts under damped b Optimum performance on load...

Page 105: ...that allowed the cold engine to start during initial start up procedures If START FUEL LIMIT is to be used it should now be adjusted after engine stability and response rates are correctly adjusted a...

Page 106: ...s to critical operating setup and diagnostic information 3 6 2 Typical system diagnostics 1 Engine overspeed has been reached with the maximum observed speed displayed 2 Indicative of a condition wher...

Page 107: ...c pickup cable is also typically the source of this fault 5 No Hall effect pickup 4 cycle indicator signal has been detected or it is improp erly synchronized with the reset pickup 6 The expected 4 20...

Page 108: ...detected on out put B may be the result of an improp erly wired coil or a short to ground inside the conduit 3 A low voltage demand condition on out put C typically indicates a shorted spark plug or...

Page 109: ...an the average of the cylinders This indicates potentially an overly rich air fuel mixture a short in the secondary wiring or perhaps an improperly gapped spark plug 7 A high spark voltage demand than...

Page 110: ...een to describe the selected mode of operation for the igni tion The energy mode E1 E2 E3 and the single strike multi strike type S or M are described in the middle of the upper line in small characte...

Page 111: ...e Fire Confirm Out switch switch opens by turning on the alarm LED inside the Ignition Module by changing the state of the Alarm Out switch switch opens by changing the state of the Fault Out switch s...

Page 112: ...cle engine A Represents the altronic pattern code A GV158TIC H GV180TIC B GV222TIC 160 Represents the number ofgear teeth or holes to be sensed FS100 001 Special pattern code UNIT 791950 16 Ignition m...

Page 113: ...ion the operator must fully purge the engine of combustible mixtures prior to selecting the test mode operation Pressing the enter key again is a confirmation of this action 2 Then the test mode scree...

Page 114: ...d the bottom line will flash View Diagnostics Note Diagnostic FAULTS will supersede diagnostic WARNINGS 2 A diagnostic warning represents the least severe classification of problems The ignition will...

Page 115: ...ult or warning is present the operator can display the actual cause of the diagnostic as depicted below 6 Then from the diagnostic description screens use the following keys 7 Diagnostic Fault screens...

Page 116: ...ynchronized d When too many or to few gear tooth pluses are seen between reset pluses The received number or pluses is displayed e When the engine speed exceeds the over speed set point Maximum observ...

Page 117: ...Disassembly and Reassembly of Major Components 111 f When the check sum of microproces sor firmware cannot be verified Unit requires service EGV22180037 BOTTOM BOARD uP CHECKSUM FAILED...

Page 118: ...oling temp sensor if it is correctly connected Backward of gauge panel Cooling water pipe Engine oil pressure gauge not operate Confirm connector that is connected to engine oil pressure sensing senso...

Page 119: ...s filter Gas pressure gauge Speed module valve Gas pressure Inter cooler Display Hall effect sensor Magnetic pick up sensor reset Magnetic pick up sensor Timing check Exhaust gas Turbo Fuel mixer Gas...

Page 120: ...arning lamp High coolant temp warning lamp Cahrge indicator lamp Engine oil pressure gauge Coolant temperature gauge 1 Circuit Breaker Main Connector 1 Light lamp Tacho meter 1 3 1 1 1 1 1 10A LED 24V...

Page 121: ...escription The Speed Controller is designed to provide basic isochronous speed control for gas engines Engines with mechanical loads and generator loads are handled equally well 1 FLO TECH SPEED 4 O5...

Page 122: ...d in series with battery and termi nal 2 Positive terminal becomes chassis ground Leads from battery to terminals 1 2 must be direct and not pass through distribution points Approximate speed change w...

Page 123: ...ch Fire confirm output switch Note RS485 serial communications MISC input to either display module or P C not both at same time Display module 24 Vdc power CPU 95 EE3OM060 Magnetic pickups reset Timin...

Page 124: ...source Determine the wire size required Starting 20 VDC min Running 24 28 VDC Distance in Cm Minimum wire size Distance in Cm Minimum wire size up to 762 16 AWG 2 012 3 048 10 AWG 793 1 219 14 AWG 3...

Page 125: ...se determine the wire size required from this common point to each ignition module Note Above 12 190 cm use multiple pairs of wires from the power source to the engine room 4 4 3 Display module 1 Feat...

Page 126: ...sted pair User 4 conduct shielded cable for power RS 485 connections Connect shield in ignition module Power module See A MISC input Colse to acivate selected feature 2 wire transmitter 24Vdc supply 2...

Page 127: ...R CR 2 3 5 4 6 CR 24V 1 A C B A S S B A 12 11 B 10 9 EE3OM066 USER INPUT CLOSE TO STOP IGNITION USER INPUT CLOSE TO ACTIVATE SELECTED FEATURE ONE STEP TIMING Note Alarm fault fire confirm outputs are...

Page 128: ...no of ignition harness GV158TIC GV180TIC GV222TIC 1 A A A 2 D E M 3 F K E 4 K M P 5 B C C 6 E B K 7 C F L 8 L L D 9 N R 10 D F 11 N 12 B GND G G G Off to GND J J J Engine model Firing order GV158TIC...

Page 129: ...k leads ENGINE control Left bank leads Igniton Panel G lead Junction box G J K U L T H S J G N M A B V P R C D F E 22 14S connector Harness COIL Ground to engine at end cylinders Spark plug lead Separ...

Page 130: ...Electrical equipment 124...

Page 131: ...2TI Turbocharger model HOLSET HX35 Rated revolution rpm 80 000 80 000 60 000 Intake air quality m3 sec 0 28 0 35 0 43 Compression efficiency 77 75 0 76 Compression ratio 1 8 2 0 1 66 Weight 14 kg 14 k...

Page 132: ...st bush 16 Thrust bearing 3 Oil shut off 17 Journal bearing 4 Fixing nut 18 Screw 5 Seal ring 19 Screw 6 Seal ring 21 Heat dissipater 7 Seal ring 22 Compressor housing 8 Compressor wing wheel 23 Clamp...

Page 133: ...order not to influence a bad effect at bearing part there are the seal ring and heat dissipater 2 Compressor It is connected to the same shaft with the turbine to make a revolving assembly and receive...

Page 134: ...e turbocharger the bearing s abnor mal wear or stuck may be caused 3 In case that engine stalled for long time and of cold weather the fluidity of oil may be get worse Immediately after starting 1 Per...

Page 135: ...eak and the stuck prevention If exhaust gas leaks from the exhaust pipe and turbocharger etc for the super charging effect will be lowered the installed states of various parts must be paid with caref...

Page 136: ...abnormal metal and rotor replace or repair the turbo charger 2 Measuring rotor clearance Disassemble the turbocharger from the engine and should inspect the end plays in axial and cir cumference dire...

Page 137: ...bricating system Prior to assembling it into the engine fill new oil into oil Inlet and turning turbine shaft with hand lubricate journal and thrust bearing In order for oil not to leak from various c...

Page 138: ...White smoke excessive 1 Oil leaks into turbine and compressor 2 Seal ring s abnormal wear or damage Overhaul and repair or replace Overhaul and repair or replace 3 Output lowered 1 Gas leak from vari...

Page 139: ...ne performance 5 2 1 Specifications 5 2 2 Oil pump Item Specifications Item Specifications Lubricating system Forced pressure circulation Oil filter type Full flow Oil pump type Gear type Filter eleme...

Page 140: ...rom the crankshaft pulley 5 3 1 Cooling water pump TIRBO CHARGER 48 6 12 TIRBO CHARGER 12 FRESH WATER PUMP EXHAUST MANIFOLD OIL COOLER 12 CYLINDER BLOCK 40 45 BY PASS 67 AIR VENT THERMOSTAT EXHAUST MA...

Page 141: ...into the radiator 5 4 2 Inspecting Check the wax pallet and spring for dam age Put the thermostat in a container of water then heat the water slowly and check temperature with a thermometer If the va...

Page 142: ...akened Fan belt loosened or broken Fan belt fouled with oil Thermostat inoperative Water pump defective Restrictions in water passages due to deposit of scales sages Ignition timing incorrect Restrict...

Page 143: ...lt is pressed by 10 15 mm between the pulleys in normal condition Pressed midway between the belt pulleys A more precise check of the V belt ten sion is possible only by using a V belt tension tester...

Page 144: ...ng and changing belts Loosen fixing bolts and nuts Adjust the alternator until belts have cor rect tensions Retighten fixing bolts and nuts To change the belts loosen fixing bolts and nuts Then push t...

Page 145: ...Be careful to assemble cover and bowl correctly There is a recess in the cover rim and a lug on filter is installed horizontally watch for top mark the collector which should register Where the on cle...

Page 146: ...w the element to soak in luke warm washing solvent for 10 minutes and then move it to and for in the sol vent for about 5 minutes Rinse thoroughly in clean water shake out and allow drying at room tem...

Page 147: ...g to the paper pleats and rubber gaskets or for bulges and dents etc in the metal jacket Cracks and holes in the paper pleating can be established by inspecting the cartridge with a flashlight Damaged...

Page 148: ...Maintenance of major parts 142...

Page 149: ...be solidly fixed at the Generator installing platform and the bed rail 6 1 3 Aligning center The center alignment of engine and Generator is the most important factor for the extension of life cycle O...

Page 150: ...wheel housing flange The surface error should not exceed 0 2 mm 2 Measuring bore of flywheel housing Attach the gauge as above so that the gauge stem may contact the flywheel housing bore as the right...

Page 151: ...flywheel Install the gauge as below so as for the gauge stem to contact to the pilot bore of the surface to be installed The eccentrics of the pilot bore of fly wheel should not exceed 0 127 mm at max...

Page 152: ...Engine installation 146...

Page 153: ...21 6 26 2 2 Initial 10 kg m rotating angle 90 Cylinder head Cylinder intermediate cover Cylinder head cover M15 x 2 M8 M14 x 1 25 12 9 8 8 8 kg m 15 kg m angle 90 angle 90 2 2 2 5 3 0 Camshaft timer...

Page 154: ...20 24 32 30 40 36 48 54 64 90 108 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 0 5 M7 0 43 0 46 0 7 0 63 0 83 0 78...

Page 155: ...0 08 Measure at 4 place Piston Outside diameter of piston 127 739 127 757 Measure 71 5 mm part from bottom long length Inside diameter of piston pin 46 003 46 009 Max allowable weight per engine 50g 1...

Page 156: ...103 75 Undersize 0 50 103 48 103 50 Undersize 0 75 103 23 103 25 Undersize 1 00 102 98 103 00 Thrust bearing journal width Standard 38 000 38 062 38H9 Con rod bearing journal diameter Standard 89 98...

Page 157: ...10 53 11 Intake valve Stem diameter 11 935 11 955 Radius direction clearance 0 035 0 064 Seat angle 30 Head diameter 57 85 58 15 A thickness of valve head 4 6 5 0 Valve seat part diameter of head 61...

Page 158: ...ubricating system Oil pressure at idling 0 9 3 0 bar Oil pressure at rated speed operation 3 0 6 5 bar Oil temperature Less than 110 C Instantaneous allowable temperature Max 100 C Bypass valve openin...

Page 159: ...8 1076 5 984 706 5 52 80 17 40 100 ENGINECOOLINGWATER INLET 75 75 ENGINE COOLINGWATER OUTLET 75 150 150 4 12 2 17 80 12 40 150 M16x2 200 376 5 66 7 39 6 9 16 7 25 4 PCD 530 2 12x30 8x45 PCD 438 15 306...

Page 160: ...1234 5 1546 1334 M16x2 2 17 12 40 80 150 200 Air coolercooling 75 75 75 1176 1154 5 894 PT 2 11 354 1 283 260 236 5 405 225 111 363 5 392 5 392 5 Air coolercooling 894 318 236 5 66 7 39 6 25 4 16 7 9...

Page 161: ...4 150 501 5 52 1222 5 405 375 375 603 6 2 17 200 150 12 40 M16x2 392 5 363 5 154 5 363 5 154 5 392 5 AIR INLET 77 8 AIR INLET 77 8 AIR COOLER COOLING WATER IN OUTLE T 75 52 100 80 17 40 150 150 4 12 1...

Page 162: ...Appendix 156...

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