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Doosan DP158L Series, Руководство по эксплуатации и техническому обслуживанию

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10. Cylinder block/head

 160

Tappet and push rod

Tappet Clearance

Measure the outer diameter of a tappet and the inner diam-
eter of the tappet bore. If the reading exceeds the tolerance 
limit, replace the tappet.

Visual inspection of tappet

Inspection if the tappet surface which contacts 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 0.3mm

normal

abnormal

abnormal

abnormal

abnormal

(crack)

(irregularit

y

)

Feeler gauge

Содержание DP158L Series

Страница 1: ...950106 037009EN DP158L DP180L DP222L DIESEL GENERATOR ENGINE Operation Maintenance Manual...

Страница 2: ......

Страница 3: ...to continuously develop and invest The design of our product may be changed without prior notice and Doosan shall not be held liable for the failure of this manual to contain all the design changes m...

Страница 4: ...ions 17 Engine specifications and performance 19 Exterior view drawing of the engine 29 Engine identification number 38 4 Regular inspection 39 General information 41 Regular inspection table 42 Cooli...

Страница 5: ...information 139 10 Cylinder block head 149 General information 151 Cylinder block 153 Cylinder head 154 Valve 156 Rocker arm 159 Tappet and push rod 160 Camshaft 161 11 Electric system 165 General in...

Страница 6: ......

Страница 7: ...formation 4 General Instructions 4 Precautions in Starting the Engine 5 Cautions for Inspection and Repair 5 General Repair 6 Other Safety Instructions and Environmental Pollution 6 Use of Genuine Par...

Страница 8: ...2...

Страница 9: ...ined by the parts the list PARTS BOOK should be used Doosan shall not be held liable for any crit ical damage or faults which may be caused by the use of unauthorized or remanufactured parts The maint...

Страница 10: ...ling to do so may result in the death or serious bodily harm of workers or others CAUTION Workers must observe this instruction since failing to do so may cause critical faults which can have impact o...

Страница 11: ...of drinking coolant WARNING Immediately after stopping the engine or during driving be careful not to touch a part of turbocharger Otherwise it can cause you to severe burns due to a hot turbocharger...

Страница 12: ...perly 8 Group and store disassembled parts in disassembling order Due to the fact that bolts and nuts vary in strength shape and torque according to their assembly position Please divide and store the...

Страница 13: ...harmonized To prevent engine faults in advance and use engines with best performance for a long period mainte nance and replacement of expendable parts should be conducted regularly Use of genuine par...

Страница 14: ...scard oil and coolant according to the regulations of the relevant authorities 3 Be careful not to let discharged oil and cooling water flow into the ground or the sewer Otherwise serious pollution of...

Страница 15: ...reak in Period of a New Engine 13 Check Points 13 Cold Start Operation 13 Inspection after Starting the Engine 13 Operation in winter 15 Cold Start 15 Preventing Coolant from Freezing 15 Preventing Ov...

Страница 16: ...10...

Страница 17: ...white smoke Always have some load connected when the gen set is run for long periods Running in It is recommended that new or overhauled engines should not be operated at a load higher than about 75...

Страница 18: ...or or said connection with ground not even by briefly bringing the connections into contact 5 Do not operate th alternator without battery connection of the alternator with those of the regulator or s...

Страница 19: ...the oil level gauge If the oil level is normal check other related parts such as the oil pressure sensor oil pump or oil line 3 Check the coolant level to check if the coolant circulates properly If t...

Страница 20: ...4 3 If color or odor of exhaust gas is unusual during opera tion stop the engine diagnose the cause and fix the fault 4 Check the engine status through the alarm indicator lamp and gauges mounted on t...

Страница 21: ...for a long period during cold weather or in areas with cold climate fully discharge the coolant from the engine Freezing of coolant leads to critical damage to the engine Please use a mixture of cool...

Страница 22: ...lts As the following parts affect the engine output and perfor mance they should be regularly checked and inspected 1 Parts affecting intake and exhaust Air filter Inter cooler turbocharger silencer O...

Страница 23: ...Output 28 Exterior view drawing of the engine 29 Front Rear DP158L 29 Left Right DP158L 30 Top DP158L 31 Front Rear DP180L 32 Left Right DP180L 33 Top DP180L 34 Front Rear DP222L 35 Left Right DP222L...

Страница 24: ...18...

Страница 25: ...rder 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 o...

Страница 26: ...ecification Oil class CI 4 or higher SAE 10W 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 no...

Страница 27: ...0 05 Intake valve Opening 24 BTDC Close 36 ABDC Exhaust valve Opening 63 BBDC Close 27 ATDC Electrical System Alternator voltage capacity V A 27 5 45 Voltage regulator Built in type IC regulator Start...

Страница 28: ...weight kg 1 250 With fan Dimension L x W x H mm 1 592 x 1 389 x 1 223 With fan Flywheel housing SAE NO 1M Flywheel Clutch NO 14M No of teeth on flywheel 160 Cooling System Cooling method Fresh water f...

Страница 29: ...type Governor Electric type Fuel feed pump Type Mechanical type injection pump Capacity L hr 630 Injection nozzle Type Multi hole 4 hole Opening pres sure MPa 28 Fuel filter Full flow Cartridge type...

Страница 30: ...haust valve Opening 63 BBDC Close 27 ATDC 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 cap...

Страница 31: ...Dry weight kg 1 420 With fan Dimension L x W x H mm 1 738 X 1 389 X 1 258 With fan Flywheel housing SAE NO 1M Flywheel Clutch NO 14M No of teeth on flywheel 160 Cooling System Cooling method Fresh wa...

Страница 32: ...ction pump Bosch in line P type Governor Electric type Fuel feed pump Type Mechanical type injection pump Capacity L hr 630 Injection noz zle Type Multi hole type Opening pressure MPa 28 Fuel filter F...

Страница 33: ...24 BTDC Close 36 ABDC Exhaust valve Opening 63 BBDC Close 27 ATDC Electrical System Alternator voltage capacity V A 27 5 45 Voltage regulator Built in type IC regulator Starting motor voltage capacit...

Страница 34: ...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...

Страница 35: ...clude all models Front Rear DP158L DV2213001A 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...

Страница 36: ...8L 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 Manifo...

Страница 37: ...ance and specifications 31 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 Air Pipe 1 2 3...

Страница 38: ...Filter 6 Cooling Fan Pulley 11 Flywheel Housing 2 Coolant Pump 7 Idle Pulley 12 Flywheel 3 Alternator 8 Engine Oil Return Pipe 13 Oil Pan 4 Engine Oil Drain Plug 9 Turbocharger 14 Oil Filter 5 Cranks...

Страница 39: ...0L DV2213002B 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 Manifo...

Страница 40: ...ance and specifications 34 Top DP180L DV2213003B 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 Air Pipe 1 2 3...

Страница 41: ...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 Oi...

Страница 42: ...2L DV2213005A 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 Manifo...

Страница 43: ...ance and specifications 37 Top DP222L DV2213006A 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 Air Pipe 1 2 3...

Страница 44: ...e 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 assurance or to order parts DV22...

Страница 45: ...e cooling circuit 47 Inter cooler 47 Lubrication system 49 General Information 49 Engine oil standards 49 Engine Oil Capacity 50 Checking the Engine Oil 50 Replacement of Engine Oil 51 Replacement of...

Страница 46: ...Filter Element 60 Changing the air filter element 61 Turbocharger 61 Routine check and serving the turbocharger 61 Disassembly and cleaning a turbocharger 61 Cylinder block head 62 Valve Clearance 62...

Страница 47: ...ly 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 noi...

Страница 48: ...r Coolant System Check of coolant level V belt tension adjusting if necessary Check of coolant hose clamp Concentration of antifreeze solution Replace V belt Cleaning of water jacket and radiator Chan...

Страница 49: ...not be held liable 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...

Страница 50: ...ion 3 Periodically check coolant to maintain the concentration 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 c...

Страница 51: ...for anticorrosion is shown on the point where the color of MOLYBDATE Middle pad on the standard color table which is identical with the Middle B of the test sheet is crossed with the color of NITRITE...

Страница 52: ...diator 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 suffi ciently Mark and sep...

Страница 53: ...k if there is any leakage in the drain plug and coolant line If the coolant is insufficient replenish it Inter cooler The air cooler adopts an air cooling fan which has sufficient cooling capacity The...

Страница 54: ...05B 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 char...

Страница 55: ...allow the engine oil to flow 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 b...

Страница 56: ...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...

Страница 57: ...he oil filter head and cartridge contact thoroughly 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...

Страница 58: ...hur 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 m...

Страница 59: ...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 t...

Страница 60: ...hould 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 authorized personnel should handle it The a...

Страница 61: ...f 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 pres...

Страница 62: ...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...

Страница 63: ...est oil Hold the needle at the pintle end only to avoid corrosion do not touch the lapped surfaces of the needle with you fingers Thoroughly clean all other parts of the nozzle holder with clean fuel...

Страница 64: ...ump 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 d...

Страница 65: ...he 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...

Страница 66: ...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 el...

Страница 67: ...r should be carefully managed For a wet type air filter the intake resistance should be small as possible 2 Exhaust system For the exhaust system when exhaust gas leaks from the exhaust pipe or turboc...

Страница 68: ...e overlap when 1 cylinder is positioned at the compression TDC Top Dead center DV2213042A DV2213213A DV2213043A 2 Loosen the lock nut of the 1 cylinder rocker arm 3 Push the feeler gauge between a roc...

Страница 69: ...after a repair turn the cylinder head bolts by a further 90 1 4 revolu tion Valve overlap cylinder No 1 5 7 2 6 3 4 8 6 3 4 8 1 5 7 2 Adjusting valve cylinder No In Ex Valve Valve overlap cylinder No...

Страница 70: ...0532 in the fuel injection nozzle holder hole DV2213046A 4 Connect the compression pressure gauge to the adapter CAUTION The two outside screws intake and exhaust side must not be retightened The cyli...

Страница 71: ...inion 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 L...

Страница 72: ...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...

Страница 73: ...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 Loo...

Страница 74: ...4 Regular inspection 68...

Страница 75: ...tening torque 72 Tightening Torque of Main Parts 72 Tightening Torque of General Bolts 74 Tightening torque of plug screw 75 Hollow Screw 4 Hole Tightening Torque 75 Engine Disassembly 76 Procedure of...

Страница 76: ...70...

Страница 77: ...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 22...

Страница 78: ...T 4 35 0 35 Thermostat mounting spacer bolt M8 x 1 25 8 8T 2 2 0 22 Thermostat plug UNF 3 4 16 1 75 0 25 Oil pan drain plug UNF 3 4 16 3 0 3 Glow plug body M8 x 1 0 1 05 0 15 Glow plug terminal M4 x 0...

Страница 79: ...bolt M6 x 1 0 8 8T 0 85 0 15 Coolant temperature sensor M12 x 1 5 2 5 0 3 Boost Sensor M14 x 1 5 4 0 0 5 Exhaust temperature sensor M14 x 1 5 4 0 0 5 NOx sensor M20 x 1 5 5 0 1 0 Main Parts Screws Dia...

Страница 80: ...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 2 1 3 1 4 1 95 2 35 M8 0 7 0 75 1 1 1 1 4 1 25 1 9 2...

Страница 81: ...25 2 2 3 1 3 8 M8 x 1 2 4 3 35 4 1 M10 x 1 5 4 4 6 2 7 4 M10 x 1 0 5 7 8 4 M12 x 1 75 7 5 10 5 12 5 M12 x 1 5 8 11 2 13 4 M14 x 1 5 13 18 5 22 M10 M12 M14 M16 M18 M22 M24 M26 M30 5 0 5 0 8 0 8 0 10 0...

Страница 82: ...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...

Страница 83: ...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 de...

Страница 84: ...olts 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 bo...

Страница 85: ...13067A 1 Loosen the fixing bolts A 2 Loosen the hollow screw B 3 Remove the fuel pipes C 18 Remove the fuel pipe DV2213068A 1 Loosen the fixing nuts A 2 Loosen the fixing nuts B and C 3 Remove the fue...

Страница 86: ...l 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 22 Remove the intake manifold DV2213066A 1 Loosen the fixing bolts A...

Страница 87: ...nd 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 ji...

Страница 88: ...r is aligned with marking on the cylin drical 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 DV2213...

Страница 89: ...ipe 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 Remo...

Страница 90: ...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 cove...

Страница 91: ...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 fix...

Страница 92: ...g 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 l...

Страница 93: ...2 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 sam...

Страница 94: ...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 tappet D 5 Remove...

Страница 95: ...V2213094A 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 Tim...

Страница 96: ...en 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 t...

Страница 97: ...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...

Страница 98: ...g 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...

Страница 99: ...top dead center OT and the 6 cylinder piston may be posiitioned at the valve overlap Note In case of 8 12 cylinder engine 6 cylinder is posi tioned at the valve overlap when 1 cylinder is posi tioned...

Страница 100: ...r with the marking on the cylindrical surface 19 Attach the fuel injection pump DV2213072A 1 Attach the fuel injection pump B with the injection pump alignment jig EF 120 189 2 Tighten 6 fixing bolts...

Страница 101: ...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 EDV2218001 1 Attach the outer washer D 2...

Страница 102: ...method 4 Attach 12 cylinder head assembly as the same proce dure 24 Attach the push rods DV2213076A EDV2218002 1 Attach 24 push rods A 25 Attach the rocker arm assembly DV2213075A 1 Attach the rocker...

Страница 103: ...r may be posi tioned 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...

Страница 104: ...the cylinder head cover B 2 Tighten 3 fixing bolts A at a tightening torque 2 2kgf m 0 33kgf m 30 Attach the breather DV2213096A 1 Attach the breather B 2 Tighten the clamp 3 Attach the other breathe...

Страница 105: ...ghtening torque 1 2kgf m 0 14kgf m 33 Attach the fuel and oil hose DV2213070A 1 Attach the fuel and oil hose C 2 Tighten the hollow screw B at a tightening torque 1 8kgf m 0 27kgf m 3 Tighten the fixi...

Страница 106: ...e nuts A of the injector at a tightening torque 5 5kgf m 0 825kgf m 5 Tighten the fixing bolt A 37 Attach the inlet pipe DV2213063A 1 Attach the inlet pipe B 2 Tighten the fixing bolt A at a tightenin...

Страница 107: ...ighten the exhaust elbow bracket fixing bolts A at a tightening torque 20 0kgf m 1 5kgf m 4 Attach the other exhaust manifold and exhaust elbow assembly as the same procedure Note Tighten the fixing b...

Страница 108: ...ch the other inlet elbow as the same procedure 45 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 Appl...

Страница 109: ...the stud head bolts in the order from 1 8 50 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...

Страница 110: ...ach 3 thermostats as the same procedure 53 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...

Страница 111: ...ing 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 58 Attach th...

Страница 112: ...5 About the engine 106...

Страница 113: ...107 6 Cooling system General information 109 General Information 109 Specifications 110 Failure Diagnosis 112 Thermostat 113 General Information 113 Check of the thermostat 113...

Страница 114: ...108...

Страница 115: ...absorbed the oil and combustion heat flows into the water temperature controller through the coolant pipe If the coolant temperature is lower than the valve opening temperature of the water temperatur...

Страница 116: ...t Type Wax pellet type Opening temp C 71 Full open temp C 85 Cooling fan Type Blow Type Diameter blades 915mm 7 blades Item DP180L Remarks DP180LBS DP180LBF DP180LAS DP180LAF Cooling System Cooling me...

Страница 117: ...x 33 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 temperature C Max for stand by and prime 103 Before start of...

Страница 118: ...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 Loosene...

Страница 119: ...C 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...

Страница 120: ...6 Cooling system 114...

Страница 121: ...115 7 Lubrication system General information 117 General Information 117 Specifications 118 Failure Diagnosis 120...

Страница 122: ...116...

Страница 123: ...on pipe to the main path of the cylinder block through the oil cooler and oil filter From the cylinder block oil is delivered to the crankshaft bearings camshaft bearings and rocker arm for lubricatio...

Страница 124: ...Idle speed Min 100 Governed speed Min 250 Max oil temperature 120 Oil specification Oil class CI 4 or higher SAE 10W 40 Item DP180L Remarks DP180LBS DP180LBF DP180LAS DP180LAF Lubrication System Lubr...

Страница 125: ...method Fully forced pressure feed type Oil pump Type Gear type Driving type Driven by crankshaft gear Oil filter Full flow Cartridge type Oil capacity L Max 40 Min 27 Lubrication oil pressure kPa Idl...

Страница 126: ...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 ge...

Страница 127: ...mation 123 General Information 123 High Sulfur content in diesel fuel 123 Water Moisture in diesel fuel 124 Specifications 124 Failure Diagnosis 126 Fuel injection pump 127 General Information 127 Adj...

Страница 128: ...122...

Страница 129: ...ear and well fastened to avoid vibrations It is important that there are no fuel leakages or air infiltration neither on the suction or return line installation Therefore securely fasten all the conne...

Страница 130: ...LCF DP158LDS DP158LDF10 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 typ...

Страница 131: ...l System Injection pump Bosch in line P type Governor Electric type Fuel feed pump Type Mechanical type injection pump Capacity L hr 630 Injection noz zle Type Multi hole type Opening pres sure MPa 28...

Страница 132: ...or replace Air bleeding Disassemble correct Replace breather 3 Insufficient engine power Excessively work plunger Improper injection timing Defective delivery valve Excessive fuel leakage in injectio...

Страница 133: ...rankshaft gear It is connected to the forced lubrication system so separate connection is not required The governor of electric fuel injection pump is consist of the actuator that is operated by the s...

Страница 134: ...08 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 injection pump Nozzle Holder Ass y 1688 901 019 Opening pressu...

Страница 135: ...g 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 injection pump Nozzle Holder Ass y 1688 901 019 Opening pressure 210 bar Injec...

Страница 136: ...0400 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 injection pump Nozzle Holder Ass y 1688 901 015 Opening press...

Страница 137: ...00400 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 injection pump Nozzle Holder Ass y 1688 901 019 Opening pre...

Страница 138: ...Firing 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 injection pump Nozzle Holder Ass y 1688 901 019 Opening press...

Страница 139: ...Firing 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 injection pump Nozzle Holder Ass y 1688 901 019 Opening press...

Страница 140: ...8 Fuel system 134...

Страница 141: ...system General information 137 General Information 137 Specifications 138 General information 139 Construction 139 Function 140 Failure Diagnosis 141 How to Maintain Turbocharger 145 Special inspectio...

Страница 142: ...136...

Страница 143: ...pplied 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 deter mined by the size of cylinder If com...

Страница 144: ...Intake Exhaust System Max back pressure kPa 5 9 Max intake air restriction kPa With clean filter element 2 16 With dirty filter element 6 23 Item DP222L Remarks DP222LAS DP222LBS DP222LBF DP222LCS DP...

Страница 145: ...ng 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 3...

Страница 146: ...ngement 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 t...

Страница 147: ...the 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 ma...

Страница 148: ...mount Check the turbo impeller and the turbo intake outlet Large gap of the turbocharger wheel causing interfer ence with the wall Check if there is any sand or metallic foreign substance Damaged turb...

Страница 149: ...lic foreign 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 th...

Страница 150: ...tance Damaged wheel and shaft of the turbocharger Check if there is any sand or metallic foreign substance Poor rotating force of the turbocharger wheel Check if there is any sand or metallic foreign...

Страница 151: ...ts 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 rotate...

Страница 152: ...er housing and slowly raise the RPM If high pitched sound continues it means that the state is abnormal In this case the bearing or the rotor assembly may be abnormal So you need to replace or repair...

Страница 153: ..._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 si...

Страница 154: ...9 Intake exhaust system 148...

Страница 155: ...ylinder Head 154 Check of Cylinder Head 155 Valve 156 General Information 156 Check of Valve 156 Check of Valve Guide 156 Valve Seat 157 Valve Spring 157 Rocker arm 159 Disassembly Rocker Arm 159 Chec...

Страница 156: ...150...

Страница 157: ...8LCS 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 0 05 Exhaust 0 35 0 05 Intak...

Страница 158: ...LBF 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 0 05 Exhaust 0 35 0 05 Intake valve Open...

Страница 159: ...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 min...

Страница 160: ...d then attach the stem seal to the valve guide of the cylinder head with the special tool 4 Attach the valve spring washer to valve guide 5 Put in the valve spring and then attach the valve spring pla...

Страница 161: ...ed with the naked eye perform the hydrostatic test or the magnetic particle testing Note Hydraulic test is same as for cylinder block 2 Distortion at the lower face DV2213115A DV2213116A 1 Measure the...

Страница 162: ...66 Check of Valve Guide 1 Inser the valve into valve guide and measure the clear ance between valve and valve guide by the shaking degree of valve If the clearance is bigger measure the valve and then...

Страница 163: ...cient 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 wit...

Страница 164: ...square If the reading exceeds the tolerance limit replace 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...

Страница 165: ...27A_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 repl...

Страница 166: ...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 o...

Страница 167: ...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 3 Cam bearing d...

Страница 168: ...mshaft bearing DV2213133A 2 Camshaft bearing inner diameter of cylinder block Using a cylinder inner gauge measure the inner diameter of the camshaft bearing DV2213134A_E 3 Clearance between camshaft...

Страница 169: ...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...

Страница 170: ...10 Cylinder block head 164...

Страница 171: ...ature Switch 169 Temperature Sensor 169 Pressure Sensor Switch 169 Magnetic Pick up 170 Starter 171 General Information 171 Specification 171 Views 172 Wiring Diagram 173 Resistance 173 Alternator 174...

Страница 172: ...166...

Страница 173: ...nded 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...

Страница 174: ...A 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 te...

Страница 175: ...re 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 10M Temp...

Страница 176: ...stance 1 8k 15 4 Inductance 3 1H 25 5 Insulation Resistance 10M or more at 500V DC 6 Resistance B Y 350 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 Revoluti...

Страница 177: ...ter 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 el...

Страница 178: ...11 Electric system 172 Views DV2213139A Ground Terminal M10X1 5 Switch Terminal Relay M5X0 8 Battery Terminal M10X1 25 Solenoid Relay Motor Switch Terminal Solenoid M Terminal...

Страница 179: ...73 Wiring Diagram DV2213140A Resistance Battery Terminal Relay Solenoid Motor M Ground Terminal Switch Terminal M Terminal Item Spec Relay Switch Terminal Relay Case 23 5k 2 35 Solenoid Switch Termina...

Страница 180: ...alternator voltage The alternator should 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 n...

Страница 181: ...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...

Страница 182: ...eration 2 During Stop 2 Check of a voltage regulators Mearsuring the resistance between the terminals 1 The resistance value between the voltage regulators Position Voltage Terminal B Body About DC27V...

Страница 183: ...use the air heater when the cooling water temperature is below 5 degrees Air heater Timer Relay is supplied and the heater oper ation time is automatically adjusted according to the cooling water tem...

Страница 184: ...11 Electric system 178 3 Air heater Diagram 4 Air heater schematic EDX1217144 EDX1217146 Heater power can be connected directly to the battery as indicated by the dotted line Engine ground...

Страница 185: ...ment of Crankshaft 182 Measurement of Crankshaft Bearing and Connecting Rod Bearing 183 Piston 185 Disassembly of Piston 185 Assembly of Piston 185 Piston Inspection 185 Piston Ring and Ring Groove 18...

Страница 186: ...180...

Страница 187: ...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...

Страница 188: ...re 5 kinds as below and the crankshaft also can be used by regrinding as below Standard 0 10 Inside diameter 0 10 mm less than standard 0 25 Inside diameter 0 25 mm less than standard 0 50 Inside diam...

Страница 189: ...journal and pin and assemble under size bearing 3 Oil cleanrance between crankshaft and bearing Method 2 Plastic gauge 1 Assemble the crankshaft to the cylinder block 2 Place the plastic gauge on the...

Страница 190: ...nd play 1 Assemble the crankshaft in the cylinder block 2 Install the dial gauge and measure the end play of crank shaft by pushing the crankshaft to axial direction DV2213153A Item Standard Limit Axi...

Страница 191: ...lier 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 Pis...

Страница 192: ...mount 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...

Страница 193: ...12 Others driving system 187 DV2213161A Item Standard Clearance 0 010 0 022mm...

Страница 194: ...ng 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 St...

Страница 195: ...12 Others driving system 189 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...

Страница 196: ...12 Others driving system 190...

Страница 197: ...Governor Actuator Controller...

Страница 198: ......

Страница 199: ...reaches the set speed In terms of operating the vehicle the driver monitors the speedometer and if there is a desired speed this cor responds to the governor s speed input while the governor s output...

Страница 200: ...nt C 1 5 A 2 0 A Max operating current C 4 5 A 3 1 A Rack operating power C 58 7 N 27 5 N Rack operating range ASTM 20 mm 21 mm Engine injection pump specs Right rack type Right rack type Item GN11 DW...

Страница 201: ...the frame of the static core and the assem bly and then fixed in place with an epoxy resin 5 Moving core assembly A welded assembly composed of several layers of pure iron When the gover nor controll...

Страница 202: ...ith the 25 turn potentiometer This speed setting output value becomes the input value traveling to the dynamic control section With the help of this dynamic control circuit most of the engine and fuel...

Страница 203: ...es when terminals G and H are connected The engine speed controller includes functions for protecting the actuator and the engine as well as addi tional functions For example the controller circuit in...

Страница 204: ...Clockwise 1 200 Hz or less Idle Adjustment Counterclockwise 4 100 Hz or less Droop Range Adjustable between 1 5 Max Droop Adjustment With Terminals K L Connected Fluctuation of 875 75 Hz 1 0 A Min Dro...

Страница 205: ...Pick up BATTERY OPTIONAL ACTUATOR CABLE SHIELDING TO MEET CE DIRECTIVE ADD JUMPER FOR 12V BATTERY OR ACTUATOR CURRENTS ABOVE 5A AUX 10V POWER FUSE 15A MAX SPEED TRIM CONTROL 5K CLOSE FOR IDLE CLOSE FO...

Страница 206: ...UP BATTERY 6 00 152 6 05 165 6 00 152 5 25 133 O 0 27 7 1 A B C D E F G H J K L N P M CAUTION GA C 2 3 OVERSPEED OVERSPEED SPEED SPEED RAMPING GAIN DROOP STABILITY DEAD TIME COMPENSATION JUMPER RESET...

Страница 207: ...When rotated clockwise the engine rpm rises 7 Overspeed Adjusts the engine overspeed rpm When rotated clockwise the maximum rpm rises 8 Droop rpm Used when running the generator in parallel 9 Reset Us...

Страница 208: ...ls G and M To maintain the idle rpm after starting the engine 2 After starting the engine Once the engine is started move the actuator to the maximum fuel supply position then maintain the idle rpm af...

Страница 209: ...terminals M and G Turn the speed potentiometer counter clockwise to adjust the engine rpm But if excessive exhaust smoke is produced while accelerating the engine adjust the starting fuel potentiomet...

Страница 210: ...nal G is short circuited the engine speed controller may be damaged 10 Remote speed adjustment A speed adjustment potentiometer is required in order to continuously adjust the engine speed remotely ov...

Страница 211: ...e 3 Faulty wiring connection 2 C D 1 0V AC when starting the engine 1 Large gap between magnetic pick up sensor and ring gear Check gap 2 Faulty wiring in magnetic pick up sensor Check whether the res...

Страница 212: ...g device is restricted when the voltage exceeds 2 0V DC 3 When the voltage is less than 1 0V DC 1 There is a fault in the speed controller 4 The gain value is too low The actuator Is not working prope...

Страница 213: ...H J F E D C B A Battery Actuator Pick up Speed Trim N M L K Droop AUX P 10V Idle 6 5 4 3 2 1 OFF D1 D2 ON Crank Run Over speed Power Pick up Crank Run Over speed Test Starting Fuel Speed Ramping Idle...

Страница 214: ...ntroller due to unnecessary nearby electromagnetic waves either mount the controller on a grounded metal surface or use a shielded metal case All wires should be shielded and the shielded part should...

Страница 215: ...is not enough fuel which may cause faulty starting In the 5 o clock or higher direction fuel efficiency worsens during starting and the amount of exhaust gas may increase 2 Adjust the speed ramping po...

Страница 216: ...t be adjusted regardless of whether or not idle mode is used 6 Adjusting the Governor Characteristics 1 After disconnecting the G M terminal initial speed switch OFF adjust it when the engine reaches...

Страница 217: ...until the engine overspeed lamp turns on and the engine shuts off It will be set to a speed around 15 higher than the engine operating speed IMPORTANT After all adjustments are complete restart the e...

Страница 218: ...lem is not resolved There may be a problem with the controller hardware so replace the controller 9 8 ON OFF 5 OFF ON 4 5 6 7 1 5 2C 1 5 2C 10 1 2 3 Idle Droop G H J F E D C B A N M L K AUX P 10V OFF...

Страница 219: ...em be sure to check whether the voltage between the terminals is DC 24V 4 V Also ground terminal E to the frame Wiring connection no 10 4 Connect a 5 kW resistor externally as shown in the picture to...

Страница 220: ...engine speed remotely and externally within a certain speed range Refer to the chart to set the resistance value accord ing to the required speed range 2 When the engine speed is set to the minimum s...

Страница 221: ...peed Ramping Facing 9 o clock Droop Full CCW Minimum E M Speed Adjustment 160 gear teeth Speed Adjustment 4 000 Hz 1 500 rpm Idle Adjustment 2 133 Hz 800 rpm 300611 00684 Overspeed 1 725 rpm based on...

Страница 222: ...ck Droop Full Full CCW Minimum E M Speed Adjustment 152 gear teeth Speed Adjustment 3 800 Hz 1 500 rpm Idle Adjustment 2 026 Hz 800 rpm 300611 00686 Overspeed 2 070 rpm based on 160 gear teeth Run lam...

Страница 223: ...erminal N receives signals from the load sharing unit auto synchronizer or other accessories in the governor system Use shielded wires when connecting wiring The engine speed drops when an accessory i...

Страница 224: ...h measures readjust the gain and stability again in order to optimize the system This will help to reduce and eliminate instability 2 Instability at slow intervals hunting The main factors involved in...

Страница 225: ...stopped 300 1 200 using test ohm meter Defective speed sensor Damaged or incorrectly connected speed sensor wiring Check sensor line Replace speed sen sor 4 C D E G starting 1 5V or higher when measu...

Страница 226: ...a black box function that manages engine operation records when faults are detected for users to have more convenience in operating this precise digital speed controller Product features Rigid and sta...

Страница 227: ...of the front side for easy connection to external devices Over speed run and crank signals are displayed on the front LED and contact points a or b are also available for outputs on external controlle...

Страница 228: ...cation RS232 57600 bps CAN J1939 250 kbps 8 Rated Power DC 24V 12V 30V 9 Current Consumption 120 mA 10 Operating Temperature 20 70 C 11 Storing Temperature 30 80 C 12 Operating Humidity 0 95 3 2 D SUB...

Страница 229: ...Terminal D should be connected to the ground in connection with the shield cable Gap between the RPM sensor and the gear tooth should be adjusted between 0 9 and 1 1 mm sensor inputs should be at leas...

Страница 230: ...oint is a shared terminal while ter minals 7 and 8 are for the contact point b and terminals 8 and 9 for the contact point a The contact point a starts to operate when the engine reaches its designate...

Страница 231: ...33 6 Product dimension 170 130 140 153 165 6 19 4 6 EDL11160004...

Страница 232: ...external devices using crank run and over speed functions RS232 and CAN port allow communication with PCs or external host computers for data transfer and monitoring functions 1 Connecting to the engi...

Страница 233: ...up sensor and the gear tooth should be adjusted between 0 9 and 1 1 mm 5 Operating sequence for digital speed controller Power On Off It means that DC 24V power is either supplied or terminated throug...

Страница 234: ...s G H and J Terminal G should be connected to the ground and it is recommended to use shielded cables Terminal H is connected to G depending on the current consumption of the actuator for actuators wi...

Страница 235: ...e idle function Inputs can be done by toggle or converting switches 5 Connecting to aux AUX is a terminal for control signal inputs from load sharing devices or synchronization devices through termina...

Страница 236: ...crank output contact point and the contact point will be in opera tion when the controller activates the crank function The second crank contact point is a shared termi nal while terminals 1 and 2 ar...

Страница 237: ...ontroller activates the over speed function The eighth over speed contact point is a shared terminal while terminals 7 and 8 are for the contact point b and terminals 8 and 9 for the contact point a C...

Страница 238: ...d Right Each key as respective functions as follows LCD LCD key turns on and off the display Mode Mode key switches the display to either operation mode or wave form display Menu Menu key lets users c...

Страница 239: ...CD Menu Tree Diagram EDL11160049 Overall LCD Menu Tree Diagram Logo Display RPM Display Main Display Menu Display MENU MENU UP LEFT RIGHT DOWN MENU MENU MODE MENU Low Battery RPM Display Main Display...

Страница 240: ...s tem errors occur the LCD display will show such errors and processing messages Step 1 DC 24V power supply to the terminals E and F When DC 24V power is supplied to the terminals E and F the controll...

Страница 241: ...he engine PID control Date Time setup It offers function for users to move to the screen for designating year month day and hour Alarm list It offers function for users to move to the alarm display fo...

Страница 242: ...s for STARTING FUEL SPEED RAMPING ACTUA TOR MAX LOW BATTERY Set run rpm Users can designate normal speed target RPM of the engine Users need to input different normal speed values depending on the spe...

Страница 243: ...es of speed changes when the speed increases or decreases in the idle condition of the engine Max current Users can designate the maximum operating current for the actuator of the engine Low battery I...

Страница 244: ...setting with YES or NO option If you select YES the controller will repeatedly change the RPM to automatically calculate the optimized P I and D values If the controller identifies the optimized P I a...

Страница 245: ...ler this menu offers the most common parameter setting values For default setup select YES and then press Enter button If you don t want to implement this function press No but ton If you press YES al...

Страница 246: ...rpm 60 Hz 102T 1 800 rpm 2 070 rpm 102 65 Optimal Value 5 DE08 1 500 rpm 50 Hz 140T 1 500 rpm 1 725 rpm 140 65 Optimal Value 6 DE08 1 800 rpm 60 Hz 140T 1 800 rpm 2 070 rpm 140 65 Optimal Value 7 DE0...

Страница 247: ...ain setting items of the controller includes GEAR NUMBER CRANKING RPM and SET RUN RPM You need to designate setting values to these items Other system setup items are optional and there fore you can d...

Страница 248: ...o increase or decrease the idle operating speed of the engine and then press Enter button Configuring set over speed Step 1 Press Menu button of the controller and then you can see DRIVE UNIT MENU Ste...

Страница 249: ...alues at which the controller starts to con trol the actuator when the engine starts to operate and then press Enter button Configuring gear number Step 1 Press Menu button of the controller and then...

Страница 250: ...nt of fuel sprayed when the engine starts and then press Enter button Configuring speed ramping Step 1 Press Menu button of the controller and then you can see DRIVE UNIT MENU Step 2 Select System set...

Страница 251: ...rease the limit of the maximum current con sumption of the actuator and then press Enter button Max 10 A Configuring low battery Step 1 Press Menu button of the controller and then you can see DRIVE U...

Страница 252: ...n press Enter button Droop Function Droop function is indicated in percentages as follows RPM with no load is subtracted by RPM with maximum load and then divided by RPM with no load Example for 3 dro...

Страница 253: ...DRIVE UNIT MENU Step 2 Select System setup menu in DRIVE UNIT MENU using Up Down Left and Right buttons and then press Enter button Step 3 Select F LOAD CURR in SYSTEM SETUP menu and then press Enter...

Страница 254: ...ns to input the operating current values of the actuator for the generator with no load and then press Enter button 3 PID gain setup configuration Configuring PID gain Kp Ki and Kd values Step 1 Press...

Страница 255: ...1 Select your type in Engine Type menu and then start the engine with the preset configuration values maintaining it with no load Step 2 During the normal operation press Menu button of the controller...

Страница 256: ...mal operation window and the auto tuned values will apply to the normal operation that will be continued Step 6 If auto tuning failed to identify optimized P I and D values within 4 to 6 minutes the s...

Страница 257: ...more than 5 seconds LCD alarm message Error LED lamp E03 Pick up Error Problems in sensor signals when the engine starts Engine RPM lower than 600 LCD alarm message Error LED lamp E04 Pick up Error P...

Страница 258: ...and Right buttons to select either YES or NO in System Message and then press Enter button Default setup will change the configuration values of the engine to the default values In order to initi ate...

Страница 259: ...for adjustment and then press Enter button Use Up and Down buttons to input set ting values and then press Enter button 11 System monitor Functions Step 1 Press Menu button of the controller and then...

Страница 260: ...attery Fault message you need to charge the battery or replace it with the one having normal voltage before starting the controller Step 2 Configure parameter values required for selection of the engi...

Страница 261: ...up Error Problems in sensor sig nals when the engine starts Engine RPM lower than 600 Alarm message pop up on LCD Check the RPM sensor and connecting circuits Error LED on Replace the RPM sensor Actu...

Страница 262: ...oller and contact our A S center for service request Step 3 Check whether the power LED turns on or not after supplying power to DC 24V input terminals E F of the battery If the LED does not turn on c...

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