Doosan DP180LBS Manuals

Manuals and User Guides for Doosan DP180LBS. We have 2 Doosan DP180LBS manuals available for free PDF download: Operation & Maintenance Manual

Doosan DP180LBS Operation & Maintenance Manual (262 pages)

DIESEL GENERATOR ENGINE

Brand: Doosan | Category: Engine | Size: 29.36 MB

Table of Contents

4
- 1 General Introduction
  7
  - General Information
    9
  - Danger, Warning, Caution, and Note
    10
    
    General Information
    10
    
    General Instructions
    10
    
    Precautions in Starting the Engine
    11
    
    Cautions for Inspection and Repair
    11
    
    General Repair
    12
    
    Other Safety Instructions and Environmental Pollution
    12
    
    Use of Genuine Parts
    13
  - Engine Maintenance
    14
    
    Prevention of Damage and Abrasion
    14
    
    Prevention of Pollution
    14
    
    Handling of Engine Oil
    14
2. Operation and Maintenance

15
- 2 Operation and Maintenance
  
  15
- Starting and Stopping of the Engine
  
  17
  - Preparing for Start
    17
  - Starting the Engine
    17
  - Running in
    17
  - During Operation
    17
  - Stopping the Engine
    18
- Break-In Period of the Engine
  
  19
  - General Information
    19
  - Break-In Period of a New Engine
    19
  - Check Points
    19
  - Cold Start Operation
    19
  - Inspection after Starting the Engine
    19
- Operation in Winter
  
  21
  - Cold Start
    21
  - Preventing Coolant from Freezing
    21
  - Preventing over Cooling of the Engine
    21
  - Engine Oil
    21
- Inspection and Repair of the Engine
  
  22
  - Checking Engine Parts after Prolonged Operation
    22
  - Inspection and Repair of Turbocharger
    22
  - Intake System
    22
  - Exhaust System
    22
  - Lubrication System
    22
3. Performance and Specifications

23
- 3 Performance and Specifications
  
  23
- Engine Specifications and Performance
  
  25
  - Engine Specifications
    25
  - Gross Engine Output
    34
- Exterior View Drawing of the Engine
  
  35
  - Front/Rear(Dp158L)
    35
  - Left/Right(Dp158L)
    36
  - Top(Dp158L)
    37
  - Front/Rear(Dp180L)
    38
  - Left/Right(Dp180L)
    39
  - Top(Dp180L)
    40
  - Front/Rear(Dp222L)
    41
  - Left/Right(Dp222L)
    42
  - Top(Dp222L)
    43
- Engine Identification Number
  
  44
  - Engine Code and Manufacturing Number
    44
  - Engine Number Engraving
    44
4. Regular Inspection

45
- 4 Regular Inspection
  
  45
- General Information
  
  47
  - Routine Inspection
    47
- Regular Inspection Table
  
  48
  - General Conditions
    48
  - Use of Genuine Parts
    49
- Cooling System
  
  50
  - General Information
    50
  - Coolant Standards
    50
  - Capacity of Coolant
    50
  - Checking the Coolant
    50
  - Measurement of Coolant Concentration
    51
  - Discharging the Coolant
    51
  - Charging the Coolant
    52
  - Cleaning the Cooling Circuit
    53
  - Inter Cooler
    53
- Lubrication System
  
  55
  - General Information
    55
  - Engine Oil Standards
    55
  - Engine Oil Capacity
    56
  - Checking the Engine Oil
    56
  - Replacement of Engine Oil
    57
  - Replacement of Engine Filter
    57
- Fuel System
  
  58
  - General Information
    58
  - Fuel Standards
    58
  - Water Draining from Fuel Filter
    59
  - Replacing Fuel Filter
    59
  - Preventing Fuel Contamination
    60
  - Fuel Injection Pump
    60
  - Cleaning the Fuel Pre-Filter
    60
  - Air Bleeding in the Fuel Circuit
    61
  - Injector Maintenance
    61
  - Fuel Injection Nozzle
    61
  - Removal of Nozzle
    62
  - Installation Nozzle
    63
  - Note for Cleaning Nozzle
    63
  - Checking the Injection Timing
    63
  - Adjusting Injection Timing
    64
- Intake/Exhaust System
  
  65
  - General Information
    65
  - Air Filter
    65
  - Disassembly of Air Filter
    65
  - Cleaning of the Air Filter Element
    66
  - Changing the Air Filter Element
    67
  - Turbocharger
    67
  - Routine Check and Serving the Turbocharger
    67
  - Disassembly and Cleaning a Turbocharger
    67
- Cylinder Block/Head
  
  68
  - Valve Clearance
    68
  - Adjusting the Valve Clearance
    68
  - Tightening Cylinder Head Bolt
    69
  - Cylinder Compression Pressure
    70
- Electric System
  
  71
  - Battery
    71
  - Starter
    71
- Others/Driving System
  
  72
  - V-Belt
    72
5. about the Engine

75
- 5 About the Engine
  
  75
- Marking System of Units
  
  77
  - Unit Conversion Methods
    77
- Tightening Torque
  
  78
- Engine Disassembly
  
  82
  - Procedure of Disassembling an Engine
    82
- Engine Assembly
  
  95
  - Procedure of Assembling Engine
    95
6. Cooling System

113
- 6 Cooling System
  113
  - General Information
    115
    
    Specifications
    116
    
    Failure Diagnosis
    118
  - Thermostat
    119
    
    General Information
    119
    
    Check of the Thermostat
    119
7. Lubrication System

121
- General Information
  123
  - Specifications
    124
  - Failure Diagnosis
    126
- Lubrication System
  123
8. Fuel System

127
- General Information
  129
  - High Sulfur Content in Diesel Fuel
    129
  - Water (Moisture) in Diesel Fuel
    130
  - Specifications
    130
  - Failure Diagnosis
    132
- Fuel Injection Pump
  133
  - General Information
    133
  - Adjustment Fuel Injection Pump
    134
9. Intake/Exhaust System

141
- General Information
  
  143
  - Specifications
    144
- Intake/Exhaust System
  
  143
- General Information
  
  145
  - Construction
    145
  - Function
    146
  - Failure Diagnosis
    147
  - How to Maintain Turbocharger
    151
  - Special Inspection of Turbocharger
    152
10. Cylinder Block/Head

155
- General Information
  
  157
  - Specifications
    157
- 10. Cylinder Block/Head
  
  157
- Cylinder Block
  
  159
  - Check of Cylinder Block
    159
  - Measurement of Cylinder Liner
    159
- Cylinder Head
  
  160
  - Measurement of Cylinder Liner
    160
  - Assembly of Cylinder Head
    160
  - Check of Cylinder Head
    161
- Valve
  
  162
  - General Information
    162
  - Check of Valve
    162
  - Check of Valve Guide
    162
  - Valve Seat
    163
  - Valve Spring
    163
- Rocker Arm
  
  165
  - Disassembly Rocker Arm
    165
  - Check of Rocker Arm
    165
  - Assembly Rocker Arm
    165
- Tappet and Push Rod
  
  166
  - Tappet Clearance
    166
  - Visual Inspection of Tappet
    166
  - Warpage of Push Rod
    166
- Camshaft
  
  167
  - Camshaft End Play
    167
  - Check and Measurement of Camshaft
    167
  - Check of Camshaft
    168
11. Electric System

171
- General Information
  
  173
  - Specification
    173
  - Electrical Wiring Diagram
    174
- Switches and Sensors
  
  175
  - Temperature Switch
    175
  - Temperature Sensor
    175
  - Pressure Sensor & Switch
    175
  - Magnetic Pick-Up
    176
- Starter
  
  177
  - General Information
    177
  - Specification
    177
  - Views
    178
  - Wiring Diagram
    179
  - Resistance
    179
- Alternator
  
  180
  - General Information
    180
  - Views
    180
  - Wiring Diagram
    181
  - Specification
    181
  - Performance
    181
  - Abnormally Charging
    182
  - Air Heater
    183
12. Others/Driving System

185
- General Information
  
  187
- 12. Others/Driving System
  
  187
- Crankshaft
  
  188
  - Measurement of Crankshaft
    188
  - Measurement of Crankshaft Bearing and Connecting Rod Bearing
    189
- Piston
  
  191
  - Disassembly of Piston
    191
  - Assembly of Piston
    191
  - Piston Inspection
    191
  - Piston Ring and Ring Groove
    192
  - Piston Pin
    192
- Connecting Rod
  
  194
  - Inspecting the Connecting Rod
    194
- Others
  
  195
  - Engine Timing
    195

Doosan DP180LBS Operation & Maintenance Manual (160 pages)

GENERATOR DIESEL ENGINE

Brand: Doosan | Category: Engine | Size: 25.19 MB

4. Regular Inspection

10
- Type
  2
- Type
  3
- Type
  4
- Table of Contents
  10
- General Information
  
  12
  - Routine Inspection
    12
- Regular Inspection Table
  
  13
  - General Conditions
    13
  - Use of Genuine Parts
    14
- Cooling System
  
  15
  - General Information
    15
  - Coolant Standards
    15
  - Capacity of Coolant
    15
  - Checking the Coolant
    15
  - Type
    15
  - Measurement of Coolant Concentration
    16
  - Discharging the Coolant
    17
  - Charging the Coolant
    18
  - Cleaning the Cooling Circuit
    18
  - Inter Cooler
    19
- Lubrication System
  
  20
  - General Information
    20
  - Engine Oil Standards
    20
  - Engine Oil Capacity
    21
  - Checking the Engine Oil
    21
  - Replacement of Engine Oil
    22
  - Replacement of Engine Filter
    22
- Fuel System
  
  23
  - Water Draining from Fuel Filter
    24
  - Replacing Fuel Filter
    24
  - Preventing Fuel Contamination
    25
  - Fuel Injection Pump
    25
  - Cleaning the Fuel Pre-Filter
    25
  - Air Bleeding in the Fuel Circuit
    26
  - Injector Maintenance
    26
  - Fuel Injection Nozzle
    26
  - Removal of Nozzle
    27
  - Installation Nozzle
    28
  - Note for Cleaning Nozzle
    28
  - Checking the Injection Timing
    28
  - Adjusting Injection Timing
    29
- Intake/Exhaust System
  
  30
  - General Information
    30
  - Air Filter
    30
  - Disassembly of Air Filter
    30
  - Cleaning of the Air Filter Element
    31
  - Changing the Air Filter Element
    32
  - Turbocharger
    32
  - Routine Check and Serving the Turbocharger
    32
  - Disassembly and Cleaning a Turbocharger
    32
- Cylinder Block/Head
  
  33
  - Valve Clearance
    33
  - Adjusting the Valve Clearance
    33
  - Tightening Cylinder Head Bolt
    34
  - Cylinder Compression Pressure
    35
- Electric System
  
  36
  - Battery
    36
  - Starter
    36
- Others/Driving System
  
  37
  - V-Belt
    37
5. about the Engine

39
- Marking System of Units
  
  40
  - Unit Conversion Methods
    40
  - About the Engine
    40
- Tightening Torque
  
  41
- Special Tool
  
  45
- Engine Disassembly
  
  49
  - Procedure of Disassembling an Engine
    49
- Engine Assembly
  
  62
  - Procedure of Assembling Engine
    62
6. Cooling System

82
- General Information
  83
  - Specifications
    83
  - Failure Diagnosis
    86
- Thermostat
  87
  - General Information
    87
  - Check of the Thermostat
    87
8. Fuel System

92
- General Information
  
  93
  - High Sulfur Content in Diesel Fuel
    93
  - Water (Moisture) in Diesel Fuel
    94
  - Specifications
    94
  - Failure Diagnosis
    95
- Fuel Injection Pump
  
  97
  - General Information
    97
- Actuator
  
  98
  - Actuator Component Parts Function
    98
- Controller System
  
  100
  - DGC-2013 Governor Controller System
    100
  - Description
    100
  - Mounting & Warning
    100
  - EMC (Electromagnetic Compatibility)
    101
  - Functions
    101
  - Adjustments
    101
  - External Wiring
    104
  - Magnetic Speed Sensor Connections
    105
  - Remote Speed Adjustment
    105
  - Droop Parallel Operation Mode (Manual Paralleling)
    106
  - Accessory Input (Automatic Paralleling)
    106
  - Controller LAMP Display (Diagnosis)
    106
  - System Troubleshooting (Instability)
    107
  - System Inoperative
    108
  - Adjustment Fuel Injection Pump
    109
9. Intake/Exhaust System

115
- General Information
  116
  - Specifications
    117
- General Information
  118
  - Construction
    118
  - Function
    119
  - Failure Diagnosis
    120
  - How to Maintain Turbocharger
    123
  - Special Inspection of Turbocharger
    124
10. Cylinder Block/Head

127
- General Information
  
  128
  - Specifications
    128
- Cylinder Block
  
  130
  - Check of Cylinder Block
    130
  - Measurement of Cylinder Liner
    130
- Cylinder Head
  
  131
  - Measurement of Cylinder Liner
    131
  - Assembly of Cylinder Head
    131
  - Check of Cylinder Head
    131
- Valve
  
  133
  - General Information
    133
  - Check of Valve
    133
  - Check of Valve Guide
    133
  - Valve Seat
    134
  - Valve Spring
    134
- Rocker Arm
  
  136
  - Disassembly Rocker Arm
    136
  - Assembly Rocker Arm
    136
  - Check of Rocker Arm
    136
- Tappet and Push Rod
  
  137
  - Tappet Clearance
    137
  - Visual Inspection of Tappet
    137
  - Warpage of Push Rod
    137
- Camshaft
  
  138
  - Camshaft End Play
    138
  - Check of Cam
    138
  - Check of Camshaft
    138
11. Electric System

140
- General Information
  
  141
  - Specification
    141
  - Electrical Wiring Diagram
    142
- Switches and Sensors
  
  143
  - Temperature Switch
    143
  - Temperature Sensor
    143
  - Pressure Sensor & Switch
    143
  - Magnetic Pick-Up
    144
- Starter
  
  145
  - General Information
    145
  - Specification
    145
  - Views
    146
  - Wiring Diagram
    147
  - Resistance
    147
- Alternator
  
  148
  - General Information
    148
  - Views
    148
  - Wiring Diagram
    149
  - Specification
    149
  - Performance
    149
  - Abnormally Charging
    149
12. Others/Driving System

151
- 12. Others/Driving System
  152
- General Information
  152
- Crankshaft
  153
  - Measurement of Crankshaft
    153
  - Measurement of Crankshaft Bearing and Connecting Rod Bearing
    154
- Piston
  156
  - Disassembly of Piston
    156
  - Assembly of Piston
    156
  - Piston Inspection
    156
  - Piston Ring and Ring Groove
    157
  - Piston Pin
    157
- Connecting Rod
  159
  - Inspecting the Connecting Rod
    159
- Others
  160
  - Engine Timing
    160

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Doosan DP180LBS Manuals

Doosan DP180LBS Operation & Maintenance Manual (262 pages)

Table of Contents

Table of Contents

2. Operation and Maintenance

2 Operation and Maintenance

Starting and Stopping of the Engine

Break-In Period of the Engine

Operation in Winter

Inspection and Repair of the Engine

3. Performance and Specifications

3 Performance and Specifications

Engine Specifications and Performance

Exterior View Drawing of the Engine

Engine Identification Number

4. Regular Inspection

4 Regular Inspection

General Information

Regular Inspection Table

Cooling System

Lubrication System

Fuel System

Intake/Exhaust System

Cylinder Block/Head

Electric System

Others/Driving System

5. about the Engine

5 About the Engine

Marking System of Units

Tightening Torque

Engine Disassembly

Engine Assembly

6. Cooling System

7. Lubrication System

8. Fuel System

9. Intake/Exhaust System

General Information

Intake/Exhaust System

General Information

10. Cylinder Block/Head

General Information

10. Cylinder Block/Head

Cylinder Block

Cylinder Head

Valve

Rocker Arm

Tappet and Push Rod

Camshaft

11. Electric System

General Information

Switches and Sensors

Starter

Alternator

12. Others/Driving System

General Information

12. Others/Driving System

Crankshaft

Piston

Connecting Rod

Others

Doosan DP180LBS Operation & Maintenance Manual (160 pages)

Table of Contents

4. Regular Inspection

General Information

Regular Inspection Table

Cooling System

Lubrication System

Fuel System

Intake/Exhaust System

Cylinder Block/Head

Electric System

Others/Driving System

5. about the Engine

Marking System of Units

Tightening Torque

Special Tool

Engine Disassembly

Engine Assembly

6. Cooling System

8. Fuel System