Doosan DP158LCF Operation & Maintenance Manual
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Doosan DP158LCF Operation & Maintenance Manual

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Operation &
Maintenance Manual
GENERATOR DIESEL ENGINE
DP158LCF/LCS/LDF/LDS
DP180LBS/LAS/LBF/LAF
DP222LAS/LBF/LBS/LCF/LCS
Doosan lnfracore
950106-01352

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Summary of Contents for Doosan DP158LCF

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

  • Page 2: Type

    3. Performance and specifications Engine specifications and performance Engine Specifications DP158L Item Remarks DP158LCS DP158LCF DP158LDS DP158LDF10 General Information Water-cooled, 4cycle, V-type, Turbo charger & inter cooled (air to Engine types air) Cylinder liner type Wet type liner No. of cylinder - bore x stroke...

  • Page 3: Type

    3. Performance and specifications DP158L Item Remarks DP158LCS DP158LCF DP158LDS DP158LDF10 Type Blow Type Cooling fan Diameter - 915mm - 7 blades blades Lubrication System Lubrication method Fully forced pressure feed type Type Gear type Oil pump Driving type Driven by crankshaft gear...

  • Page 4: Type

    3. Performance and specifications DP158L Item Remarks DP158LCS DP158LCF DP158LDS DP158LDF10 Intake No. of valve (per cylinder) Exhaust Intake 0.25 Valve lashes (at cold) (mm) Exhaust 0.35 Opening 24° (BTDC) Intake valve (°) Close 36° (ABDC) Opening 63° (BBDC) Exhaust valve (°)
  • Page 5 3. Performance and specifications Gross Engine Output Performance Engine Model Prime Stand by Remark 60Hz DP158LCS (1,800rpm) 50Hz DP158LCF (1,500rpm) DP158L 60Hz DP158LDS (1,800rpm) 50Hz DP158LDF (1,500rpm) 60Hz DP180LBS (1,800rpm) 60Hz DP180LAS (1,800rpm) 180L 50Hz DP180LBF (1,500rpm) 50Hz DP180LAF (1,500rpm)
  • Page 6 3. Performance and specifications Exterior view drawing of the engine 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.
  • Page 7 3. Performance and specifications Left/Right(DP158L) 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.
  • Page 8 3. Performance and specifications Top(DP158L) DV2213003A 1. Injector 4. Fuel Injection Pump 7. Oil Filler Cap 2. Fuel Injection Pipe 5. Intake Manifold 8. Inlet Pipe 3. Fuel Pre-Filter/Priming Pump 6. Intake Stake http://www.brizmotors.ru/equipment/ctm/400/...
  • Page 9 3. Performance and specifications Engine identification number Engine Code and Manufacturing Number • Type 4 The engine code and manufacturing number are engraved in the position marked (A) in the drawing. These numbers are necessary to request quality assur- ance or to order parts. •...

  • Page 10: Table Of Contents

    4. Regular inspection General information ............43 General Information .
  • Page 11 Disassembly of air filter ..........61 Cleaning of the Air Filter Element .

  • Page 12: General Information

    4. Regular inspection General information General Information CAUTION As time passes after purchasing an engine, each of the engines parts age and initial engine performance cannot • Incorrect inspection methods may cause of be maintained. engine faults. Regular inspection and replacement according to the •...

  • Page 13: Regular Inspection Table

    4. Regular inspection Regular inspection table General Conditions Regular inspection and replacement according to the recommended regular inspection table allows you to maintain the engine with optimum conditionsand best performance for a long period and prevent unexpected accidents in advance. ( ○...

  • Page 14: Use Of Genuine Parts

    Use of genuine parts is recommended. Using unautho- rized or remanufactured parts may cause critical damage and faults to engine for which Doosan shall not be held liable.

  • Page 15: Cooling System

    4. Regular inspection Cooling system General Information Coolant capacity ( ℓ ) Engine Mode The coolant should be replaced according to the cycle Inside engine With radiator specified in the inspection interval table. If the coolant gets dirty, the engine is overheated, and the coolant over- About 91 flows in the thermal expansion tank.

  • Page 16: Measurement Of Coolant Concentration

    4. Regular inspection Measurement of Coolant Concentration 1) Compare the color of part A on the test sheet to the color of GLYCOL/FREEZEPOINT (End pad) of the • Special Tools standard color table. Figure Product Number/Name 2) Compare the color of the test sheet (B) to the color of MOLYBDATE (Middle pad) of the standard color table.

  • Page 17: Discharging The Coolant

    4. Regular inspection 3) If the measurement result is below 0.3, replenish anti- 3. Loosen the drain valve which is located under the corrosion additives (DCA4). If it is above 0.8 or, drain radiator to discharge the coolant. a little coolant and then add clean tap water to adjust the concentration.

  • Page 18: Charging The Coolant

    4. Regular inspection Charging the Coolant WARNING 1. Make sure that engine is coolant. 2. Open the radiator cap. Discard exchanged coolant according to the regula- tions set forth by the relevant authorities. Disposing DANGER of exchanged coolant into the ground, sewers, drains, rivers, or the sea will cause serious environ- •...

  • Page 19: Inter Cooler

    4. Regular inspection Inter cooler The air cooler adopts an air cooling fan, which has suffi- cient cooling capacity. The life and performance of an air cooler greatly depends on the intake air conditions. Dirty air may contaminate and clog the cooling pins. This results in reduced engine power or engine failure.

  • Page 20: Lubrication System

    Engine Model and Product Code SAE Classification Oil Class DP 158L SAE 15W40 API CD or above DP180L SAE 15W40 API CD or above DP 222L SAE 15W40 API CD or above Note) Use of Doosan genuine engine oil is recommended.

  • Page 21: Engine Oil Capacity

    4. Regular inspection Engine Oil Capacity 3. Insert the oil level gauge, and then pull it out to check the engine oil level, viscosity, and contamination. Please replenish the engine oil based on the following Replenish or replace the engine oil if required. recommended oil amount.

  • Page 22: Replacement Of Engine Oil

    When replacing the oil filter cartridge, be sure to use circulate through the lubrication system. the genuine part of Doosan. 7. Then, stop the engine, wait for about 10 minutes, check the oil level, and fill the oil if required.

  • Page 23: Fuel System

    Doosan engine engine is designed to the fuel injection pump components may be seized. So, use diesel fuel available in the local market. If you want be sure to keep the fuel system clean all the time.

  • Page 24: Water Draining From Fuel Filter

    4. Regular inspection Water draining from fuel filter Replacing fuel filter An oil filter has two functions: oil filtering and water sepa- ration. 1. the water separation function of the fuel filter discharges water and sediment from the water separator. 2.

  • Page 25: Preventing Fuel Contamination

    4. Regular inspection 9. Turn it by 3/4 to 1 turn with a fuel filter wrench. • The adjustment and test of the fuel injection pump must be conducted using a tester. CAUTION If you separate the parts where the seal ring (copper seal ring, rubber coating seal ring, etc.) is assem- bled, you should replace the seal ring with a new one.

  • Page 26: Air Bleeding In The Fuel Circuit

    4. Regular inspection Air bleeding in the fuel circuit When the engine stops due to replacement of fuel filter, fuel injection pump or insufficient fuel, you should perform air bleeding. 1. Loosen the air bleeding plug (B) on the fuel filter. 2.

  • Page 27: Removal Of Nozzle

    (Mpa) 2. Remove fuel return pipe. DP158LCS 3. loosen the Union screw(A) of nozzle holder with Nozzle plug socket (EI.03004-0225) DP158LCF DP158L 4. Remove nozzle holder with sealing from the cylinder DP158LDS head. DP158LDF Nozzle plug socket...

  • Page 28: Installation Nozzle

    4. Regular inspection Installation nozzle • Before reassembly thoroughly wash nozzle body and needle in clean test oil. 1. Clean seat in cylinder head. • Hold the needle at the pintle end only ; to avoid corro- 2. Insert nozzle holder with new gasket. sion do not touch the lapped surfaces of the needle 3.

  • Page 29: Adjusting Injection Timing

    23° ± 1° DP158LCS flywheel housing sight hole is aligned with the injection timing degree of the engine. 18° ± 1° DP158LCF 3. Coincide the mark on pointer provided in injection DP158L 23° ± 1° DP158LDS pump with the matching mark(FB) on the flange surface of the drive gear by turning the flange in the 18°...

  • Page 30: Intake/Exhaust System

    4. Regular inspection Intake/exhaust system General Information Disassembly of air filter The air filter purifies dust and foreign substances included in the air and supplies clean air into the engine. The air DANGER filter is directly related to engine lifetime, emissions, and engine output.

  • Page 31: Cleaning Of The Air Filter Element

    4. Regular inspection Cleaning of the Air Filter Element 2) Soak the element in the warm cleaning solvent for 10 minutes and then shake it back and forth for about 5 Clean the air filter element by using the most suitable minutes.

  • Page 32: Changing The Air Filter Element

    4. Regular inspection Changing the air filter element 1. Intake system For the intake system, the air filter should be carefully 1. Remove the hex nut, remove the dirty element. managed. For a wet type air filter, the intake resis- tance should be small as possible.

  • Page 33: Cylinder Block/Head

    4. Regular inspection Cylinder block/head Valve Clearance Adjust the valve clearance. • When disassembling the engine or cylinder head. • When there is excessive noise in the valve connec- tion. • When the engine runs abnormally even if the fuel injection system is normal.

  • Page 34: Tightening Cylinder Head Bolt

    4. Regular inspection Tightening Cylinder Head Bolt Engine Model In. valve Ex. valve 1. Retightening cylinder head bodt on new engine. DP158LCS 0.25mm 0.35mm Intake side injector DP158LCF 0.25mm 0.35mm DP158L DP158LDS 0.25mm 0.35mm DP158LDF 0.25mm 0.35mm DP180LBS 0.25mm 0.35mm DP180LBF 0.25mm...

  • Page 35: Cylinder Compression Pressure

    4. Regular inspection 2. Tightening cylinder head bolts after a repair. (Engine 7) After 400 hours of operation turn the cylinder head cold) bolts by a further 90°(1/4 revolution). CAUTION Intake side injector • The two outside screws (intake and exhaust side) must not be retightened.

  • Page 36: Electric System

    4. Regular inspection Electric system Battery • Check the amount of electrolyte, and replenish distilled water if insufficient. • Check for the electrolyte leakage by crack in the • Check the specific gravity of electrolyte. If it is below battery, and replace the battery if defective. the specified value (1.12 ~ 1.28), replenish it.

  • Page 37: Others/Driving System

    4. Regular inspection Others/driving system V-Belt The tension of the V-belts should be checked daily . 1. Change the V-belts if necessary 1) If in the case of a multiple V-belt drive, wear or differing tensions are found, always replace the complete set of V-belts.
  • Page 38 4. Regular inspection 5. Tension adjustment and V-belt replacement DV2213050B 1) Loosen the fixing bolt(1). 2) Loosen the lock nut(2). 3) Adjust the bolt(3) until belt have correct tension. 4) Tighten the fixing bolt(1) and nut(2). 5) To replace the V-belt, loosen the fixing bolts(1) and the lock nut(2) and push the tension pulley inwards by turning the adjusting bolt(3) counter clockwise.
  • Page 39 5. About the engine Marking system of units ..........73 Unit Conversion Methods .

  • Page 40: Marking System Of Units

    5. About the engine Marking system of units Unit Conversion Methods Item Number SI Unit US Unit The following methods show how to convert SI units to Power 1.340483 US units and vice versa. 1. To convert an SI unit to a US unit, multiply a SI unit 0.01 with the number in the following table.

  • Page 41: Tightening Torque

    5. About the engine Tightening torque Tightening Torque of Main Parts Nominal Tensile Strength Main Parts Tightening Torque Remarks (Diameter x Pitch) Rank 1st: 30.0 kgf·m Cylinder Block Main M18 X 2 12.9T 2nd: 90° Bearing Cap Bolt (Angle Method) Cylinder Block Bear- M12 X 1.5 10.9T...

  • Page 42: Tightening Torque Of General Bolts

    5. About the engine Nominal Tensile Strength Main Parts Tightening Torque Remarks (Diameter x Pitch) Rank 7.0 kgf·m ±1.05 kgf·m Exhaust Manifold 10.9T 2.2 kgf·m ±0.33 kgf·m Intake Manifold 8.8T Fuel Injection Pump 5.0 kgf·m ±0.5 kgf·m M10 X 1.5 10.9T (Cylinder Block) 7.5 kgf·m ±1.12 kgf·m...
  • Page 43 5. About the engine Strength Classification 10.9 12.9 Nomi- (4A) (4D) (4S) (5D) (5S) (6D) (6S) (6G) (8G) (10K) (12K) Diame- ter × Elastic Limit Value (kg/mm Pitch (mm) Tightening Torque (kg·m) M16 x 12.5 11.3 19.5 12.5 14.5 24.2 M18 x 14.5 12.5...

  • Page 44: Tightening Torque Of Plug Screw

    5. About the engine Tightening torque of plug screw 10.0 10.0 12.0 12.0 15.0 Hollow Screw (4-Hole) Tightening Torque Material Classifi- cation SM25C 13.0 18.0 30.0 11.0 16.0 20.0 35.0 SUM22L STS304 11.0 16.0 20.0 35.0 a. Applied to Doosan Engines...

  • Page 45: Special Tool

    5. About the engine Special tool Special Tool Product Num- Shape Application Work Tips First, place the tool onto the cylinder block, and insert "T" shape plate of the tool EF.120-030 into the cylinder liner and Front Oil Seal hook it on the bottom of the Assembly Jig cylinder liner.
  • Page 46 5. About the engine Product Num- Shape Application Work Tips First, detach the injection nozzle from cylinder head and assemble the tool into the nozzle hole. Attach the extension at the nozzle end, then join the compression EU.2-0532 pressure gauge to the Adapter for Cyl- extension end.
  • Page 47 5. About the engine Product Num- Shape Application Work Tips First, assemble the connect- ing rod and piston rings to the piston. Then, insert the connecting rod of the piston assembly into the tool from tapered part of the tool, and push the pistoon until the piston is still in the tool.
  • Page 48 5. About the engine Product Num- Shape Application Work Tips Put two sharp points of the tool into theholes of snap ring at the same time and T7610001E grip the both lever of the Snap Ring Plier tool a little, then remove the snap ring from the position pin.

  • Page 49: Engine Disassembly

    5. About the engine Engine Disassembly Procedure of Disassembling an Engine 2) Remove the starter(B). 3. Discharge cooling water. "Discharging the coolant" on page 48 CAUTION 4. Drain engine oil. • Prepare tools and genuine parts necessary before disassembling engine. •...
  • Page 50 5. About the engine 6. Remove the alternator. 8. Remove the inlet elbow. DV2213055A DV2213057A 1) Loosen the fixing nut(A) and bolt(B). 1) Loosen the hose clamp(A). 2) Remove the alternator(C). 2) Loosen the V-clamp(B). 7. Remove the alternator bracket. 3) Remove the inlet elbow(C).
  • Page 51 5. About the engine 10. Remove the oil return pipe. 12. Remove the exhaust manifold and elbow assembly. DV2213169A DV2213060A 1) Loosen the clamp(A). 1) Remove the heat screen. 2) Loosen 2 fixing bolts(B) 2) Loosen the fixing bolts(A) of the exhaust elbow 11.
  • Page 52 5. About the engine 5) Remove the other side intake stake as the same 16. Remove the fuel injection pipe assembly. procedure. CAUTION Be careful not to let dust inside the engine. 14. Remove the fuel filter. DV2213064A 1) Loosen the fixing bolts(A). 2) Loosen 12 fuel injection pipe nuts(B) connected the injector.
  • Page 53 5. About the engine 3) Remove the fuel pipes(C). 20. Remove the oil filter assembly. CAUTION • Be careful not to loss the O-ring. • Be careful not to damage the fuel pipes. 18. Remove the fuel pipe. DV2213082A 1) Remove the oil filter with the chain plier(EF.200-038). 2) Loosen the fixing bolt(B) and (C).
  • Page 54 5. About the engine 22. Remove the intake manifold. 24. Remove the fuel return pipe. DV2213066A DV2213069A 1) Loosen the fixing bolts(A). 1) Remove the hollow screw and 6 seal rings(A). 2) Remove the intake manifold(B). 2) Remove the fuel return pipe(B). 3) Remove the other side intake manifold as the same 3) Remove the other side fuel return pipe as the same procedure.
  • Page 55 5. About the engine 26. Remove the flywheel housing cover. 28. Remove the fuel injection pump. DV2213071A DV2213072A 1) Loosen the fixing bolts(A). 1) Loosen 6 fixing bolts(A). 2) Remove the flywheel housing cover(B). 2) Remove the fuel injection pump(B). 27.
  • Page 56 5. About the engine 30. Remove the push rods. 1) Loosen the fixing bolts(A) and nuts(B). 2) Remove the cooling water pipe(C). 33. Remove the thermostat. DV2213076A 1) Remove 24 push rods(A). DV2213172A 31. Remove the cylinder head assembly. 1) Remove the O-ring(B). 2) Remove the thermostat(A).
  • Page 57 5. About the engine 35. Remove the idle pulley and cooling fan pulley 37. Remove the oil cooler cover. assembly. DV2213083A DV2213174A 1) Loosen 20 fixing bolts(A). 1) Loosen 1 fixing bolt(A) and 2 fixing nuts(B). 2) Remove the oil cooler cover(B). 2) Remove the idle pulley(C).
  • Page 58 5. About the engine 39. Remove the oil cooler housting. 1) Loosen 20 fixing bolts(A). 2) Remove the oil pan(B). CAUTION Remove the gasket on the assembly surface. 42. Remove the oil suction pipe and the oil pump. DV2213085A 1) Loosen 5 inner socket bolts(A). 2) Loosen 5 outer fixing bolts(B).
  • Page 59 5. About the engine 3) Remove 12 cononecting rod and pistonb assemblies 45. Remove the cylinder liner. as the same procedure. CAUTION • Be careful not to interference between the crank- shaft and the crank weight. • Be careful not to mix disconnected connecting rods, connecting rod caps, and removed connecting rod bolts as they are set aside.
  • Page 60 5. About the engine 1) loosen 6 fixing bolts(A). 50. Remove the crankshaft. 2) Remove the front oil seal(B). 48. Remove the flywheel. DV2213093A 1) Loosen 2 side fixing bolts(A) and 2 bearing cap DV2213091A bolts(B). 1) Remove the tacho sensor(A). 2) Remove bearing cap(C).
  • Page 61 5. About the engine 52. Remove the vavle tapet and the spray nozzle. DV2213095A 1) Loosen 2 fixing bolts(A) and 1 hollow screw(B). 2) Remove the oil spray nozzle(C). 3) Remove 12 oil spray nozzles as the same procedure. 4) Remove the valve tapet(D). 5) Remove 24 valve tapets as the same procedure.

  • Page 62: Engine Assembly

    5. About the engine Engine Assembly Procedure of Assembling Engine 5) Tighten 2 M6 fixing bolts(A) at a tightening torque of 1.2 kgf•m. 6) Attaht 12 oil spray nozzle as the same procedure. CAUTION 2. Attach the crankshaft.dps • Cleanse all disassembled and disconnected parts. Especially, clean the oil and coolant path with compressed air and check if there is any resis- tance.
  • Page 63 5. About the engine 4. Attach the oil seal to the flywheel housing. 4) Tighten 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. DV2213180A 1) Apply engine oil on the surface of the oil seal rotation contact.
  • Page 64 5. About the engine 8. Attach the oil seal to the front oil seal cover. 10. Change the engine position. DV2213183A DV2213184A 1) Apply engine oil on the surface of the oil seal rotation 1) Change the engine positon. The flywheel direction is contact.
  • Page 65 5. About the engine 12. Attach the piston to the connecting rod. 4) Attach the piston pin(C). CAUTION Check the attached piston and piston ring. If the piston should be replaced, replace the piston pin along with the piston. 5) Attach 2 snap rings(B) with the snap ring plier (T7610001E).
  • Page 66 5. About the engine 4) Attach 12 connecting rod and piston assembly as the 15. Attach the oil pan. same procedure. CAUTION • Be careful to note the direction when attaching the connecting rods and the connecting rod caps. Ensure that the number engraved on the connecting rods is same with that engraved on the connecting rod caps and the assembly direc- tion is same.
  • Page 67 3) Adjust the fuel injection timing with rotating the DV2213186A flywheel to the engine rotating direction. Engine Model Fuel Injection Timing (°) 23° ± 1° DP158LCS 18° ± 1° DP158LCF DP158L 23° ± 1° DP158LDS 18° ± 1° DP158LDF 21° ± 1° DP180LBS 19°...
  • Page 68 5. About the engine 19. Attach the fuel injection pump. 21. Attach the flywheel housing cover. DV2213072A DV2213188A 1) Attach the fuel injection pump(B) with the injection 1) Attach the flywheel housing cover(A). pump alignment jig(EF.120-189). 2) Tighten 4 M8 fixing bolts(B) at a tightening torque 2.2 kgf·m ±...
  • Page 69 5. About the engine 3) Attach the vavle(B). 24. Attach the push rods. CAUTION Be careful to use the right valve without confusing the intake valve with the exhaust valve. The intake valve is the mark “ I ” engraved on the head and the exhaust valve is the mark “...
  • Page 70 5. About the engine 1) Attach the seal ring and then attach the injector(A). 2) Tighten the injector holder fixing nut with the jig for injection nozzle detach(60.99901-0036). 3) Attach 12 injectors as the same procedure. CAUTION Be careful not to damage the fuel pipes. 27.
  • Page 71 5) As for the valve clearance, adjust it when in cold, as follws. Engine Model In. valve Ex. valve Adjusting valve cylinder No. (In./Ex. Valve) DP158LCS 0.25mm 0.35mm 29. Adjust the valve clearance. (Method 2) DP158LCF 0.25mm 0.35mm DP158L DP158LDS 0.25mm 0.35mm DP158LDF 0.25mm 0.35mm DP180LBS 0.25mm...
  • Page 72 5. About the engine Engine Model In. valve Ex. valve DP158LCS 0.25mm 0.35mm DP158LCF 0.25mm 0.35mm DP158L DP158LDS 0.25mm 0.35mm DP158LDF 0.25mm 0.35mm DP180LBS 0.25mm 0.35mm DP180LBF 0.25mm 0.35mm DP180L DP180LAS 0.25mm 0.35mm DP180LAF 0.25mm 0.35mm 10 Cylinder engine DV2213214A DP222LAS 0.25mm...
  • Page 73 5. About the engine 31. Attach the breather. Cylinder No. Valve #1TDC ● ● ● ○ ○ ● ● ○ #6TDC Cylinder No. Valve #1TDC ○ ● ○ ○ ○ ○ ● ○ #6TDC Cylinder No. Valve #1TDC ● ● ○...
  • Page 74 5. About the engine 33. Attach the fuel pre filter. 35. Attach the fuel pipe. DV2213065A DV2213068A 1) Attach the fuel return pipe and fuel pre filter(C). 1) Attach the fuel pipe(D). 2) Tighten the fixing bolts(B) at a tightening torque 2) Tighten the fixing nut(B) and (C) at a tightening torque 2.2kgf·m ±...
  • Page 75 5. About the engine 37. Attach the fuel injection pipe. Note) Tighten the fixing bolts to attach the inlet elbow and the inlet pipe at a tightening torque 2.2kgf·m ± 0.33kgf·m. CAUTION Be careful not to let dust inside the engine. 39.
  • Page 76 5. About the engine 5) Attach the other intake stake as the same procedure. 42. Attach the turbocharger. CAUTION Be careful not to let dust inside the engine. 41. Attach the exhaust manifold and exhaust elbow. DV2213070A 1) Attach the turbocharger(B). 2) Tighten 4 fixing bolts(A).
  • Page 77 5. About the engine 44. Attach the oil delivery pipe. 4) Attach the other inlet elbow as the same procedure. CAUTION Make sure that the O-ring and the insert parts have been attached. 46. Attach the oil cooler housing. DV2213058A 1) Attach the oil delivery pipe(D).
  • Page 78 5. About the engine 48. Attach the oil cooler cover. 50. Attach the crankshaft pulley. DV2213083A DV2213190A 1) Attach the oil cooler and the oil cooler cover(B). 1) Attach the crankshaft pulley(B). 2) Tighten 20 M8 fixing bolts(A) at a tightening torque 2) Tighten 8 M16 stud head bolts(A) at a tightening torque 21.0kgf·m ±1.0kgf·m.
  • Page 79 5. About the engine 9) Tighten 1 fixing bolt(A) and 2 fixing nuts(B). 54. Attach the cooling water pipe. CAUTION Make sure that the cooling fan pulley can be rotated after attaching. 52. Attach the water pump. DV2213078A 1) Attach the cooling water pipe(C). 2) Tighten the fixing bolts(A) and nuts(B) at a tightening torque 2.2kgf·m ±...
  • Page 80 2) Tighten the fixing bolt(B). freeze and 3~5% additives (DCA4) to prevent corro- 3) Tighten the fixing nut(A) at a tightening torque sion. 2.2kgf·m ± 0.33kgf·m. 2) Add the coolant of the correct mixing ratio. CAUTION Use coolant recommended by Doosan.
  • Page 81 5. About the engine 61. Add the engine oil. 1) Add our recommended genuine oil to replenish the oil level. CAUTION Use genuine engine oil recommended by Doosan.
  • Page 82 6. Cooling system General information ........... . . 117 General Information .

  • Page 83: General Information

    Detail of Jacket Heater Port M30 x 1.5 JACKET WATER PUMP To Jacket Heater JACKET HEATER DV2213098A Specifications DP158L Item Remarks DP158LCS DP158LCF DP158LDS DP158LDF10 Cooling System Cooling method Fresh water forced circulation Engine only Approx. 20 Coolant capac- ity (L) With radiator...
  • Page 84 6. Cooling system DP158L Item Remarks DP158LCS DP158LCF DP158LDS DP158LDF10 Coolant flow rate (L /min) Pressure cap (kPa) Max. 49 Max. for stand by and prime Water tempera- ture (°C) Before start of full load Water pump Centrifugal type driven by belt...
  • Page 85 6. Cooling system DP222L Item Remarks DP222LAS DP222LBS DP222LBF DP222LCS DP222LCF Cooling System Cooling method Fresh water forced circulation Engine only Approx. 23 Coolant capacity (L) With radiator Approx. 114 (Air on 43°C) / Approx 125 (Air on 52°C) Coolant flow rate (L/min) Pressure cap (kPa) Max.

  • Page 86: Failure Diagnosis

    6. Cooling system Failure Diagnosis Phenomenon Causes Troubleshooting Not enough coolant Replenish the coolant Defective radiator cap Replace it Contaminated radiator Clean the exterior of the radiator Defective V-belt offset Adjust or replace it Contaminated or damaged V-belt Replace it Damaged impeller Replace the coolant pump Overheated engine...

  • Page 87: Thermostat

    6. Cooling system Thermostat General Information 1. Heat exchanger 3. Coolant pump The thermosatat maintains water temperature in the 2. Bypass valve 4. Coolant pipe engine consistently and prevents heat loss to improve heat efficiency of the engine. Check of the thermostat When the coolant temperature is below the normal 1.
  • Page 88 7. Lubrication system General information ........... . . 125 General Information .
  • Page 89 Engine oil is filtered through the oil filter and purified. through the oil cooler and oil filter. DV2213101A Specifications DP158L Item Remarks DP158LCS DP158LCF DP158LDS DP158LDF10 Lubrication System Lubrication method Fully forced pressure feed type Type Gear type Oil pump...
  • Page 90 7. Lubrication system DP158L Item Remarks DP158LCS DP158LCF DP158LDS DP158LDF10 Max. Oil capacity (L) Min. Idle speed Min. 100 Lubrication oil Governed pressure (kPa) Min. 250 speed Max. oil temperature (°) Oil class Above API CD Oil specification 15W/40 DP180L...
  • Page 91 7. Lubrication system DP222L Item Remarks DP222LAS DP222LBS DP222LBF DP222LCS DP222LCF Idle speed Min. 100 Lubrication oil pressure Governed Min. 250 (kPa) speed Max. oil temperature (°C) Oil class above API CD Oil specifica- tion 15W/40 Failure Diagnosis Phenomenon Causes Troubleshooting Bad oil Replace oil with specified oil.
  • Page 92 8. Fuel system General information ........... . . 131 General Information .

  • Page 93: General Information

    High Sulfur content in diesel fuel The fuel lines should be routed so that the fuel is not Doosan diesel engines can be operated with fuels Whose excessively heated by the heat radiation from the engine. sulfur content is max. 0.05wt%.

  • Page 94: Water (Moisture) In Diesel Fuel

    • Damaged to the injection pump scope. • Piston damage Specifications DP158L Item Remarks DP158LCS DP158LCF DP158LDS DP158LDF10 Fuel System Injection pump Bosch in-line "P" type Governor Electric type Type Mechanical type injection pump...

  • Page 95: Failure Diagnosis

    8. Fuel system DP222L Item Remarks DP222LAS DP222LBS DP222LBF DP222LCS DP222LCF Governor Electric type Type Mechanical type injection pump Fuel feed Capacity pump (L/hr) Type Multi hole type Injection noz- Opening pres- sure (MPa) Fuel filter Full flow, Cartridge type with water drain valve Fuel Used Diesel fuel oil Failure Diagnosis...
  • Page 96 8. Fuel system Symptom Causes Troubleshooting • Defective injection timing • Adjust • Too low nozzle injection pressure • Adjust • Broken nozzle spring • Replace it 5. Excessive engine smoke • Nozzle not working properly • Replace it and knocking •...

  • Page 97: Fuel Injection Pump

    8. Fuel system Fuel injection pump General Information The fuel injection pump is driven by the crankshaft gear. It is connected to the forced lubrication system, so sepa- rate connection is not required. The governor of electric fuel injection pump is consist of the actuator that is operated by the signal of the control system and the control system that maintain the engine RPM as the changing load.

  • Page 98: Actuator

    8. Fuel system Actuator Actuator Component Parts Function 7. Fuel rack: It controls the fuel capacity of the fuel injec- tion pump connected link lever. Side view CAUTION Emergency stop lever Adjusting fuel injection pump is critical part for the Upper control chamber enfine performance and durability.
  • Page 99 8. Fuel system 14, 15 2, 3 4, 5 Fuel rack DV2213210 Title Amount Remarks Title Amount Remarks Operating Lever Ball link ASS"Y M5xL15 Stop Lever Screw, Ball link M5xL15 Manual Stop Device Φ5.5x Plain Washer ASS'Y Φ14xT1.2 Stop Screw M6xL25 Lock Nut M6xP1.0...

  • Page 100: Controller System

    8. Fuel system Controller system DGC-2013 Governor Controller System Crank Over speed Starting Power Pick-up Crank Run Over speed Fuel Test Speed Ramping Idle Droop Speed Gain Stability Battery Speed Trim Idle Droop Frame Pick-up Actuator DV2213203B Description 1. Mount the controller unit vertically to the surface of a control cabinet, protected from the weather and high DGC-2013 Governor Controller Unit is an electronic humidity, and do not expose the controller unit to the...

  • Page 101: Emc (Electromagnetic Compatibility)

    8. Fuel system EMC (Electromagnetic Compatibility) 3. Check that all electrical connections are correctly made and terminal screws tightened. To satisfy EMC requirements, the controller unit should be mounted on the grounded metal side, and it is required to use shielded wires for all signal lines and ground all the shields to one of the bolts used to mount the controller.
  • Page 102 8. Fuel system Note) With (5) Speed Ramping biased to counterclock- 2) Gain adjustment. wise direction, a symptom of overshoot or hunting Note) Turn (2) Gain clockwise until instability develops at can occur. no load. 3) Start cranking the engine. Note) Gradually move (2) Gain counterclockwise until 5.
  • Page 103 8. Fuel system Note) With the adjustment above, the overspeed function is triggered at around 115% of the rated speed. CAUTION On completion of all the adjustments, start up the engine again to ensure the stable operation at engine startup, at no load, and at load operation, respectively.

  • Page 104: External Wiring

    8. Fuel system External Wiring Idle Droop Speed Battery Speed Trim Droop Idle Frame Actuator Pick-up 10V POWER Load sharing Jumper Actuator unit Auto synchronizer <Auxiliary unit> Magnetic Pick-up Droop switch 2C shield shield cable(cover with insulation tube) BATTERY Idle switch Power switch Fuse(10A) DV2213211A •...

  • Page 105: Magnetic Speed Sensor Connections

    8. Fuel system 9. Accessory power supply: The +10[V] and 20[mA] of Potentiometer Value by Speed Range current supply, Terminal P, can be utilized to provide Engine RPM for Each Ring power to governor system accessory and for various Pote Speed Gear tiometer...

  • Page 106: Droop Parallel Operation Mode (Manual Paralleling)

    8. Fuel system DROOP(%) = {(No Load Speed - Full Load Rated 300611-00684 Speed) x 100} / Full Load Rated Speed Speed Adjustment 4,800Hz (1800rpm) • Description: Droop is typically used for the load sharing and paralleling of engine driven generators. Idle Adjustment 2,133Hz (800rpm) Without the Droop mode in paralleling system, gener-...

  • Page 107: System Troubleshooting (Instability)

    8. Fuel system • Over Speed : When the engine reaches the preset overspeed, the lamp is on and relevant relay is acti- vated and the power to the actuator is shut off. System Troubleshooting (Instability) 1. Fast instability (Hunting) 1) When the position of switch D1 is ON, the differential function is activated.

  • Page 108: System Inoperative

    8. Fuel system System inoperative If the engine governing system does not function, the fault may be determined by performing the voltage tests described in steps 1, 2 and 3. (+) and (-) refer to meter polarity. If normal values should be indicated as a result of following the troubleshooting steps, the fault may be with the actuator or the wiring to the actuator.

  • Page 109: Adjustment Fuel Injection Pump

    • Model : PE8P120A500/4LS7935 (0 412 628 937) 4) Injection pipe : 420208-00453, 420208-00454 • Governor : Doosan electronic governor 5) Firing order : 1 - 5 - 7 - 2 - 6 - 3 - 4 - 8 • Plunger & Barrel : 2 418 455 545 •...
  • Page 110 2) Nozzle holder assembly : 65.10101-7051 (0 432 131 • Model : PE8P120A500/4LS7935 (0 412 628 937) 667) • Governor : Doosan electronic governor 3) Nozzle : 65.10102-6047 (0 433 171 174) • Plunger & Barrel : 2 418 455 545 4) Injection pipe : 420208-00453, 420208-00454 •...
  • Page 111 667) • Model : PE10P120A500LS7936 (0 412 629 815) 3) Nozzle : 65.10102-6047 (0 433 171 174) • Governor : Doosan electronic governor 4) Injection pipe : 420208-00399, 420208-00400 • Plunger & Barrel : 2 418 455 545 5) Firing order : 1 - 6 - 5 - 10 - 2 - 7 - 3 - 8 - 4 - 9 •...
  • Page 112 667) • Model : PE10P120A500LS7936 (0 412 629 815) 3) Nozzle : 65.10102-6047 (0 433 171 174) • Governor : Doosan electronic governor 4) Injection pipe : 420208-00399, 420208-00400 • Plunger & Barrel : 2 418 455 545 5) Firing order : 1 - 6 - 5 - 10 - 2 - 7 - 3 - 8 - 4 - 9 •...
  • Page 113 8. Fuel system 5. DP222L (60Hz) 2) Nozzle holder assembly : 65.10101-7051 (0 432 131 1) Fuel injection pump : 65.11101-7303 (0 402 619 807) 667) • Model : PE12P120A500LS7937 (0 412 620 854) 3) Nozzle : 65.10102-6047 (0 433 171 174) •...
  • Page 114 8. Fuel system 6. DP222L (50Hz) 2) Nozzle holder assembly : 65.10101-7051 (0 432 131 1) Fuel injection pump : 65.11101-7303 (0 402 619 807) 667) • Model : PE12P120A500LS7937 (0 412 620 854) 3) Nozzle : 65.10102-6047 (0 433 171 174) •...
  • Page 115 9. Intake/exhaust system General information ........... . . 155 General Information .

  • Page 116: General Information

    9. Intake/exhaust system General information General Information In order to make the supplied fuel burned completely to work for the engine efficiently, the sufficient air should be The exhaust gas of the engine passes through the turbine delivered to the cylinder. That is, the enfine power is wing of turbocharger to rotate the rutbine.

  • Page 117: Specifications

    9. Intake/exhaust system Specifications DP158L Item Remarks DP158LCS DP158LCF DP158LDS DP158LDF10 Intake/Exhaust System Max. back pressure (kPa) With clean filter 2.16 element Max. intake air restriction (kPa) With dirty filter 6.23 element DP180L Item Remarks DP180LBS DP180LBF DP180LAS DP180LAF Intake/Exhaust System Max.

  • Page 118: General Information

    9. Intake/exhaust system General information Construction 27, 30, 31 DV2213108A Name Name Name Turbine shaft Bolt Heat screen Thrust bush Clamp Compressor housing Oil shut off Bearing housing Clamp Fixing nut Retainer ring Bolt Seal ring Seal plate Liquid gasket Seal ring Thrust bearing Loctite...

  • Page 119: Function

    9. Intake/exhaust system Function 1. Turbine The exhaust gas that is discharged from combustion chamger passes through turbine housing conveying an energy to turbine wings to give the rotating power, Compressor This is called as the turbine and in order not to influ- Engine ence a bad effect at bearing part, there are the seal Exhaust gas...

  • Page 120: Failure Diagnosis

    9. Intake/exhaust system Failure Diagnosis Phenomenon Causes Troubleshooting Rotating part is contacted Repair or replace it Unbalanced rotation of a rotor Repair or replace it Burn Repair or replace it Loose joint Check or repair it Deformed or damaged intake systemhose Replace it Poor clamping state Adjust and tighten the clamp...
  • Page 121 9. Intake/exhaust system Phenomenon Causes Troubleshooting Leakage of gas from each part of the exhaust sys- Check or repair it Clogged air filter element Replace or clean it Contaminated or damaged turbocharger Repair or replace it Leakage of air from the discharging part of the com- Check or repair it pressor shaft Deformed or damaged intake system hose...
  • Page 122 9. Intake/exhaust system Phenomenon Causes Troubleshooting Leakage from the engine block and the exhaust Check the engine manifold Check the turbo impeller and the turbo Contaminated blowby gas and abnormal oil amount intake outlet Large gap of the turbocharger wheel, causing inter- Check if there is any sand or metallic for- ference with the wall eign substance...

  • Page 123: How To Maintain Turbocharger

    9. Intake/exhaust system Phenomenon Causes Troubleshooting Deformed or damaged intake system hose Replace it Replace and check if the impeller of the Contaminated or damaged air filter turbocharger is damaged Leakage of coolant from the turbocharger or oil from Replace the hose and the gasket the oil hose Poor turbo actuator operation Replace the turbocharger...

  • Page 124: Special Inspection Of Turbocharger

    9. Intake/exhaust system Item Cautions Reasons 1) Check the oil amount 2) Therefore, start the engine with the starter 2) Overhasty start of engine leads to motor to check the rise of oil pressure (until the engine rotation without lubricating turbo- gradation of the oil pressure gauge moves or charger and other engine parts, causing the pressure indicator lamp is turned on).
  • Page 125 9. Intake/exhaust system DV2213034A DV2213036A Turbine wheel room Magnet vise Shift the turbine shaft to axial direction. Dial gauge Wear limit : 0.20 mm DV2213035A DV2213037A_E 1. Checking the rotating state of a rotor assembly Check 2) Radial clearance tis rotating state when strange noise is heard during Wear limit 0.65 mm rotation.
  • Page 126 9. Intake/exhaust system Dial indicator Magnetic stand Oil outlet Move turbine shaft at both right and left sides simultaneously in radial direction Oil inlet DV2213039A_E 3) In case that the end plays to axial and circumference directions, replace or repair the turbocharger.
  • Page 127 10. Cylinder block/head General information ........... . . 169 General Information .

  • Page 128: General Information

    The engine has replaceable wet cylinder liners and individual cylinder heads with strung-in valve seat rings and replaceable valve guides. Specifications DP158L Item Remarks DP158LCS DP158LCF DP158LDS DP158LDF10 Cylinder block/head Valve system type Overhead valve type Intake No. of valve...
  • Page 129 10. Cylinder block/head DP222L Item Remarks DP222LAS DP222LBS DP222LBF DP222LCS DP222LCF Cylinder block/head Valve system type Overhead valve type Intake No. of valve (per cylinder) Exhaust Valve lashes Intake 0.25 (at cold) Exhaust 0.35 (mm) Opening 24° (BTDC) Intake valve (°) Close 36°...

  • Page 130: Cylinder Block

    10. Cylinder block/head Cylinder block Check of Cylinder Block 1. Cleanse the cylinder block and check if there is any cracked or damaged part with naked eye. 2. Replace the cylinder block if it is seriously cracked or damaged. Repair tiny cracks if existing. 3.

  • Page 131: Cylinder Head

    10. Cylinder block/head Cylinder head Measurement of Cylinder Liner 3. Replace the new valve stem seal and then attach the stem seal to the valve guide of the cylinder head with 1. Remove the cotter pin pressing the valve spring by the special tool.
  • Page 132 10. Cylinder block/head 3) For cracks or damage which cannot be checked 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 amount of distortion using a straight...

  • Page 133: Valve

    10. Cylinder block/head Valve General Information The overhead valves are actuated via chilled cast iron tapets, push rods and rocker arms from the camshaft. Check of Valve After cleaning the valves with clean diesel oil, measure the valve as follow. 1.

  • Page 134: Valve Seat

    10. Cylinder block/head Valve Seat 3. The disassembly of valve seat cam be pulled out by means of a special tool with the arc welding done at 1. Visual inspection: Inspect the damage and wear of two points of valve seat rotating tool or valve seat. valve seat and if necessary replace.
  • Page 135 10. Cylinder block/head Spring tester DV2213123A DV2213125A_E 3. Squareness of valve spring: Measure the sequareness of the valve spring with the surface plate and the right-angle square. If the reading exceeds the toler- ance limit, replace the valve spring. Item Standard Squareness of valve spring Below 1.0mm...

  • Page 136: Rocker Arm

    10. Cylinder block/head Rocker arm Disassembly Rocker Arm 1. Remove the snap ring on both sides of the rocker arm shaft using snap ring plier. 2. Remove the washer and rocker arm. 3. Remove the rocker arm bush using press. Outside diameter DV2213127A_E 2.

  • Page 137: Tappet And Push Rod

    10. Cylinder block/head Tappet and push rod Tappet Clearance Measure the outer diameter of a tappet and the inner diameter of the tappet bore. If the reading exceeds the tolerance limit, replace the tappet. Standard Limit 0.035mm ~ 0.077mm 0.25mm Visual inspection of tappet Inspection if the tappet surface which contacts the camshaft has damage like crack or scratch.

  • Page 138: Camshaft

    10. Cylinder block/head Camshaft Camshaft End Play 2. Cam lobe height: Use a micrometer to measure the cam lobe height and journal diameter. If the measured Measure the camshaf’st axial end play. number is less than the specified limit, the camshaft 1.
  • Page 139 10. Cylinder block/head 2. Camshaft bearing inner diameter of cylinder block: 5. Warpage of camshaft: Place the camshaft on 2 V Using a cylinder inner gauge, measure the inner diam- blocks, and inspect the warpage of the camshaft by eter of the camshaft bearing. using a dial gauge to correct it.
  • Page 140 11. Electric system General information ........... . . 183 Specification .

  • Page 141: General Information

    11. Electric system General information Specification DP158L Item Remarks DP158LCS DP158LCF DP158LDS DP158LDF10 Electrical System Alternator voltage - capacity (V - 27.5 - 45 Voltage regulator Built-in type IC regulator Starting motor voltage - capacity 24 - 7.0 (V - kW)

  • Page 142: Electrical Wiring Diagram

    11. Electric system Electrical Wiring diagram 87a 30 2.0R 2.0R 2.0R IDLE-RUN DROOP SWITCH SWITCH SPEED TRIM ON - IDLE ON - DROOP REGISTER OFF - RUN OFF - STANDARD CONTROL UNIT ON-OFF Control Unit Ass'y 65.11220-7011/7012 over speed 3.0Y 0.85B 0.85B Bat.-...

  • Page 143: Switches And Sensors

    11. Electric system Switches and sensors Temperature Switch Pressure Sensor & Switch NPTF 1/8-27 M16x1.5 DV2213141A DV2213143B 1. Output characteristic ON: 103°C ± 3°C, OFF: Operation Temperature Resistance ( Ω ) 96°C Pressure (bar) Current Capacity DC12V, 9A ~ 10 TYPE Normal Open 31 ±...

  • Page 144: Magnetic Pick-Up

    11. Electric system Magnetic Pick-up KET:MG640322-5 Lock Nut SW 19 M16x1.5 0.5 B 0.5 Y SIGNAL DV2213146B 1. Operating temperature: -40°C ~ 120°C 2. Output Volt (P-P) above 14V above 7V Module M=3, Gear M=3, Z=32 Teeth Z=32 1.0 ± 0.1mm 1.0 ±...

  • Page 145: Starter

    11. Electric system Starter General Information Specification The starter is attached to the back of the flywheel housing. When disassembling the engine, immerse the pinion gear and ring gear of the starter in fuel, brush them, and then apply greases to them in order to prevent rust.

  • Page 146: Views

    11. Electric system Views “Switch” Terminal (Solenoid) “Switch” Terminal (Relay) M5X0.8 Solenoid “Battery” Terminal “Ground” Terminal M10X1.25 M10X1.5 Relay Motor M Terminal DV2213139A...

  • Page 147: Wiring Diagram

    11. Electric system Wiring Diagram “Battery” Terminal M Terminal Solenoid Relay Motor “Switch” Terminal “Ground” Terminal DV2213140A Resistance Item Spec. 23.5k Ω ± 2.35 Relay Switch Terminal Relay Case 0.124 Ω ± 5% Solenoid Switch Terminal M Terminal...

  • Page 148: Alternator

    11. Electric system Alternator General Information Views The alternator is fitted with integral silicon redtifiers. A transistorized requlaor mounted on the alternator body interior limits the 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, nevertheless, it must be protected against dust and, above all, against...

  • Page 149: Wiring Diagram

    11. Electric system Wiring Diagram 0.5 MFD Termianl R =150~250 DV2213138A Specification Performance Specification Performance RATING Continuous rating Output current (A) Voltage Speed (RPM) ROTATION DIRECTION Clockwise COLD BATTERY VOLTAGE (22) 17.5 1,800 27.5V TURN ON RPM Max. 1,050 RPM (48) 5,000 SPEED IN USE...
  • Page 150 11. Electric system Position Voltage Terminal B - Body About DC27V ~ 29.5V Terminal L - Body About DC27V ~ 29.5V Terminal R - Body About DC3V ~ 5V 2) During Stop Position Voltage Terminal B - Body About DC22V ~ 27V Terminal L - Body About DC22V ~ 27V Terminal R - Body...
  • Page 151 12. Others/driving system General information ........... . . 195 General Information .

  • Page 152: 12. Others/Driving System

    12. Others/driving system General information General Information The forged crankshaft has screwed-on dounterweights. Radial seals with replaceable wearing rings on crankshaft and flywheel are provided to seal the crankcase penetra- tions. The connecting rods are die-forged, diagonally split and can be removed through the top of the cylinders together with the pistons.

  • Page 153: Crankshaft

    12. Others/driving system Crankshaft Measurement of Crankshaft 2) If the amount of wear exceeds the tolerance limit, grind the crankshaft and assemble an under-size 1. Inspection and measurement bearing. 1) Visually inspect whether there is any crack or scratch 3) There are 4 kinds as below, and the crankshaft also on the journal and pins of the crankshaft.

  • Page 154: Measurement Of Crankshaft Bearing And Connecting Rod Bearing

    12. Others/driving system 3) Assemble the bearing to the connecting rod, tighten the bearing cap to the specified torque. Item Standard Tightening torque First 30 kgf·m + 90° 4) Measure the connecting rod bearing journal inner diameter. Section DV2213150A Item Standard Limit Warpage of crankshaft...
  • Page 155 12. Others/driving system DV2213153A Item Standard Limit Axial end play 0.190~0.322mm 0.452mm...

  • Page 156: Piston

    12. Others/driving system Piston Disassembly of Piston Assembly of Piston 1. Pull out the snap ring for piston pin and with a pair 1. Heat the piston at the piston heater for about 5 of snap ring pliers. minutes (120 ~ 150°C). DV2213154A DV2213156A 2.

  • Page 157: Piston Ring And Ring Groove

    12. Others/driving system Gap gauge DV2213157A DV2213159A_E Item Standard Item Standard Limit Ø127.739~ Ø127.757mm Top ring 0.35 ~ 0.55mm 1.5mm Piston outside diameter 2nd ring 0.50 ~ 0.82mm 1.5mm CAUTION Oil ring 0.30 ~ 0.62mm 1.5mm By comparing the measured value of the piston Piston pin outside diameter with the cylinder liner inside diam- 1.
  • Page 158 12. Others/driving system 2) If the reading exceeds the tolerance limit, replace the one which are worn more. DV2213161A Item Standard Clearance 0.003 ~ 0.015mm...

  • Page 159: Connecting Rod

    12. Others/driving system Connecting rod Inspecting the connecting rod 1. Measure the parallelism between the connecting rod small end’s bush hole and the large end bearing hole. Here, use both the connecting rod measuring device and feeler gauge. Piston Burners DV2213162A_E Item Standard...

  • Page 160: Others

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

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