Doosan PU158TI Operation & Maintenance Manual
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Doosan PU158TI Operation & Maintenance Manual

Generator diesel engine, power unit diesel engine
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Operation &
Maintenance Manual
GENERATOR DIESEL ENGINE
P158LE / -1 / - 2 / -S / -III
P180LE / -1 / -S / -II
P222LE / -1 / -S / -II
POWER UNIT DIESEL ENGINE
PU158TI
PU180TI
PU222TI
65.99897-8076C

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Summary of Contents for Doosan PU158TI

  • Page 1 65.99897-8076C Operation & Maintenance Manual GENERATOR DIESEL ENGINE P158LE / -1 / - 2 / -S / -III P180LE / -1 / -S / -II P222LE / -1 / -S / -II POWER UNIT DIESEL ENGINE PU158TI PU180TI PU222TI...
  • Page 2 This manual is designed to serve as an instruction for Diesel generator engine and Power Unit engine of DOOSAN series (P158LE /P180LE /P222LE, PU158TI/ PU180TI/ PU222TI). The engines are 4 strokes, 2 valves per cylinder, V-type, and direct injection mode and thus, are also satisfying with various features required as generator and power unit engine such as quiet operation, economical fuel consumption, durability in high speed operation and so forth.

  • Page 3: Table Of Contents

    CONTENTS 1. Safety Regulations & Engine Specifications 1.1. Safety regulations ..........................1 1.2. Engine Specification ........................... 5 1.3. Engine Assembly ..........................11 2. Technical Information 2.1. Engine Model and Serial Number ..................... 19 2.2. Engines Characteristic ........................20 2.3. Troubleshooting ..........................41 2.4.

  • Page 4: Safety Regulations

    1. Safety Regulations & Engine Specifications 1.1. Safety Regulations 1.1.1. General notes Handling diesel engines and the necessary resources is no problem when the personnel commissioned with operation and maintenance are trained accordingly and use their common sense. This summary is a compilation of the most important regulations, These are broken down into main sections which contain the information necessary for preventing injury to persons, damage to property and pollution.
  • Page 5 2) During maintenance and care Always carry out maintenance work when the engine is switched off. If the engine has to be maintained while it Is running, e.g. changing the elements of change-over filters, remember that there is a risk of scalding. Do not get too close to rotating parts. Change the oil when the engine is warm from operation.
  • Page 6 1.1.3. Regulations designed to prevent damage to engine and premature wear 1) Never demand more of the engine than it was designed to yield for its intended purpose. Detailed information on this can be found in the sales literature. The injection pump must not be adjusted without prior written permission of DHI.
  • Page 7 4. The use of proper tools and special tools where specified is important to efficient and reliable service operation. 5. Use genuine DOOSAN parts necessarily. 6. Used cotter pins, gaskets, O-rings, oil seals, lock washer and self-lock nuts should be discarded and new ones should be prepared for installation as normal function of the parts can not be maintained if these parts are reused.

  • Page 8: Engine Specification

    1.2. Engine Specification 1.2.1. Specification for generator engine Engine Model P158LE series P180LE series P222LE series Items Water-cooled, 4 cycle Vee type Engine type Turbo charged & intercooled Combustion chamber type Direct injection type Cylinder liner type Wet type, chromated or casting liner Timing gear system Gear driven type No.
  • Page 9 1.2.2. Specification for power unit engine Engine Model PU158TI PU180TI PU222TI Items Water-cooled, 4 cycle Vee type Engine type Turbo charged & intercooled Combustion chamber type Direct injection type Cylinder liner type Wet type, chromated or casting liner Timing gear system Gear driven type No.
  • Page 10 1.2.3. Engine power for generator Production tolerance : ±5% Condition Engine model Timing Prime Stand by (BTDC) 50 HZ(1,500 rpm) 399 PS(293 kW) 437 PS(321 kW) P158LE-2 (EAZOC/QC) 60 HZ(1,800 rpm) 470 PS(346 kW) 510 PS(375 kW) 50 HZ(1,500 rpm) 444 PS(327 kW) 492 PS(362 kW) P158LE-1...
  • Page 11 1.2.4. Engine performance curve 1) PU158TI engine 900 1,000 1,000 1,200 1,300 1,400 1,500 1,600 1,700 1,800 1,900 2,000 2,100 2,200 Engine Speed (rpm) EH5OM001 Performance ISO 3046, DIN 6270B Output (max.) 397 kW (540 PS) / 2,100 rpm ⋅...
  • Page 12 2) PU180TI engine 900 1,000 1,000 1,200 1,300 1,400 1,500 1,600 1,700 1,800 1,900 2,000 2,100 2,200 Engine Speed (rpm) EH5OM002 Performance ISO 3046, DIN 6270B Output (max.) 478 kW (650 PS) / 2,100 rpm ⋅ ⋅ Torque (max) 2,303 N m (235 kg m) / 1,500 rpm - 9 -...
  • Page 13 3) PU222TI engine 900 1,000 1,000 1,200 1,300 1,400 1,500 1,600 1,700 1,800 1,900 2,000 2,100 2,200 Engine Speed (rpm) EH5OM003 Performance ISO 3046, DIN 6270B Output (max.) 588 kW (800 PS) / 2,100 rpm ⋅ ⋅ Torque (max) 3,205 N m (327 kg m) / 1,500 rpm Safety Regulations &...

  • Page 14: Engine Assembly

    1.3. Engine Assembly 1.3.1. Engine sectional view (Longitudinal) EA6O1004 1. Piston 11. Vibration damper 2. Combustion camper 12. Oil spray nozzle 3. Valve 13. Oil pan 4. Tappet 14. Oil suction pipe 5. Cam shaft 15. Oil pump relief valve 6.
  • Page 15 1.3.2. Engine sectional view (Cross) EA6O1005 1. Cylinder head 8. Cylinder block 2. Cylinder head cover 9. Oil filter 3. Push rod 10. Oil cooler 4. Injection pump 11. Connecting rod 5. Intake manifold 12. Exhaust manifold 6. Injection pipe 13.
  • Page 16 1.3.3. Engine assembly views 1) PU158TI : Power unit engine EH5OM004 1. Cooling fan 9. Air pipe 2. Water outlet (Turbocharger to inter cooler) 3. Air pipe 10. Idle pulley (Intercooler to intake manifold) 11. Injection pump 4. Fuel filter 12.
  • Page 17 2) PU180TI : Power unit engine EH5OM005 1. Cooling fan 9. Air pipe 2. Water outlet (Turbocharger to inter cooler) 3. Air pipe 10. Starter (Intercooler to intake manifold) 11. Idle pulley 4. Fuel filter 12. Injection pump 5. Breather 13.
  • Page 18 3) PU222TI : Power unit engine EH5OM006 1. Cooling fan 9. Air pipe 2. Water outlet (Turbocharger to inter cooler) 3. Air pipe 10. Idle pulley (Intercooler to intake manifold) 11. Injection pump 4. Fuel filter 12. Fly wheel housing 5.
  • Page 19 4) P158LE : Generator engine 18 17 EA6O1001 1. Cooling fan 10. Oil filler cap 18. Air pipe 2. Air pipe 11. Pick up sensor (Air cleaner to turbocharger) 3. Cylinder head cover 12. Oil cooler 19. Fuel filter 4. Turbocharger 13.
  • Page 20 5) P180LE : Generator engine EA6O1002 1. Cooling fan 10. Oil filler cap 18. Air pipe 2. Air pipe 11. Pick up sensor (Air cleaner to turbocharger) 3. Cylinder head cover 12. Oil cooler 19. Fuel filter 4. Turbocharger 13. Alternator 20.
  • Page 21 6) P222LE : Generator engine EA6O1003 1. Cooling fan 10. Oil filler cap 18. Air pipe 2. Air pipe 11. Pick up sensor (Air cleaner to turbocharger) 3. Cylinder head cover 12. Oil cooler 19. Fuel filter 4. Turbocharger 13. Alternator 20.

  • Page 22: Engine Model And Serial Number

    2. Technical Information 2.1. Engine Model and Serial Number The engine model and serial number is located on the engine as illustrated. These numbers are required when requesting warranty and ordering parts. They are also referred to as engine model and serial Engine number because of their location.

  • Page 23: Engines Characteristic

    Engine serial No. (example 4 : PU158TI) EAZPA 8 00001 Serial No. Production Year(2008) Engine Model Suffix Engine serial No. (example 5 : PU180TI) EASPA 8 00001 Serial No. Production Year(2008) Engine Model Suffix Engine serial No. (example 6 : PU222TI) EAYPA 8 00001 Serial No.
  • Page 24 2.2.2. Engine block The cylinder block is a single piece of alloy cast iron. To increase its stiffness, it is extended to a level below the crankshaft center line. The engine has replaceable wet cylinder liners and individual cylinder heads with strung-in valve seat rings and replaceable valve guides. 2.2.3.
  • Page 25 2.2.6. Engine lubrication The engine is equipped with force-feed lubrication. The pressure is produced by a gear pump whose drive gear is in direct mesh with the crankshaft gear at the flywheel end. The oil pump draws the oil from the oil sump and delivers it through the oil cooler and oil filter to the main distributor gallery and from there to the main bearings, big-end bearings and camshaft bearings as well as to the small-end bearings and the rocker arms.
  • Page 26 The injection pump and the turbocharger are also connected to the engine lubricating system. The cylinder walls and timing gears are splash-lubricated. Each cylinder has an oil jet provided for cooling the underside of the pistons. The lube oil is cleaned in a full-flow oil filter. Depending on the agreed extent of delivery and the design of the engine, the lube oil circuit can be equipped with oil pressure monitors (advance warning and cut-off function) which shut the engine down in the event of a sudden loss of pressure.
  • Page 27 2.2.8. Fuel system The fuel is delivered by the fuel lift pump via the fuel filter to the injection pump and from there to the injectors. The fuel is sprayed into the cylinder through nozzles fitted in screw-fit injections in the cylinder heads. Excessive fuel delivered and leak fuel from the injectors flow through the return pipe back to the tank.
  • Page 28 If Diesel fuel which contains moisture is used the injection system and the cylinder liners / pistons will be damaged. This can be prevented to same extent by filling the tank as soon as the engine is switched off while the fuel tank is still warm (formation of condensation is prevented). Drain moisture from storage tanks regularly.
  • Page 29 2.2.9. Injection pump No alterations must be made to the injection pump. If the lead seal is damaged the warranty on the engine will become null and avoid. Faults We strongly recommend that any faults developing in the injection pump should be taken care of by authorized specialist personnel.
  • Page 30 2.2.11. Replacement of fuel filter Clean the area around the fuel filter head(3). Remove the fuel filter(2). Remove the fuel filter thread adapter seal ring(4). Use a clean lint free cloth to clean the gasket surface of the fuel filter head(3). Install the new thread adapter seal ring(4)supplied with the new filter.
  • Page 31 2.2.13. Removal, dismantling and cleaning Unscrew delivery pipe at nozzle holder and at the injection pump. Remove leak-off pipe. Release union screw of nozzle holder with special wrench. (EI.03004-0225) Remove nozzle holder with gasket from the cylinder head. EA6O5007 Note for cleaning nozzles Clean nozzle body externally from soot and carbon, When cleaning several nozzles at the same time, make sure nozzle bodies and needles are not mixed up.
  • Page 32 2.2.14. Installation Clean seat in cylinder head. Insert nozzle holder with new gasket. ⋅ Tighten union nut with 120 N Install injection lines free of constraint. Install leak fuel lines. screw delivery pipe at nozzle holder and at the injection pump. ⋅...
  • Page 33 2.2.17. Turbo charger The exhaust gases of the engine are passed through the turbine rotor of the turbo charger Air impeller mounted on the same shaft draws in fresh air and delivers it at a higher pressure to the cylinders. The turbo charger is air-cooled.
  • Page 34 2.2.18. Intercooler The intercooler is air to air type and has a large cooling fan capacity. The intercooler life and performance depends on the intake air condition greatly. Fouled air pollutes and clogs the air fins of intercooler. As a result of this, the engine output is decreased and engine malfunction is occurred. So you always check whether the intake air systems like air filter element are worn or polluted.
  • Page 35 2.2.20. Filling-in of coolant (only when engine has cooled down) Fill in the coolant slowly. Make sure that all air can escape from the cooling system. Rediater Cap Run the engine briefly and then check coolant level once more. If, in an exceptional case, the coolant level Rediater has to be checked when the engine is warm from operation, first turn the...
  • Page 36 2.2.21. Draining of coolant Drain coolant as follows when cooling system has cooled down; Remove cover from filler neck of radiator. Remove drain plug in the cylinder block. EA6O5010 Improper mixing of anti-freeze and corrosion inhibitors may lead to lime and corrosion deposits in the engine cooling system which can jeopardize cooling efficiency.
  • Page 37 Since P158LE/P180LE/P222LE/PU158TI/PU180TI/PU222TI cylinder liner is wet type, particularly the cooling water control should be applied thoroughly. The density of antifreezing solution and additive for rust prevention is able to be confirmed by the cooling water test kit (Fleetguard CC2602M) How to use the cooling water test kit (1) When the cooling water temp.
  • Page 38 As for the valve clearance, adjust it when in cold, as follows. Model Intake Valve Exhaust Valve P158LE/P180LE/P222LE 0.3 mm 0.4 mm PU158TI/PU180TI/PU222TI - 35 - Technical Information...
  • Page 39 Adjusting Sequence of Valve Clearance This is a precision method, but it takes more time. * 8 Cylinder Engine (P158LE/PU158TI) Valve overlapping on cylinder (Intake & Exhaust valve) Adjusting valves on cylinder (Intake & Exhaust valve) * 10 Cylinder Engine (P180LE/PU180TI) Valve overlapping on cylinder (Intake &...
  • Page 40 2.2.26. Cylinder compression pressure Stop the engine after warming up, and take out nozzle holder assembly. EFM1004I Install the special tool (compression gauge adapter) at the nozzle holder hole, and connect the compression pressure gauge there. Standard value 28 kg/cm over Limit value 24 kg/cm...
  • Page 41 2.2.28. Fuel injection pump Check the housing crack, damage etc. and replace it if abnormal. Check if the idle operation and speed regulating lever’s sealing is removed. The adjustment and testing of fuel injection pump should necessarily be done at the test bench. 2.2.29.
  • Page 42 2.2.33. Air cleaner Air cleaner is mounted on the engine to purify the air for combustion. The intervals at which the air cleaner requires servicing depend on the specific operating conditions encountered. Clogged air filters may cause black smoke and reduce power. A check should be made from time to time to see that the fastening elements securing the air cleaner to the intake manifold seal the connection tightly.
  • Page 43 2) Starter motor The sliding-gear starter motor is flanged to the rear of the flywheel housing on the left-hand side. As part of every engine overhaul, the starter pinion and ring gear should be cleaned with a brush dipped in fuel and then a coat of grease should be applied again. Always protect starter motor against moisture.

  • Page 44: Troubleshooting

    2.3. Troubleshooting 1. Engine Starting Impossible Starting motor operation poor Starting motor revolution Inspection of battery electorlytic Engine Fuel Ilquid amount & gravity Inspect air cleaner Inspect amount of fuel Normal Too low Ajustment . Normal Normal None Polluted Recharging Replace or Replenish clean element...
  • Page 45 2. Engine Overheated Operating state 1. Overload 2. Radiator core clogged 3. Continuous over-run Fuel unit Cooling unit Check coolant Inspect fuel quality Fuel excessive supply Normal Too low Poor Check fan belt Clean and replace Check injection nozzle Repair tension wear with specilied fuel Replace...
  • Page 46 3. Output Insufficient Engine Installation improper Check for coupling Fuel unit Others alignemnt Check for air mixing Inspect air cleaner Adjust or replace in fuel coupling Normal Clean Relpace Inspect fuel supply pump Inspect air leakage Inspect engine control Normal Clean Replace of air piping line rod, link, cable, etc.
  • Page 47 4. Oil pressure lowered Check if oil pressure gauge indicates wrongly Check oil amount Too low Normal Use recommended oil Check cooling (replenish) temperature Too high Normal Refer to engine overhea Inspect oil quality Normal Check oil relief Water & fuel mixed Improper valve in oil...
  • Page 48 5. Fuel Consumption Excessive Causes according to Use Conditions 1. Overload 2. Govemor’s Arbitrary Adjustment 3. Full Speed Operation for Long time 4. Sudden Speed Change from Low to Inspect fuel leakage High Speed Normal Oil leakage Inspect injection nozzle (injection pressure Adjust Replace atomizing state etc.)
  • Page 49 6. Oil Consumption Excessive Cause according to use conditions 1. Excessive oil infusing 2. Continuous operation in low or extremely cold state Inspect oil leakage Inspect air cleaner Clean Replace Normal Oil leakage Check oil quality Internal External Retighten Check compressed Replace with Replace pressure...
  • Page 50 8. Battery Discharge Generator Wiring Switch Battery Inspect cut wire Check fan belt Check electrolytic shorts and loose tension & damage liquid amount connections Repair Replace Normal Battery over Battery self Battery room Electrolytic charging discharge damage liquid’s standard Inspect generator Charging Replace Voltage regulator...
  • Page 51 Condition Causes Remedies 1) Starting difficult (1) Compression pressure Valve’s poor shut, stem distortion Repair or replace Valve spring damage Replace valve spring Cylinder head gasket’s leak Replace gasket Wear of piston, piston ring or liner Adjust 2) Idle operation abnormal Injection timing incorrect Adjust Air mixing at injection pump...
  • Page 52 Condition Causes Remedies 5) Engine noisy For noises arise compositely such as rotating parts, lapping parts etc., there is necessity to search the cause of noises accurately. (1) Crankshaft As the wear of bearing or crankshaft Replace bearing & progress, the oil clearances increase. grind crankshaft Lopsided wear of crankshaft Grind or replace...
  • Page 53 Condition Causes Remedies 7) Oil Consumption Excessive (1) Oil level elevated Clearance between cylinder liner & piston Replace Wear of piston ring, ring groove Replace piston, piston ring Piston ring’s damage, stick, wear Replace piston ring Piston ring opening’s disposition improper Correct position Piston skirt part damaged or abnormal wear Replace piston...

  • Page 54: Operation Tip

    2.4. Operation Tip 2.4.1. Periodic Inspection cycle : Check & adjust : Replace Inspection time (hours) Inspection Daily Remark 1,200 Check for leakage (hoses, clamp) Check the water level Cooling Change the coolant water System Every Adjust the V-belt tension 2,000 hrs Clean the radiator Check for leakage...

  • Page 55: Engine Disassembly

    3. Disassembly and Reassembly of Major Components 3.1. Engine Disassembly Engine part’s disassembly procedures are as follows; For the various tool storage before disassembly and parts storage after disassembly, the shelf for parts is prepared. At the time of disassembly and reassembly, do the work with the naked and clean hand, and also the working place must be maintained clean.
  • Page 56 3.1.6. Alternator Remove the supporting guide piece for installing the alternator and the bracket bolts. Disassemble the alternator. EA6O6014 3.1.7. Vibration damper Remove the fixing bolts for crankshaft pulley in reverse order of assembling and disassemble the crankshaft pulley and vibration damper. EFM2004I 3.1.8.
  • Page 57 3.1.9. Cooling water pump Loosen the various hose clamps for the connections. Remove the cooling water discharging pipe and disassemble the thermostat. Remove the cooling water pump fixing bolts and disassemble the cooling water pump. EFM2007I 3.1.10. Starting motor Remove the starting motor fixing nuts and disassemble the starting motor.
  • Page 58 3.1.13. Oil cooler assembly By removing the plug screw of cooling water discharge port, the cooling water is discharged. EFM2012I Remove the oil cooler cover fixing bolts and disassemble the oil cooler. By removing the cooler housing fixing bolts and disassemble the oil cooler housing from the cylinder block.
  • Page 59 3.1.15. Intercooler Tear down the various hoses and air pipes from the inter cooler. Remove the intercooler fixing bolts and tear it down. EA6M2001 3.1.16. Exhaust manifold Remove the exhaust manifold fixing bolts and tear the manifold from the cylinder head. EPM2012I 3.1.17.
  • Page 60 3.1.19. Fuel injection pump Remove the oil hoses for lubrication and the fuel hoses. Remove the fixing bolts of fuel injection pump and take out the fuel Injection pump. EFM2019I 3.1.20. Cylinder head cover Remove the fixing bolts and tear the cylinder head cover down.
  • Page 61 3.1.23. Cylinder head Loosen the cylinder head fixing bolts in the reverse order of assembling, and remove them all and then take the cylinder head out. Remove the cylinder head gasket and scrap it. Eliminate the residue from the cylinder head face and cylinder block face.
  • Page 62 3.1.26. Piston Remove the connecting rod cap bolts in the reverse order of assembling and follow the similar method as in the cylinder head bolt removal. Tapping the upper and lower connecting rod caps lightly with an urethane hammer, separate them and take the bearings out.
  • Page 63 Remove the flywheel ring gear. – Heat the ring gear evenly with a gas burner (up to 200 °C) to invite volumetric expansion. – Tapping around the edges of the ring gear with a hammer and brass bar to remove it. CAUTION : Do not damage the flywheel.
  • Page 64 3.1.31. Camshaft and tappet Pull out the tappets from the cylinder block. Remove the camshaft being careful not to damage the camshaft and its bearings. EFM2059I 3.1.32. Oil spray nozzle Remove the oil injection nozzle fixing bolts and tear down the oil injection nozzles.

  • Page 65: Inspection

    3.2. Inspection 3.2.1. Cylinder block 1) Clean the cylinder block thoroughly and check a visual inspection for cracks or damage. 2) Replace if cracked or severely damaged, and correct if slightly damaged. 3) Check the oil and water passing lines for restriction or corrosion. 4) Inspect the cylinder block’s camshaft bush to any damage and the alignment of oil supply holes and if abnormal or severe wears, replace it.
  • Page 66 3.2.3. Cylinder head Carefully remove carbon from the lower face of the cylinder head using nonmetallic material to prevent scratching of the valve seat faces. Check the entire cylinder head for very fine cracks or damage invisible to ordinary sight using a hydraulic tester or a magnetic flaw detector.
  • Page 67 b) Distortion at the lower face Measure the amount of distortion using a straight edge and a feeler gauge at six positions as shown in the right figure. EA3M2031 If the measured value exceeds the standard value, retrace the head with grinding paper of fine grain size to correct such defects.
  • Page 68 Inspect the scratch and wear of valve stem seal contacting face, and if necessary correct with the grinding paper but if severe replace it. If valve head thickness (H) becomes less than 1.6 mm for intake and 1.3 mm for exhaust, replace the valve.
  • Page 69 <Valve seat thickness> Standard Limit 0.65 ~ 0.95 mm 2.5 mm EFM2038I <Valve seat angle> Intake Valve 30° Exhaust Valve 45° EA0M4048 The disassembly of valve seat can be pulled out by means of a Valve seat special tool with the arc welding insert done at two points of valve seat rotating tool or valve seat.
  • Page 70 d) Valve spring Inspect the outlook of valve spring and if necessary replace it. 1.0 mm or less By means of spring tester, measure the tension and free length. Measure the perpendicularity of valve spring. In case that the measured value EFM2039I exceeds the limit value, replace it.
  • Page 71 3.2.4. Rocker arm 1) Cylinder head disassembly Remove the snap rings in both ends of rocker arm with a pair of pliers. Tear down washer, rocker arm. Disassemble the rocker arm bush by means of a press. 2) Inspection and measurement EFM2091I a) Rocker arm bracket (Single unit type with a shaft)
  • Page 72 c) Tappet and push rod By means of outside micrometer, measure the outer diameter of tappet and replace the severe ones. (1) Unevenness (2) Crack (3) Normal Standard Limit Tappet 0.035 ~ 0.25 mm clearance 0.077 mm (4) Abnormal EA0M4070 By inspecting the tappet surface that contacts with the camshaft's cam for any crack and scratch...
  • Page 73 3.2.5. Camshaft 1) Axial end play Push the camshaft toward the pulley side. Place a dial gauge onto the camshaft gear. EPM2016S Measure the camshaft's axial end play, moving the camshaft gear by means of a driver. Limit 0.2 ~ 0.9 mm If excessive end play, assemble it by means of other thrust washer.
  • Page 74 Cam bearing diameter Measure the camshaft bush inside diameter with a cylinder gauge and Camshaft bearing by comparing the inside and outside diameters, replace if abnormal. Standard Limit 70.077 ~ 70.061 mm 69.897 mm EA0M4063 Clearance between camshaft journal and body Standard Limit 0.060 ~ 0.120 mm...
  • Page 75 3.2.6. Crankshaft 1) Inspection and measurement Inspect for any scratch or damage I II with naked eyes, and grind to the undersize according to the damaged degree and use the undersized bearing. Inspect for any crack by means of magnetic powder and color check, and replace the cracked ones.
  • Page 76 There are 4 kinds as above, and the " R " crankshaft also can be used by regrinding as above. " R " <“R part” standard value> ① Crank pin 'R' : 4.0 -0.5 " R " " R " "...
  • Page 77 Assemble the bearing at the Section bigger end of connecting rod, and after tightening the bearing cap at the specified torque, measure the diameter. Connecting rod 89.98 ~ bearing journal 90.00 mm diameter EFM2049I ⋅ Connecting rod Initial 10 kg Bolt torque + angle 90°...
  • Page 78 3.2.7. Piston 1) Piston disassembling Pull out the snap ring for piston pin and with a pair of snap ring pliers. With a round bar, remove the piston pin. EA3M2029 With a pair of pliers, remove the piston rings. Clean the piston thoroughly. EFM2051I 2) Inspection &...
  • Page 79 Measurement of cylinder bore Assemble the cylinder liner at the cylinder block and measure inner diameter at upper, middle, lower that is, 3 steps by 45° interval and calculate the average values after eliminating the maximum and minimum values. Standard 127.739 ~ 127.757 mm EAMD067I...
  • Page 80 c) Piston side clearance Assemble the piston ring at the piston. Feeler gauge Measure the each ring’s side clearance and if the measured value exceeds the limit value, replace rings or piston. <Piston side clearance> EA4M2007 Limit Division Specified value value 0.050 ~ 2nd ring...
  • Page 81 5) Connecting rod a) Distortion and parallel Install the measurement tester as figure. Measure the distortion of the bigger and smaller end bearing holes after that do as regard parallel of both holes and if abnormal, replace the connecting rod. EA0M4034 Standard Limit...
  • Page 82 With the snap ring plier, insert the snap rings of the piston pin. 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. Arrange the assembled piston in order as the cylinder number.
  • Page 83 Inspect the disassembled parts if there is any damage, replace it. Assembling can be done in the reverse order of disassembling. After assembling the nozzle, set it in the injection pressure measuring tester. By manipulating the tester handle, inspect the injection pressure and EFM2056I atomizing state.

  • Page 84: Engine Reassembly

    3.3. Engine Reassembly 3.3.1. General preparation Clean all the disassembled parts, particularly oil and water ports, using compressed air, then check that they are free from restrictions. Arrange the general and special tools in order for engine assembly operation. To wet each sliding part, prepare the clean engine oil. Prepare service materials such as sealant, gaskets, etc.
  • Page 85 3.3.4. Oil spray nozzle Assemble the oil spray nozzle. Tighten the fixing bolts. EFM2059I 3.3.5. Tappet Coat the tappet wholly with clean oil and push in the tappet hole of the cylinder block. EAMD072S 3.3.6. Crankshaft Put the wear ring into the heater to heat it up to 150 ~ 200 °C level, push it over the crankshaft by means of a jig.
  • Page 86 Assemble temporarily one bolt each at both bolt' holes and by connecting the wire to the bolts, lift it with crane or chain block and put down on the cylinder block carefully. Coat the crankshaft journal and pin parts with clean engine oil, and after fitting the main bearing into the bearing cap and assemble it to the cylinder block making EFM2061I...
  • Page 87 3.3.7. Camshaft Coat the cam bush of cylinder block and camshaft with engine oil. Assemble the cam bush and camshaft for them not to be damaged. Assemble the crankshaft gear and the camshaft gear making sure that the gear marks on both gears are aligned together as right figure.
  • Page 88 3.3.9. Tacho sensor Loosen the lock nut to hexagonal side of sensor. Rock nut Ring gear Rotate (CW) the tacho-sensor on fly wheel housing, until the end of it reach on fly wheel ring gear as figure. Rotate (CCW) the tacho-sensor for 270° (gap : about 1.0 mm) and fix the lock nut.
  • Page 89 3.3.11. Oil cooler Attach a gasket on the surface in the oil cooler housing where the oil cooler is installed. Tighten the oil cooler with fixing bolts. Install the oil cooler assembly by tightening the fixing bolts in the zigzag order.
  • Page 90 Pushing the piston down, rotate the Top ring crankshaft about 180° and fit the bearing cap to the connecting rod. 2nd ring Coat the tap parts of connecting rod bolts and their seats with engine oil, Oil ring and after engaging 2 ~ 3 threads of bolts primarily rind then tighten them to the ⋅...
  • Page 91 3.3.14. Front oil seal holder After placing the oil seal in the oil holder hole properly, press it in with a mandrel. (Be careful for oil seal not be damaged.) Attach the gasket at oil seal holder. Align the dowel pin with the oil seal holder dowel hole and assemble them by tapping lightly the dowel pin part with an urethane hammer.
  • Page 92 3.3.16. Oil pump Put the oil pump at the place to be installed on the cylinder block. Attach the gasket at the surface of oil pump where the pressure regulating valve is to be installed and place the regulating valve on the gasket. Assemble the oil pump by tightening the fixing bolts.
  • Page 93 Fit the cylinder head assembly on the cylinder block aligning with its dowel pin. (Take care not to damage the head gasket.) Coat the cylinder head bolts with engine oil and tighten them to the specified torque according to step by step.
  • Page 94 3.3.20. Rocker arm Coat the push rod with engine oil and put it into the push rod hole. Make a position the rocker arm assembly on the cylinder head and tighten the fixing bolts to the specified tightening torque. ⋅ Torque 6.5 kg EFM2091I...
  • Page 95 3.3.23. Fuel injection pump Turn the crank shaft so as to let the cylinder No.6 for P158LE, PU158TI, P222LE, PU222TI engines and the cylinder No.7 for P180LE, PU180TI come to the overlap TDC (Top Dead Center). Rotate the crankshaft to reverse about 30°...
  • Page 96 In case of exchange the injection pump, should fill the engine oil in the governor of the injection pump before the engine running. <Oil quantity of the injection pump> P158LE / PU158TI P180LE / PU180TI P222LE / PU222TI 0.95 liter 1.1 liter...
  • Page 97 How to adjust injection timing If upper pre-checked injection timing degree is wrong, follow as below. (1) Loosen the fixing bolts(M8) of the injection pump driving gear in order to adjust the injection timing slightly. (2) Turn the crank pulley clockwise until V-groove of the flywheel housing sight hole is aligned with EBO4016I...
  • Page 98 3.3.27. Cooling water pump Attach the gasket of the fresh water pump. (at cylinder block side) Assemble the fresh water pump by tightening the fixing bolts. (zigzag method) Insert the thermostat of fresh water pump. Insert the O-ring to the thermostat and EFM2081I assemble the cooling water pipes by tightening the fixing bolts.
  • Page 99 3.3.30. Turbo charger Attach a gasket to the exhaust elbow and assemble the turbocharger with fixing bolts. Install the connecting pipes and an O-ring between the inlet flange and turbocharger Then, it is assembled with the O-ring that was coated with engine oil.
  • Page 100 3.3.33. Fuel filter Assemble the fuel filter to the intake stake by tightening bolts. As for the replacement method of fuel filter element, loosen the fixing bolts of upper parts, and assemble the element with O-ring that must necessarily be a new one.

  • Page 101: Breaking-In

    At the end of the break-in period, remove break-in oil and replace the oil filter. Fill oil pan with recommended engine oil. Refer to following table. <Engine Oil capacity> Oil pan (only) P158LE / PU158TI 21 liter P180LE / PU180TI 35 liter...

  • Page 102: Preparations

    4. Commissioning and Operation 4.1. Preparations Before daily starting the engine, check fuel level, coolant level and engine oil level and replenish, if necessary. The notches in the dipstick indicate the highest and lowest permissible oil levels. CAUTION : Do not add so much engine oil that the oil level rises above the max. marking on the dipstick.

  • Page 103: Running In

    4.3. Running In It is recommended that new or overhauled engines should not be operated at a load higher than about 75 % maximum load during the first few hours of operation. Initial run-in should be at varying speeds. After this initial run-in, the engine should be brought up to fuel output gradually. 4.4.

  • Page 104: Maintenance And Care

    4.6. Maintenance and Care 4.6.1. Oil level Check the oil level in the engine sump daily with a dipstick. The level should be between the two notches cut into the dipstick and should never be allowed to drop below the lower notch. CAUTION : Do not add so much engine oil that the oil level rises above the max.
  • Page 105 Recommend of lubricating oil Initial factory fill is high quality break-in oil for API Service CH-4 grade. During the break-in period, frequently check the oil level. Somewhat higher oil consumption is normal until piston rings are seated. The oil level should be maintained in the safe range between the Min. and Max. mark on the dipstick.
  • Page 106 4.6.4. Lubricating oil filter Cleaning of the lubricating oil is effected in a full-flow oil filter with paper cartridges. A bypass valve ensures continuity of oil supply if the filter elements should be clogged. After draining off the oil release tie screw.
  • Page 107 4.6.5. Renewal of filter cartridges Allow the filter content to run off along drain plugs. Hold a suitable vessel under hole. CAUTION : Oil is hot and under pressure! After releasing the clamping bolts remove filter bowls. Renew filter cartridges. Thoroughly clean all other parts in cleaning fluid. (do not allow cleaning fluid to enter the oil circuit) NOTE : To prevent the seal from twisting hold the filter bowl firmly when tightening the...

  • Page 108: Fuel Injection System

    5. Maintenance of Major Components 5.1. Fuel Injection System 5.1.1. Governor system for generator engine Governor system for fuel injection pump consists of “Integral Actuator” and “Speed Control Unit”. Integral actuator (4.016) (6.260) (3.504) 48.5 (1.909) (2.677) (1.417) 9.5 SPLINE (36 TEETH) ( 0.375) 4- 6.4 (0.252)
  • Page 109 5.1.2. Speed control unit for governor system (DWC-2000 series speed control unit) <Introduction> This speed control unit performs the electronic function of the engine governing system. The speed control unit senses the pulses from the magnetic speed sensor, compares them with the speed control unit's set point and supplies the appropriate current output to the actuator to control the engine's fuel system.
  • Page 110 The engine speed signal is usually obtained from a magnetic speed sensor mounted in close proximity to the teeth of a ferrous ring gear that is driven by the engine. The frequency of the speed sensor signal is proportional to the engine speed. The speed control unit will accept any signal if the frequency is proportional to engine signal, and in the frequency range of the speed control unit (1 K to 7.5 K Hz.).
  • Page 111 5.1.3. Specification Performance Isochronous operation / steady state stability ............± 0.25 % or better Speed range / governor ................1 K ~ 7.5 K Hz continuous Speed drift with temperature ................... ± 0.5 % maximum Idle adjust CW ......................60 % of set speed Idle adjust CCW ....................
  • Page 112 5.1.4. DWG-2000 wiring and outline Reset Crank Overspeed Crank Speed Test Gain : DWC-2000 Stability : DC24V : 65.11220-7006 Starting GHANA CONTROL Fuel 826-1 Kuro 3-Dong, Duro-Gu Seoul 152-053 KOREA(DONG-IL TECKNO-TOWN) MADE IN KOREA Speed Ramping Idle Idle Speed Trim Droop Droop Autuator...
  • Page 113 5.1.5. Application and installation information The speed control unit is rugged enough for mounting in a control cabinet or engine mounted enclosure or in a remote console up to 20 meters(65 ft.) from the engine. Care should be taken to insure that the speed control unit, mount it vertically so that condensation will not accumulate in the speed control unit.
  • Page 114 Start engine The speed control unit governed speed setting is factory set at approximately engine idle speed. Crank the engine with DC power applied to the governor system. The actuator will energize to the maximum fuel position until the engine starts. The governor system should control the engine at a low idle speed.
  • Page 115 One of two methods of operation for the DWC-2000 may now be selected Method 1 : Start the engine and accelerate directly to the operating speed(Gen Sets, etc.). Remove the connection between Terminals M & G. Start the engine and adjust the SPEED RAMPING for the least smoke on acceleration from idle to rated speed.
  • Page 116 Accessory input The Auxiliary Terminal N accepts input signals from load sharing units, auto synchronizers, and other governor system accessories, DWC accessories are directly connected to this terminal. It is recommended that this connection from accessories be shielded as it is a sensitive input terminal. If the auto synchronizer is used alone, not in conjunction with a load sharing module, a 3M ohm resistor should be connected between Terminals N and P.
  • Page 117 OVERSPEED shutdown setting DWC-2000 has a Test switch to determine the OVERSPEED set point and test the engine shutdown function. If you want to adjust the OVERSPEED set point at the speed about 10 % higher than the RUN set speed, use the Test switch. When the engine is operating at the Run set speed in pushing the Test switch, rotate the Overspeed Adjust.
  • Page 118 Unsatisfactory performance If the governing system functions poorly, perform the following tests. Symptom Test Probable fault Actuator goes to full fuel. then, disconnect speed sensor at terminals C & D. → Do not crank. Apply DC – If actuator still at full fuel speed control unit power to the governor defective.
  • Page 119 Electromagnetic compatibility (EMC) EMI SUSCEPTIBILITY - The governor system can be adversely affected by large inter – fering signals that are conducted through the cabling or through direct radiation into the control circuits. All DWC-2000 speed control units contain filters and shielding designed to protect the units sensitive circuits from moderate external interfering sources.
  • Page 120 5.1.9. Injection pump calibration 1) P158LE series engine (1) Injection pump : 65.11101-7301 (0 402 618 813 BOSCH) – Model : PE8P120A500/4LS7935 (0 412 628 937) – Governor : Ghana control(DWA-2000) – Plunger & barrel : 2 418 455 545 –...
  • Page 121 2) P180LE series engine (1) Injection pump : 65.11101-7302 (0 402 619 802 BOSCH) – Model : PE10P120A500LS7936 (0 412 629 815) – Governor : Ghana Control (DWA-2000) – Plunger & barrel : 2 418 455 545 – Delivery valve : 2 418 559 045 –...
  • Page 122 3) P222LE series engine (1) Injection pump : 65.11101-7303 (0 402 610 807 BOSCH) – Model : PE12P120A500LS7937 (0 412 620 854) – Governor : Ghana control(DWA-2000) – Plunger & barrel : 2 418 455 545 – Delivery valve : 2 418 559 045 –...
  • Page 123 4) PU158TI engine (1) Injection pump : 65.11101-7680 (A 401 881 102 BOSCH) – Model : PE8P120A520/4LS7947 (0 412 628 942) – Governor : RQV250…900PA1434(0 440 008 152) – Plunger & barrel : 2 418 455 188 – Delivery valve : 2 418 552 039 –...
  • Page 124 (6) Rack diagram 1000 1200 1400 Engine speed(rpm) EH5OM007 (7) Boost compensator pressure 1000 1200 1400 Boost pressure(mmHg) EH5OM008 - 121 - Maintenance of Major Components...
  • Page 125 5) PU180TI engine (1) Injection pump : 65.11101-7681 (A 401 890 895 BOSCH) – Model : PE10P120A520LS7948 (0 412 629 816) – Governor : RQV250…900PA1434 – Plunger & barrel : 2 418 455 188 – Delivery valve : 2 418 552 039 –...
  • Page 126 (6) Rack diagram 1000 1200 1400 Engine speed(rpm) EH5OM009 (7) Boost compensator pressure 1000 1200 Boost pressure(mmHg) EH5OM010 - 123 - Maintenance of Major Components...
  • Page 127 6) PU222TI engine (1) Injection pump : 65.11101-7319 (0 401 890 979E BOSCH) – Model : PE12P120A520LS7972 (0 412 620 869) – Governor : RQV250…900PA1434 – Plunger & barrel : 2 418 455 545 – Delivery valve : 2 418 559 045 –...
  • Page 128 (6) Rack diagram 1000 1200 1400 Engine speed(rpm) EH5OM011 (7) Boost compensator pressure 1000 1200 1400 Boost pressure(mmHg) EH5OM012 - 125 - Maintenance of Major Components...

  • Page 129: Cooling System

    5.2. Cooling System 5.2.1. General information This engine is water-cooling type. Heat from the combustion chamber and engine oil heat are cooled down by coolant and radiated to the outside, resulting in the normal operation of the engine. Looking into the cooling system, the water pumped up by the water pump circulates around the oil cooler through the water pipe to absorb the oil heat, and then flows through the water jacket of the cylinder block and water passage of the cylinder head to absorb the heat of the combustion chamber.
  • Page 130 5.2.2. Thermostat General descriptions and main data The thermostat maintains a constant To radiator temperature of coolant (71 ~ 85 °C) and improves thermal efficiency of the engine by preventing heat loss. Namely, when the temperature of coolant is low, the thermostat valve is Bypass closed to make the coolant bypass to valve...
  • Page 131 Replacing thermostat and precautions for handling (1) Precautions for handling The wax pallet type thermostat does not react as quickly as bellows type one to a variation of temperature of coolant. Such relatively slow reaction is mainly due to the large heat capacity of the wax pellet type thermostat.

  • Page 132: Lubricating System

    5.3. Lubricating System 5.3.1. General descriptions and main data General descriptions All the engine oil pumped up from the oil pan by the gear type oil pump is filtrated through the oil cooler and oil filter, and this filtrated oil is forced through the main oil gallery in the cylinder block from where it is distributed to lubricate the various sliding parts, and fuel injection pump in order to ensure normal engine performance.
  • Page 133 5.3.2. Oil filter This oil filter mounted in this engine is a full flow type, so it is necessary to replace it with a new one at the specified intervals. EFM2010I 5.3.3. Diagnostics and troubleshooting Complaints Possible causes Corrections 1. Oil consumption Poor oil Use suggested oil excessive...

  • Page 134: Turbo Charger

    Compression Efficiency (%) 75.5 75.0 77.5 Compression Ratio 3.00 2.80 2.90 2) Technical data of power unit engine Generator Engine PU158TI PU180TI PU222TI Turbocharger Model Allied Signal T04E Allied Signal T45 Allied Signal TV51 Rated Revolution (rpm) 111,800 92,200 82,000...
  • Page 135 5.4.2. Construction Make sure that serving should be performed at the professional maintenance shop as authorized by allied signal Company. 27, 30, 31 EFM3001I 1. Turbine shaft 15. Seal plate 2. Thrust bush 16. Thrust bearing 3. Oil shut off 17.
  • Page 136 5.4.3. Summary The engine output depends upon the supplied fuel quantity and the engine efficiency. In order to transform into the effective work of engine by burning the supplied fuel fully, the sufficient air to burn the fuel should be supplied to the cylinder. Therefore, the engine output is essentially determined by the size of the cylinder, and for if the air is supplied to the given volume of cylinder with the air being compressed, the air quantity in the cylinder will Increase as much to result in that it may burn more fuel.
  • Page 137 5.4.5. Maintenance The turbochargers do not call for any specific maintenance. The only points to be observed are the oil pipes which should be checked at every oil change for leakage and restrictions. The air cleaners should be carefully serviced. Furthermore, a regular check should be kept on charge air and exhaust gas pipes.
  • Page 138 5.4.6. Handling 1) Precautions at engine Operation following items must be observed at the starting, operation and stop of engine. Item Care Items At starting 1) Inspect oil quantity 2) After confirming that oil pressure rises 2) If engine is started quickly, of course by starting engine with starter (until the beginning with every parts of engine, for pointer of oil pressure gauge moves or...
  • Page 139 5.4.7. Routine inspection and maintenance Since the state of turbocharger depends largely on the state of engine maintenance, to perform the specified up keep thoroughly is needed. 1) Intake air System in the intake air system, care must be taken to the air cleaner. In case of oil passing type air cleaner, if the oil level is lower than the specified value, the cleaning efficiency get worse, if higher, the sucked oil pollutes a case.
  • Page 140 5.4.8. Periodic inspection and maintenance The turbocharger assembly must be inspected periodically. 1) Revolving state and inspection points of rotor Inspection on the revolving state of rotor is performed according to abnormal noises. In case of using an acoustic bar, touch the turbocharger housing with a tip of bar and raise the engine revolution slowly, Then, in case that high sound is heard by every 2 ~ 3 sec.
  • Page 141 3) Overhaul and cleaning points Disassemble the turbocharger from engine and perform a cleaning and inspection, and in this case, the oil inlet and outlet should necessarily be sealed with tape etc. 4) Precautions in assembling engine When in assembling the turbocharger or the handling after assembling should work observing the following precautions necessarily.
  • Page 142 5.4.9. Trouble cause diagnosis and remedy Condition Causes Remedies 1. Exhaust gas 1) Air cleaner elements clogged Replace or clean excessive 2) Air Inlet port clogged Inspect or repair 3) Air leaks from air intake system Inspect or repair 4) Turbocharger impossible to rotate due to stuck Overhaul and repair or replace 5) Turbine wing’s contact Overhaul and repair or replace...

  • Page 143: Installation

    5.5. Installation 5.5.1. Inspection prior to installation Measure the correctness of flywheel and flywheel housing. Prior to inspection, clean the flywheel and flywheel housing. 1) Measuring flywheel housing Measure the flywheel housing surface and install the dial gauge (1/1,000) at the Dial gauge flywheel so as to be vertical to the Flywheel...
  • Page 144 4) Measuring pilot bore of flywheel Install the gauge as below so as for the gauge stem to contact to the pilot bore of Dial gauge the surface to be installed. The Flywheel eccentrics of the pilot bore of flywheel should not exceed 0.127 mm at maximum.
  • Page 145 3) Aligning center The center alignment of engine and Generator is the most important factor for the extension of life cycle. Output shaft flange and opponent side flange of Generator should be aligned in their centers horizontal and parallel direction. The adjustment between flange surfaces at the lower part should maintain less than 0.15 mm when the upper part’s surfaces just meet and the deviation around the circumference should be maintained within 0.1 mm as following figure.

  • Page 146: Air Cleaner

    5.6. Air Cleaner 1. Connection port, fouling indicator 2. Cleaner housing 3. Clamp 4. Element 5. Hexagon nut 6. Cover 7. Dust bowl EA6O5012 5.6.1. Maintenance (only when engine is switched off) Empty the dust bowl (7) regularly. The bowl should never be filled more than halfway with dust. On slipping off the two clamps (3), the dust bowl can be removed.
  • Page 147 5.6.3. Cleaning filter elements By compressed air (wear goggles) For the purpose, the air gun should be fitted with a nozzle extension which is bent 90° at the discharge end and which is long enough to reach down inside to the bottom of the element.

  • Page 148: Tightening Cylinder Head Bolts

    5.7. Tightening Cylinder Head Bolts 1) Retightening cylinder head bolts on new engines by authorized specialist personnel (engine cold or warm) The cylinder heads are mounted with Intake side injector cylinder head bolts which are tightened by the angle-of-rotation method. On new engines the cylinder head bolts are tightened up for the first time at the factory after the engine has been broken in.
  • Page 149 3) Retightening cylinder head bolts after repairs by authorized specialist personnel (engine cold or warm) After the first 10 to 20 hours of operation after a repair turn the cylinder head bolts by a further 90° (1/ 4 revolution) in the order shown in above figure. ((2) Tightening cylinder head bolts after repair) The cylinder head bolts to be retightened must not be loosened first, but simply tightened by a further 90°...

  • Page 150: V-Belts

    5.8. V-belts The tension of the V-belts should be checked after every 2,000 hours of operation. 1) Change the V-belts if necessary If in the case of a multiple belt drive, wear or differing tensions are found, always replace the complete set of belts.
  • Page 151 60 kg 20.2 mm 75 kg 70 kg 60 kg * : Adopted in P158LE, PU158TI, P180LE, PU180TI, P222LE, PU222TI 5) Tensioning and changing V-belt Remove fixing bolts. (1) Remove lock nut. (2) Adjust bolt (3) until V-belts have correct tensions.

  • Page 152: Special Tool List

    6. Special Tool List Part no. Figure Tool name EF.120-029 Oil seal insert Assembly (RR) EF.120-183 Valve stern oil seal installer EI.00308-0084 Nozzle holder extractor EU.2-0532 Compression gauge adapter EI.03004-0225 Nozzle plug socket EF.120-189 Injection pump alignment EF.120-031 Piston sleeve EF.120-028 Liner assembly - 149 -...
  • Page 153 Part no. Figure Tool name T7621010E Piston ring plier 60.99901-0027 Feeler gauge T7610001E Snap ring plier EF.123-065 Valve cotter extractor EF.120-069 F.W.H. Pin installer E1.05508-0815 CRS Wear ring installer EF.120-032 Can gear sub jig EF.120-030 Oil seal insert assembly (FR) Special Tool List - 150 -...
  • Page 154 Appendix Standard table of tightening torque ⋅ Specification Screw Strength Tightening Torque kg Cylinder block bearing cap ⋅ – main bolt M18 × 2 12.9 Initial 30 kg m + rotating angle 90° – side bolt M12 × 1.5 10.9 Flywheel housing –...
  • Page 155 Standard bolt tightening torque table Refer to the following table for bolts other then described above. Degree of strength 10.9 12.9 Diameter (4A) (4D) (4S) (5D) (5S) (6D) (6S) (6G) (8G) (10K) (12K) × Limit value for elasticity (kg/mm pitch (mm) ⋅...
  • Page 156 Tightening torque for plug screw Items Specifications Remarks Inside dia. of liner forced in joint part (upper part) 145.800 ~ 145.840 145.8 H7 Cylinder Inside dia. of liner forced in joint part (lower part) 144.500 ~ 144.540 144.5 H7 block Inside dia.
  • Page 157 Items Specifications Remarks Con rod small end part width 38.070 ~ 39.000 Con rod large end part width 35.341 ~ 35.380 35.5 C8 Con rod cap 32.800 ~ 33.100 32.8 + 0.3 Con rod axial direction clearance 0.240 ~ 0.392 Con rod small end part axial direction clearance 0.064 ~ 0.126 Con rod bush oil clearance...
  • Page 158 Items Specifications Remarks Crankshaft’s axial direction’s clearance 0.190 ~ 0.322 Main bearing thickness Standard 3.460 ~ 3.472 Oversize 0.10 3.510 ~ 3.522 Oversize 0.25 3.585 ~ 3.597 Crank shaft Oversize 0.50 3.710 ~ 3.722 Oversize 0.75 3.835 ~ 3.847 Oversize 1.00 3.960 ~ 3.972 Main bearing oil gap 0.066 ~ 0.132...
  • Page 159 Items Specifications Remarks Valve lift 14.1 Projecting amount of valve guide 17.1 ~ 17.5 Above valve spring Free length of inside spring 72.43 Spring load of inside spring 15 ~ 17kg at 46.3 mm Valve spring Spring load of inside spring 27 ~ 32kg at 32.3 mm Free length of outside spring...
  • Page 160 1) P158LE : Generator engine assembly EH5OM013 - 157 - Appendix...
  • Page 161 2) P180LE : Generator engine assembly EH5OM014 Appendix - 158 -...
  • Page 162 3) P222LE : Generator engine assembly EH5OM015 - 159 - Appendix...
  • Page 163 4) PU158TI : Power unit engine assembly EH5OM016 Appendix - 160 -...
  • Page 164 5) PU180TI : Power unit engine assembly EH5OM017 - 161 - Appendix...
  • Page 165 6) PU222TI : Power unit engine assembly EH5OM018 Appendix - 162 -...

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