Doosan DP158L Series Operation & Maintenance Manual
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Doosan DP158L Series Operation & Maintenance Manual

Doosan DP158L Series Operation & Maintenance Manual

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950106-037009EN
Operation &
Maintenance Manual
DIESEL GENERATOR ENGINE
DP158L, DP180L, DP222L

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Summary of Contents for Doosan DP158L Series

  • Page 1 950106-037009EN Operation & Maintenance Manual DIESEL GENERATOR ENGINE DP158L, DP180L, DP222L...
  • Page 3 To ensure best performance and quality as well as to enhance maintenance techniques, Doosan Infracore is doing it's best to continuously develop and invest. The design of our product may be changed without prior notice and Doosan shall not be held liable for the failure of this manual to contain all the design changes made to improve the product.

  • Page 4: Table Of Contents

    Table of contents 1. General introduction .........................1 General information ........................... 3 Danger, warning, caution, and note ......................4 Engine maintenance ..........................8 2. Operation and maintenance .....................9 Starting and stopping of the engine ......................11 Break-in period of the engine ........................13 Operation in winter ...........................
  • Page 5 7. Lubrication system .......................115 General information ..........................117 8. Fuel system ..........................121 General information ..........................123 Fuel injection pump ..........................127 9. Intake/exhaust system ......................135 General information ..........................137 General information ..........................139 10. Cylinder block/head ......................149 General information ..........................151 Cylinder block ............................

  • Page 7: General Introduction

    1. General introduction General information ........................3 General Information ............................3 Danger, warning, caution, and note ...................4 General Information ............................4 General Instructions ............................4 Precautions in Starting the Engine........................5 Cautions for Inspection and Repair........................5 General Repair..............................6 Other Safety Instructions and Environmental Pollution..................6 Use of Genuine Parts............................

  • Page 9: General Information

    In the event that a part must be replaced, only genuine parts as defined by the parts the list (PARTS BOOK) should be used. Doosan shall not be held liable for any crit- ical damage or faults which may be caused by the use of unauthorized or remanufactured parts.

  • Page 10: Danger, Warning, Caution, And Note

    Doosan engines. The recommended repair methods and eyes to fuel or antifreeze, occurs while starting, 'Danger,' 'Warning,' and 'Caution' can enhance the degree of...

  • Page 11: Precautions In Starting The Engine

    1. General introduction 5. Do not touch the hot engine during operation since. WARNING 6. Exhaust gas is poisonous. Fully ventilate before starting engine. If the space is enclosed, ensure that it is well Immediately after stopping the engine or during ventilated.

  • Page 12: General Repair

    1. General introduction 7. Follow the instructions provided by the battery manufac- 7. Replace parts such as cotter pins, gaskets, O-rings, seal turer when checking or handling batteries. rings, oil seals, and washers with new ones during repairs. Reuse of parts may be the cause of engine faults WARNING and engine may not operate properly.

  • Page 13: Use Of Genuine Parts

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

  • Page 14: Engine Maintenance

    Use of genuine parts is recommended. Using unauthorized or remanufactured parts may cause critical damage and Consider the following to manage engine without causing faults to engine for which Doosan shall not be held liable. environmental pollution. Consider the following while managing engines.

  • Page 15: Operation And Maintenance

    2. Operation and maintenance Starting and stopping of the engine ..................11 Preparing for Start............................11 Starting the Engine ............................11 Running in ............................... 11 During Operation............................. 11 Stopping the Engine............................12 Break-in period of the engine ....................13 General Information ............................13 Break-in Period of a New Engine ........................

  • Page 17: Starting And Stopping Of The Engine

    Use fuel, oil, and coolant load during the first few hours of operation. Initial run-in recommended by Doosan. Otherwise, critical damage to should be at varying speeds or load. After this initial run-in, the engine may occur the engine should be brought up to fuel output gradually.

  • Page 18: Stopping The Engine

    2. Operation and maintenance 1) Do not switch off the main battery. 2) Do not disconnect the battery or pole terminals or the cables. 3) If during operation the battery charge lamp suddenly lights up, stop the engine immediately and remedy the fault in the electrical system.

  • Page 19: Break-In Period Of The Engine

    2. If the oil indicator lamp on the apparatus is turned on or blinks, the oil pressure may be insufficient. In this case, Doosan engines are subjected to a final approval test to check the oil level and replenish oil if required. When...
  • Page 20 2. Operation and maintenance 3. If color or odor of exhaust gas is unusual during opera- tion, stop the engine, diagnose the cause and fix the fault. 4. Check the engine status through the alarm indicator lamp and gauges mounted on the apparatus during operation.

  • Page 21: Operation In Winter

    When replacing engine oil, use of off, turn the key switch to the ignition position. When the Doosan genuine engine oil is recommended. key switch is turned to the ignition position, the pre-heater plug or air heater runs continuously to make starting the engine easier and reduce white exhaust gas.

  • Page 22: Inspection And Repair Of The Engine

    2. Operation and maintenance Inspection and repair of the engine Checking Engine Parts after Prolonged Oper- Exhaust System ation If exhaust gas is leaked from the connections in the exhaust Wear, corrosion, or degradation of engine elements and pipe, the turbocharger efficiency is lowered, causing assemblies may occur, causing lowered performance of degraded engine output and seizure of related parts in the engine parts.

  • Page 23: Performance And Specifications

    3. Performance and specifications Engine specifications and performance ...................19 Engine Specifications............................19 Gross Engine Output ............................28 Exterior view drawing of the engine ..................29 Front/Rear(DP158L) ............................29 Left/Right(DP158L) ............................30 Top(DP158L) ..............................31 Front/Rear(DP180L) ............................32 Left/Right(DP180L) ............................33 Top(DP180L) ..............................34 Front/Rear(DP222L) ............................

  • Page 25: Engine Specifications And Performance

    3. Performance and specifications Engine specifications and performance Engine Specifications DP158L Item Remarks DP158LCS DP158LCF DP158LDS DP158LDF10 General Information Engine types Water-cooled, 4cycle, V-type, Turbo charger & inter cooled (air to air) Cylinder liner type Wet type liner No. of cylinder - bore x stroke 8 - 128 X 142 (mm) Total displacement(cc)
  • Page 26 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 Oil filter Full flow, Cartridge type Max.
  • Page 27 3. Performance and specifications DP158L Item Remarks DP158LCS DP158LCF DP158LDS DP158LDF10 Intake No. of valve (per cylinder) Exhaust Intake 0.25 ±0.05 Valve lashes (at cold) (mm) Exhaust 0.35 ±0.05 Opening 24° (BTDC) Intake valve (°) Close 36° (ABDC) Opening 63° (BBDC) Exhaust valve (°) Close...
  • Page 28 3. Performance and specifications DP180L Item Remarks DP180LBS DP180LBF DP180LAS DP180LAF General Information Engine types Water-cooled, 4cycle, V-type, Turbo charger & inter cooled (air to air) Cylinder liner type Wet type liner No. of cylinder - bore x stroke 10 - 128 X 142 (mm) Total displacement(cc) 18,273...
  • Page 29 3. Performance and specifications DP180L Item Remarks DP180LBS DP180LBF DP180LAS DP180LAF Lubrication method Fully forced pressure feed type Type Gear type Oil pump Driving type Driven by crankshaft gear Oil filter Full flow, Cartridge type Max. Oil capacity (L) Min. Idle speed Min.
  • Page 30 3. Performance and specifications DP180L Item Remarks DP180LBS DP180LBF DP180LAS DP180LAF Opening 24° (BTDC) Intake valve (°) Close 36° (ABDC) Opening 63° (BBDC) Exhaust valve (°) Close 27° (ATDC) Electrical System Alternator voltage - capacity (V - 27.5 - 45 Voltage regulator Built-in type IC regulator Starting motor voltage - capacity...
  • Page 31 3. Performance and specifications DP222L Item Remarks DP222LAS DP222LBS DP222LBF DP222LCS DP222LCF General Information Engine types Water-cooled, 4cylcle, V-type Turbo charger & Inter cooled (air to air) Cylinder liner type Wet Type No. of cylinder - bore x stroke 12 - 128 X 142 (mm) Total displacement(cc) 21,927...
  • Page 32 3. Performance and specifications DP222L Item Remarks DP222LAS DP222LBS DP222LBF DP222LCS DP222LCF Lubrication method Fully forced pressure feed type Type Gear type Oil pump Driving type Driven by crankshaft gear Oil filter Full flow Cartridge type Max. Oil capacity Min. Idle speed Min.
  • Page 33 3. Performance and specifications DP222L Item Remarks DP222LAS DP222LBS DP222LBF DP222LCS DP222LCF Intake 0.25 ±0.05 Valve lashes (at cold) (mm) Exhaust 0.35 ±0.05 Opening 24° (BTDC) Intake valve (°) Close 36° (ABDC) Opening 63° (BBDC) Exhaust valve (°) Close 27° (ATDC) Electrical System Alternator voltage - capacity 27.5 - 45...

  • Page 34: Gross Engine Output

    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) 60Hz DP222LCS 1,023...

  • Page 35: Exterior View Drawing Of The Engine

    3. Performance and specifications Exterior view drawing of the engine Note) The images shown represent the standard model; they do not include all models. Front/Rear(DP158L) DV2213001A 1. Fuel Filter 6. Crankshaft Pulley 11. Engine Oil Supply Pipe 2. Breather 7. Cooling Fan Pulley 12.

  • Page 36: Left/Right(Dp158L)

    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 37: Top(Dp158L)

    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. Air Pipe...

  • Page 38: Front/Rear(Dp180L)

    3. Performance and specifications Front/Rear(DP180L) DV2213001B 1. Fuel Filter 6. Cooling Fan Pulley 11. Flywheel Housing 2. Coolant Pump 7. Idle Pulley 12. Flywheel 3. Alternator 8. Engine Oil Return Pipe 13. Oil Pan 4. Engine Oil Drain Plug 9. Turbocharger 14.

  • Page 39: Left/Right(Dp180L)

    3. Performance and specifications Left/Right(DP180L) DV2213002B 1. Cooling Fan 6. Turbocharger 11. Flywheel Housing 2. Oil Pan 7. Breather 12. Oil Filter 3. Engine Oil Drain Plug 8. Fuel Filter 13. Alternator 4. Starter 9. Oil Cooler 14. Oil Cap 5.

  • Page 40: Top(Dp180L)

    3. Performance and specifications Top(DP180L) DV2213003B 1. Injector 4. Fuel Injection Pump 7. Oil Filler Cap 2. Fuel Injection Pipe 5. Intake Manifold 8. Inlet Pipe 3. Fuel Pre-Filter/Priming Pump 6. Air Pipe...

  • Page 41: Front/Rear(Dp222L)

    3. Performance and specifications Front/Rear(DP222L) DV2213004A 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. Alternator 9. Engine Oil Return Pipe 14.

  • Page 42: Left/Right(Dp222L)

    3. Performance and specifications Left/Right(DP222L) DV2213005A 1. Cooling Fan 6. Turbocharger 11. Flywheel Housing 2. Oil Pan 7. Breather 12. Oil Filter 3. Engine Oil Drain Plug 8. Fuel Filter 13. Alternator 4. Starter 9. Oil Cooler 14. Oil Cap 5.

  • Page 43: Top(Dp222L)

    3. Performance and specifications Top(DP222L) DV2213006A 1. Injector 4. Fuel Injection Pump 7. Oil Filler Cap 2. Fuel Injection Pipe 5. Intake Manifold 8. Inlet Pipe 3. Fuel Pre-Filter/Priming Pump 6. Air Pipe...

  • Page 44: Engine Identification Number

    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 assurance or to order parts. •...

  • Page 45: Regular Inspection

    4. Regular inspection General information ......................41 General Information ........................... 41 Routine Inspection ............................. 41 Regular inspection table .....................42 General Conditions ............................ 42 Use of Genuine Parts..........................43 Cooling system ........................44 General Information ........................... 44 Coolant standards............................44 Capacity of coolant ............................ 44 Checking the Coolant..........................
  • Page 46 Checking the injection timing ........................57 Adjusting injection timing ........................... 58 Intake/exhaust system ......................59 General Information ........................... 59 Air Filter..............................59 Disassembly of air filter..........................59 Cleaning of the Air Filter Element ......................60 Changing the air filter element ........................61 Turbocharger .............................

  • Page 47: 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 be • Incorrect inspection methods may cause of engine maintained. faults. Regular inspection and replacement according to the recom- •...

  • Page 48: Regular Inspection Table

    4. Regular inspection Regular inspection table General Conditions Regular inspection and replacement according to the recom- mended 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 49: Use Of Genuine Parts

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

  • Page 50: Cooling System

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

  • Page 51: Measurement Of Coolant Concentration

    4. Regular inspection Measurement of Coolant Concentration 2) Compare the color of the test sheet (B) to the color of MOLYBDATE (Middle pad) of the standard color table. • Special Tools 3) Compare the color of the test sheet (C) to the color of Figure Product Number/Name NITRITE of the standard color table.

  • Page 52: Charging The Coolant

    4. Regular inspection 1. Make sure that engine and radiator are cooled. 5. Drain cooling water in the oil cooler. 2. Open the radiator cap. DANGER • Never open the radiator cap while the engine is overheated. If the radiator cap is opened while the engine is overheated, hot water will spurt out and may cause serious burns.

  • Page 53: Cleaning The Cooling Circuit

    4. Regular inspection 5. After checking the coolant level when the engine is 2. If you want to clean the cooling circuit swiftly, remove the warmed up, replenish coolant if necessary. thermostat. 3. Mix water and 1.5% of cleaning solution and fill the DANGER cooling circuit with this liquid.
  • Page 54 4. Regular inspection Air/air intercooler with downstream radiator (Combined radiator) Cooling air Hot charge air from compressor Recooled charge air to intake pipe (max. 50 C) DV2213205B CAUTION To keep the optimum performance of the air cooler, clean it regularly.

  • Page 55: Lubrication System

    Engine Oil Viscosity by temperature Ambient temperature EDL0213001A Please use the engine oil which satisfies the following recommended specifications. Engine Model and Product Code SAE Classification Oil Class DP158L/DP180L/DP 222L SAE 10W40 CI-4 or higher Note) Use of Doosan genuine engine oil is recommended.

  • Page 56: 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. Replenish Please replenish the engine oil based on the following or replace the engine oil if required. recommended oil amount.

  • Page 57: Replacement Of Engine Oil

    When replacing the oil filter cartridge, be sure to use 6. Idle the engine for several minutes so that the oil circulate the genuine part of Doosan. through the lubrication system. 7. Then, stop the engine, wait for about 10 minutes, check the oil level, and fill the oil if required.

  • Page 58: Fuel System

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

  • Page 59: 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 separa- tion. 1. the water separation function of the fuel filter discharges water and sediment from the water separator. 2.

  • Page 60: 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 assembled, you should replace the seal ring with a new one.

  • Page 61: 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 62: Removal Of Nozzle

    4. Regular inspection 3. Check the nozzle spray status. If it is defective, replace the nozzle. CAUTION • As the nozzle injection nozzle is designed to operate under high pressure, you should handle it with special care. • Do not hold your hands under the fuel jet, as there is a rise of injury.

  • Page 63: Installation Nozzle

    4. Regular inspection Installation nozzle • Hold the needle at the pintle end only ; to avoid corrosion do not touch the lapped surfaces of the needle with you 1. Clean seat in cylinder head. fingers. 2. Insert nozzle holder with new gasket. •...

  • Page 64: Adjusting Injection Timing

    4. Regular inspection Adjusting injection timing Injection Timing If upper pre-checked injection timing degree is wrong, follow Engine Model (°) as below. DP158LCS 1. Loosen the fixing bolts(M8) of the injection pump driving 23° ± 1° gear in order to adjust the injection timing slightly. DP158LCF 18°...

  • Page 65: 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 filter is DANGER directly related to engine lifetime, emissions, and engine output.

  • Page 66: 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 method minutes.

  • Page 67: 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 resistance should be small as possible.

  • Page 68: 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 connection. • When the engine runs abnormally even if the fuel injec- tion system is normal.

  • Page 69: Tightening Cylinder Head Bolt

    4. Regular inspection • 8 cylinder engine(DP158L) 3) After the first 400 hours of operation retighten cylinder head bolts 1 to 4 in the order shown in right figure by a Valve overlap cylinder No. further 90°(1/4 revolution). CAUTION Adjusting valve cylinder No. (In./Ex. Valve) •...

  • Page 70: Cylinder Compression Pressure

    4. Regular inspection 7) After 400 hours of operation turn the cylinder head bolts by a further 90°(1/4 revolution). CAUTION • The two outside screws (intake and exhaust side) must not be retightened. • The cylinder head bolts to be retightened must not be loosened first, but simply tightened by a further 90°(1/4 revolution) from their actual position.

  • Page 71: 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 battery, • Check the specific gravity of electrolyte. If it is below the and replace the battery if defective.

  • Page 72: 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 73 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 74 4. Regular inspection...

  • Page 75: About The Engine

    5. About the engine Marking system of units ......................71 Unit Conversion Methods........................... 71 Tightening torque ........................72 Tightening Torque of Main Parts........................ 72 Tightening Torque of General Bolts ......................74 Tightening torque of plug screw......................... 75 Hollow Screw (4-Hole) Tightening Torque ....................75 Engine Disassembly ......................76 Procedure of Disassembling an Engine.....................

  • Page 77: 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 US Power 1.340483 units and vice versa. 1. To convert an SI unit to a US unit, multiply a SI unit with 0.01 the number in the following table.

  • Page 78: Tightening Torque

    5. About the engine Tightening torque Tightening Torque of Main Parts Screws Tightening Torque Main Parts Strength (Diameter X Pitch) (kgf·m) Bedplate bolt M8 x 1.25 8.8T 2.2 ± 0.22 Cylinder block & bedplate Screw plug (PT) PT 3/8 6.5 ± 0.5 Coolant drain plug M12 x 1.5 5 ±...
  • Page 79 5. About the engine Screws Tightening Torque Main Parts Strength (Diameter X Pitch) (kgf·m) Pressure sensor adapter bolt M6 x 1.0 8.8T 0.85 ± 0.15 Coolant temperature sensor M12 x 1.5 2.5 ± 0.3 Boost Sensor M14 x 1.5 4.0 ± 0.5 Exhaust temperature sensor M14 x 1.5 4.0 ±...

  • Page 80: Tightening Torque Of General Bolts

    5. About the engine Tightening Torque of General Bolts Please refer to the following tightening torque for the bolts which are not listed in Tightening Torque of Main Parts. 1. Tightening Torque of General Bolts Strength Classification 10.9 12.9 Nominal (4A) (4D) (4S)

  • Page 81: Tightening Torque Of Plug Screw

    M14 x 1.5 18.5 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 82: 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 83 5. About the engine 6. Remove the alternator. 1) Loosen the hose clamp(A). 2) Loosen the V-clamp(B). 3) Remove the inlet elbow(C). 4) Remove the other side elbow as the same procedure. CAUTION Be careful not to loss the O-ring and insert parts when removing the inlet elbow.
  • Page 84 5. About the engine 1) Loosen the clamp(A). 13. Remove the intake stake. 2) Loosen 2 fixing bolts(B) 11. Remove the turbocharger. DV2213061A 1) Loosen the fixing bolt(A). DV2213170A 2) Loosen the hose clamp(B). 1) Loosen 4 fixing nuts(A). 3) Loosen the V-clamp(C). 2) Remove the turbocharger(B).
  • Page 85 5. About the engine 17. Remove the fuel pipe. DV2213063A DV2213067A 1) Loosen the fixing bolts(A). 1) Loosen the fixing bolts(A). 2) Remove the inlet pipe(B). 2) Loosen the hollow screw(B). 16. Remove the fuel injection pipe assembly. 3) Remove the fuel pipes(C). CAUTION •...
  • Page 86 5. About the engine 21. Remove the fuel pre-filter. DV2213070A DV2213065A 1) Loosen the fixing bolts(A). 1) Loosen the hollow screws(A). 2) Loosen the hollow scres(B). 2) Loosen the fixing bolts(B). 3) Remove the fuel and oil hoses(C). 3) Remove the fuel return pipe and fuel pre-filter. 20.
  • Page 87 5. About the engine 23. Remove the cylinder head cover. 25. Remove the injectors. DV2213074A DV2213073A 1) Loosen 3 fixing bolts(A). 1) Remove the injector holer fixing nut(B) with the jig for 2) Remove the cylinder head cover(B) and the gasket. injection nozzle detach(60.99901-0036).
  • Page 88 5. About the engine 27. Align the fuel injection pump pointer. 29. Remove the rocker arm assembly. DV2213171A DV2213075A 1) Rotate the flywhee to the eingine rotation direction. 1) Loosen the fixing bolts(A). 2) The injection timing pointer marking on the fuel injection 2) Remove the rocker arm assembly(B).
  • Page 89 5. About the engine 31. Remove the cylinder head assembly. 33. Remove the thermostat. DV2213077A DV2213172A 1) Loosen 6 fixing bolts(A). 1) Remove the O-ring(B). 2) Remove the cylinder head assembly(B). 2) Remove the thermostat(A). 3) Remove 12 cylinder head assemblies as the same proce- 3) Remove the gasket(C).
  • Page 90 5. About the engine 35. Remove the idle pulley and cooling fan pulley assembly. 37. Remove the oil cooler cover. DV2213174A DV2213083A 1) Loosen 1 fixing bolt(A) and 2 fixing nuts(B). 1) Loosen 20 fixing bolts(A). 2) Remove the idle pulley(C). 2) Remove the oil cooler cover(B).
  • Page 91 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 92 5. About the engine 3) Remove 12 cononecting rod and pistonb assemblies as 45. Remove the cylinder liner. 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 93 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 bolts(B). DV2213091A 2) Remove bearing cap(C). 1) Remove the tacho sensor(A).
  • Page 94 5. About the engine 52. Remove the vavle tappet and the spray nozzle. DV2213095A 1) Loosen 2 fixing bolts(A) and 1 hollow screw(B). 2) Remove the oil spray nozzle(C). 3) Remove 12 oil spray nozzles as the same procedure. 4) Remove the valve tappet(D). 5) Remove 24 valve tappets as the same procedure.

  • Page 95: Engine Assembly

    5. About the engine Engine Assembly Procedure of Assembling Engine 2. Attach the crankshaft.dps CAUTION • Cleanse all disassembled and disconnected parts. Especially, clean the oil and coolant path with compressed air and check if there is any resistance. • Arrange general tools and special tools for engine assembly.
  • Page 96 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 97 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 98 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 99 5. About the engine 4) Attach 12 connecting rod and piston assembly as the 1) Attach the oil pan(B). same procedure. 2) Tighten 20 M8 fixing bolts(A) at a tightening torque 2.2 ± 0.33kgf·m. CAUTION 16. Change the engine position. •...
  • Page 100 5. About the engine Engine Model Fuel Injection Timing (°) DP158LCS 23° ± 1° DP158LCF 18° ± 1° DP158L DP158LDS 23° ± 1° DP158LDF 18° ± 1° DP180LBS 21° ± 1° DP180LBF 19° ± 1° DP180L DP180LAS 21° ± 1° DP180LAF 19°...
  • Page 101 5. About the engine 20. Attatch the fuel injection pump driven gear. 22. Attach the cylinder head. DV2213187A DV2213189A 1) Tighten 3 M8 fixing bolts(A) of the fuel injection pump driven gear at a tightening torque 3.1 kgf·m ± 0.46kgf·m. 2) Rotate the fuel injection pump driven gear 360°...
  • Page 102 5. About the engine 4) Attach the valve spring(E). 24. Attach the push rods. CAUTION Be carful the valve direction. Install the valve spring seat with “TOP” (painted in Dual Spring - Yellow / Single Spring - Red) side up. 5) Compress the valve with the valve spring press (EF.120-262).
  • Page 103 5. About the engine 26. Attach the injectors. Note) In case of 8/12 cylinder engine, #6. cylinder is posi- tioned at the valve overlap when #1. cylinder is posi- tioned at the compression TDC(Top Dead Center). Note) In case of 10 cylinder engine, #7. cylinder is positioned at the valve overlap when #1.
  • Page 104 5. About the engine 3) Push the feeler gauge between a rocker arm and a valve • 12cyliner engine (DP222L) stem. Valve overlap cylinder No. 4) Adjust the clearance screw respectively and then tighten with the lock nut. Adjusting valve cylinder No. (In./Ex. Valve) 29.
  • Page 105 5. About the engine 31. Attach the intake manifold. 33. Attach the fuel and oil hose. DV2213066A DV2213070A 1) Attach the intake mainfold(B). 1) Attach the fuel and oil hose(C). 2) Tighten the fixing bolts(A) by hand temporarily. 2) Tighten the hollow screw(B) at a tightening torque 3) Tighten thd fixing bolts(A) at a tightening torque 2.2kgf·m 1.8kgf·m ±...
  • Page 106 5. About the engine 35. Attach the fuel pipe. 5) Tighten the fixing bolt(A). CAUTION • Be careful not to damage the fuel pipes. • Be careful not to let dust inside the engine. 37. Attach the inlet pipe. DV2213067A 1) Attch the fuel pipe(C).
  • Page 107 5. About the engine 4) Attach the other exhaust manifold and exhaust elbow 2) Tighten the fixing bolt(A) at a tightening torque 7.5kgf·m assembly as the same procedure. ± 1.12kgf·m. Note) Tighten the fixing bolts to attach the exhaust manifole 39.
  • Page 108 5. About the engine 43. 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. 45. Attach the oil cooler housing. DV2213058A 1) Attach the oil delivery pipe(D).
  • Page 109 5. About the engine 47. Attach the oil cooler cover. 49. 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 3.1kgf·m. 2) Tighten 8 M16 stud head bolts(A) at a tightening torque CAUTION 21.0kgf·m ±1.0kgf·m.
  • Page 110 5. About the engine 9) Tighten 1 fixing bolt(A) and 2 fixing nuts(B). 53. Attach the cooling water pipe. CAUTION Make sure that the cooling fan pulley can be rotated after attaching. 51. 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 111 3) Tighten the fixing nut(A) at a tightening torque 2.2kgf·m ± 0.33kgf·m. CAUTION Use coolant recommended by Doosan. 60. Add the engine oil. 1) Add our recommended genuine oil to replenish the oil level. CAUTION Use genuine engine oil recommended by Doosan.
  • Page 112 5. About the engine...

  • Page 113: Cooling System

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

  • Page 115: General Information

    6. Cooling system General information General Information Coolant which absorbed the oil and combustion heat flows into the water temperature controller through the coolant This engine is water-cooled. It uses coolant to cool the pipe. If the coolant temperature is lower than the engine by absorbing heat from the combustion chamber and valve-opening temperature of the water temperature the engine oil and then releases the heat, allowing for normal...

  • Page 116: Specifications

    6. Cooling system Specifications DP158L Item Remarks DP158LCS DP158LCF DP158LDS DP158LDF10 Cooling System Cooling method Fresh water forced circulation Engine only Approx. 23 Coolant capac- ity (L) With radiator Approx. 79 (Air on 43°C) / Approx 90 (Air on 52°C) Coolant flow rate (L /min) Pressure cap (kPa) Max.
  • Page 117 6. Cooling system DP222L Item Remarks DP222LAS DP222LBS DP222LBF DP222LCS DP222LCF Cooling System Cooling method Fresh water forced circulation Engine only Approx. 33 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 118: 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 119: Thermostat

    6. Cooling system Thermostat General Information Check of the thermostat The thermosatat maintains water temperature in the engine 1. Check whether the wax pellet and the spring are consistently and prevents heat loss to improve heat effi- damaged or not. ciency of the engine.
  • Page 120 6. Cooling system...
  • Page 121 7. Lubrication system General information ......................117 General Information ..........................117 Specifications............................118 Failure Diagnosis ............................. 120...

  • Page 123: Lubrication System

    7. Lubrication system General information General Information From the cylinder block, oil is delivered to the crankshaft bearings, camshaft bearings, and rocker arm for lubrication. This engine is the forced lubrication type of engine. Oil pres- In addition, the turbocharger is connected to the engine lubri- sure is generated and delivered by rotating the gear of the oil cation circuit.

  • Page 124: Specifications

    7. Lubrication system Specifications DP158L Item Remarks DP158LCS DP158LCF DP158LDS DP158LDF10 Lubrication System Lubrication method Fully forced pressure feed type Type Gear type Oil pump Driving type Driven by crankshaft gear Oil filter Full flow, Cartridge type Max. Oil capacity (L) Min.
  • Page 125 7. Lubrication system DP222L Item Remarks DP222LAS DP222LBS DP222LBF DP222LCS DP222LCF Lubrication System Lubrication method Fully forced pressure feed type Type Gear type Oil pump Driving type Driven by crankshaft gear Oil filter Full flow Cartridge type Max. Oil capacity Min.

  • Page 126: Failure Diagnosis

    7. Lubrication system Failure Diagnosis Phenomenon Causes Troubleshooting Bad oil Replace oil with specified oil. Oil leakage from the oil seal ring and packing part Replace it Worn or damaged piston and piston ring Replace it Too much oil consumption Worn cylinder liner Replace it Burnt piston ring...
  • Page 127 8. Fuel system General information ......................123 General Information ..........................123 High Sulfur content in diesel fuel ......................123 Water (Moisture) in diesel fuel ......................... 124 Specifications............................124 Failure Diagnosis ............................. 126 Fuel injection pump ......................127 General Information ..........................127 Adjustment Fuel Injection Pump ......................128...

  • Page 129: General Information

    The fuel lines should have a sufficient inner diameter. The fuel lines should be routed so that the fuel is not exces- Doosan diesel engines can be operated with fuels Whose sively heated by the heat radiation from the engine.

  • Page 130: Water (Moisture) In Diesel Fuel

    8. Fuel system Water (Moisture) in diesel fuel • Destruction of engine In case of diesel fuel containing high water content due to Water in the fuel causes; insufficient fuel quality, maintenance difficulty or environ- • Incomplete combustion mental adversity, an extra water separator with adequate •...
  • Page 131 8. Fuel system DP222L Item Remarks DP222LAS DP222LBS DP222LBF DP222LCS DP222LCF Fuel System Injection pump Bosch in-line "P" type 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...

  • Page 132: Failure Diagnosis

    8. Fuel system Failure Diagnosis Symptom Causes Troubleshooting • Clogged fuel pipe, or air entered the fuel pipe line • Correct 1. Engine does not start A. Fuel is not supplied from the • Defective delivery pump valve • Replace fuel delivery pump •...

  • Page 133: 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 separate 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 134: 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 6) Fuel injection timing : BTDC 23°...
  • Page 135 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 136 667) • 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 137 667) • 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 138 8. Fuel system 5. DP222L (60Hz) • Prestroke : 4.5 ± 0.05 mm (13 ± 1.5 mm) 1) Fuel injection pump : 65.11101-7303 (0 402 619 807) 2) Nozzle holder assembly : 65.10101-7051 (0 432 131 • Model : PE12P120A500LS7937 (0 412 620 854) 667) •...
  • Page 139 8. Fuel system 6. DP222L (50Hz) • Prestroke : 4.5 ± 0.05 mm (13 ± 1.5 mm) 1) Fuel injection pump : 65.11101-7303 (0 402 619 807) 2) Nozzle holder assembly : 65.10101-7051 (0 432 131 • Model : PE12P120A500LS7937 (0 412 620 854) 667) •...
  • Page 140 8. Fuel system...
  • Page 141 9. Intake/exhaust system General information ......................137 General Information ..........................137 Specifications............................138 General information ......................139 Construction............................. 139 Function ..............................140 Failure Diagnosis ............................. 141 How to Maintain Turbocharger......................... 145 Special inspection of turbocharger......................146...

  • Page 143: Intake/Exhaust System

    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 delivered The exhaust gas of the engine passes through the turbine to the cylinder. That is, the enfine power is virtually deter- wing of turbocharger to rotate the rutbine.

  • Page 144: 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 145: General Information

    9. Intake/exhaust system General information Construction 27, 30, 31 DV2213108A 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 Seal ring Journal bearing...

  • Page 146: 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, This is called as the turbine and in order not to influence a bad Compressor Engine effect at bearing part, there are the seal ring and heat...

  • Page 147: 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 148 9. Intake/exhaust system Phenomenon Causes Troubleshooting Leakage of gas from each part of the exhaust system 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 compres- Check or repair it sor shaft Deformed or damaged intake system hose...
  • Page 149 9. Intake/exhaust system Phenomenon Causes Troubleshooting Leakage from the engine block and the exhaust mani- Check the engine fold Check the turbo impeller and the turbo intake Contaminated blowby gas and abnormal oil amount outlet Large gap of the turbocharger wheel, causing interfer- Check if there is any sand or metallic foreign ence with the wall substance...
  • Page 150 9. Intake/exhaust system Phenomenon Causes Troubleshooting Deformed or damaged intake system hose Replace it Replace and check if the impeller of the turbo- Contaminated or damaged air filter charger is damaged Leakage of coolant from the turbocharger or oil from the Replace the hose and the gasket oil hose Poor turbo actuator operation...

  • Page 151: How To Maintain Turbocharger

    9. Intake/exhaust system How to Maintain Turbocharger 1. Cautions for engine operation 1) Observe the followings when starting, operating, and stopping an engine. Item Cautions Reasons 1) Check the oil amount 2) Therefore, start the engine with the starter motor 2) Overhasty start of engine leads to engine to check the rise of oil pressure (until the gradation rotation without lubricating turbocharger...

  • Page 152: Special Inspection Of Turbocharger

    9. Intake/exhaust system Special inspection of turbocharger You should check the radial and axial clearance of a rotor. This preventive action is to find the bearing wear status of the axial clearance so as to prevent the severe damage to the rotor and bearing.
  • Page 153 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 154 9. Intake/exhaust system...
  • Page 155 10. Cylinder block/head General information ......................151 General Information ..........................151 Specifications............................151 Cylinder block ........................153 Check of Cylinder Block........................... 153 Measurement of Cylinder Liner........................ 153 Cylinder head ........................154 Measurement of Cylinder Liner........................ 154 Assembly of Cylinder Head........................154 Check of Cylinder Head ........................... 155 Valve ..........................156 General Information ..........................

  • Page 157: 10. Cylinder Block/Head

    10. Cylinder block/head General information General Information 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.
  • Page 158 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 Intake 0.25 ±0.05 Valve lashes (at cold) (mm) Exhaust 0.35 ±0.05 Opening 24° (BTDC) Intake valve (°) Close...

  • Page 159: 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 160: 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 the 1. Remove the cotter pin pressing the valve spring by special tool.

  • Page 161: Check Of Cylinder Head

    10. Cylinder block/head Check of Cylinder Head Standard Limit 1. Checking cylinder head 1) Check cracks or damage of the cylinder head. Below 0.05mm 0.2mm 2) Remove carbon from the bottom surface of the cylinder head. Here, be careful not to scratch the valve seat surface.

  • Page 162: 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 163: Valve Seat

    10. Cylinder block/head 2. Valve seat thickness and angle: Assemble the valves at 4. Regarding the valve seat assembling, shrink the valve the cylinder head and using the measuring instrument seat by putting it in the dry ices for about 1 hour or so, and from the lower face, measure the projection amount of then press it into the cylinder head by means of a special valve.
  • Page 164 10. Cylinder block/head Spring tester 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 tolerance limit, replace the valve spring. Item Standard Limit Intake / Outside 1.2 mm...

  • Page 165: 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 166: Tappet And Push Rod

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

  • Page 167: Camshaft

    10. Cylinder block/head Camshaft Camshaft End Play Check and measurement of Camshaft Measure the camshaf’st axial end play. 1. Visual check 1. Push the camshaft toward the pulley side. With inspecing the cam surface for any damage with 2. Place a dial gauge onto the camshaft gear. naked eyes and correct any minor scratches by means of an oil stone grinding and if severe, replace it.

  • Page 168: Check Of Camshaft

    10. Cylinder block/head Check of camshaft 5. Camshaft bearing replacement Replace the camshaft bearing with a special tool. 1. Camshaft bearing outer diameter: Using an outer diam- eter micrometer, measure the outer diameter of the camshaft bearing. Item Standard Camshaft bearing outer Ø69.91 ~ Ø69.94mm diameter EDP2218003...
  • Page 169 10. Cylinder block/head Item Limit Clearance between cam- 0.18mm shaft and bearing 4. Camshaft bearing replacement: Replace the camshaft bearing with a special tool. DV2213135A 5. Warpage of camshaft: Place the camshaft on 2 V blocks, and inspect the warpage of the camshaft by using a dial gauge to correct it.
  • Page 170 10. Cylinder block/head...
  • Page 171 11. Electric system General information ......................167 Specification............................. 167 Electrical Wiring diagram ......................... 168 Switches and sensors .......................169 Temperature Switch..........................169 Temperature Sensor ..........................169 Pressure Sensor & Switch ........................169 Magnetic Pick-up ............................. 170 Starter ..........................171 General Information ..........................171 Specification.............................

  • Page 173: 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) Battery capacity 2-200Ah (recommended) DP180L...

  • Page 174: 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 175: 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 96°C Pressure (bar) Resistance ( Ω ) Current Capacity DC12V, 9A ~ 10 TYPE Normal Open (1.5)

  • Page 176: 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 Clearance 1.0 ± 0.1mm 1.0 ±...

  • Page 177: 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. CAUTION •...

  • Page 178: 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 179: Wiring Diagram

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

  • Page 180: Alternator

    11. Electric system Alternator General Information The alternator is fitted with integral silicon redtifiers. A tran- sistorized 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 moisture and...

  • Page 181: 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 182: Abnormally Charging

    11. Electric system Abnormally Charging 1. Measuring the voltage between the terminal and the alternator body when operating. Note) Measuring the voltage in order to check the wire condition needs only the terminal when the engine is stopped. 1) During operation Position Voltage Terminal B - Body...

  • Page 183: Air Heater

    11. Electric system Air Heater 1. Air heater Operating Conditions • It is recommended to use the air heater when the cooling water temperature is below 5 degrees. • Air heater, Timer, Relay is supplied, and the heater oper- ation time is automatically adjusted according to the cooling water temperature.
  • Page 184 11. Electric system 3. Air heater Diagram EDX1217144 4. Air heater schematic Engine ground Heater power can be connected directly to the battery as indicated by the dotted line EDX1217146...
  • Page 185 12. Others/driving system General information ......................181 General Information ..........................181 Crankshaft ........................182 Measurement of Crankshaft........................182 Measurement of Crankshaft Bearing and Connecting Rod Bearing ............183 Piston ..........................185 Disassembly of Piston..........................185 Assembly of Piston ..........................185 Piston Inspection............................185 Piston Ring and Ring Groove ........................

  • Page 187: 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 188: 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 bearing. 1. Inspection and measurement 3) There are 5 kinds as below, and the crankshaft also can 1) Visually inspect whether there is any crack or scratch on be used by regrinding as below.

  • Page 189: 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 10 kgf·m + 90° 4) Measure the connecting rod bearing journal inner diam- eter. Section DV2213150A Item Standard Limit...
  • Page 190 12. Others/driving system 4. End play 1) Assemble the crankshaft in the cylinder block. 2) Install the dial gauge, and measure the end play of crank- shaft by pushing the crankshaft to axial direction. DV2213153A Item Standard Limit Axial end play 0.140 ~ 0.361mm 0.4mm...

  • Page 191: 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 of snap 1. Heat the piston at the piston heater for about 5 minutes ring pliers. (120 ~ 150°C). DV2213154A DV2213156A 2.

  • Page 192: Piston Ring And Ring Groove

    12. Others/driving system Gap gauge DV2213157A DV2213159A_E Item Standard Item Standard Limit Top ring 0.35 ~ 0.50mm 1.5mm Piston outside diameter Ø127.739 ~ Ø127.757mm 2nd ring 0.40 ~ 0.60mm 1.5mm CAUTION Oil ring 0.40 ~ 0.70mm 1.5mm By comparing the measured value of the piston outside Piston pin diameter with the cylinder liner inside diameter, the 1.
  • Page 193 12. Others/driving system DV2213161A Item Standard Clearance 0.010 ~ 0.022mm...

  • Page 194: 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 195: 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...
  • Page 196 12. Others/driving system...
  • Page 197 Governor Actuator Controller...
  • Page 199 Governor Actuator Definition The governor detects the engine rpm using a magnetic pick-up sensor to adjust the flow rate of the injection pump and maintain the desired rpm. The governor activates the engine’s fuel injection pump when the accelerator pedal is pressed while the vehi- cle is in operation and adjusts the speed of the vehicle.
  • Page 200 Product Specifications 1. General specifications Item GN11 (DWA-2000) GN12 (GNSA-2002) Operating voltage (kg/lit) DC 24V DC 24V Max. fuel quantity (°C) Adjust Adjust Production capacity (40°C) (cst) 200 ~ 1,000 KW 150 ~ 250 KW Allowable humidity (wt%) 100% 100% Operating current (°C) 1.5 A...
  • Page 201 3. Outside view and main components of governor EDL11180002 1) Frame : The body of the governor. Made of ALDC-12 with high corrosion resistance. 2) Ball link assembly : A bearing assembly which connects the injection pump rack and governor actuator operating lever.
  • Page 202 Control Unit (1) The engine speed control unit used by Doosan is an electronic control unit designed to be able to respond quickly and accurately to changes in the instantaneous load. This control unit is designed to receive a signal from the magnetic pick-up sensor (speed sensor) of the engine when a fluctuation occurs in the engine load and then be automatically fine-tuned to the changes in the engine rpm, thereby providing high reliability and satisfying adverse environmental engine conditions.
  • Page 203 The performance of the speed controller is stable in its standard state. In order to switch this to the droop mode, ter- minals "K" and "L" must be connected to one another, and the amount of change must be adjusted with the adjust- ment control lever.
  • Page 204 Specifications Item Details Specifications Simultaneous Operation / ±0.25 % or less Relative Normal Stability Speed Range / Governor 1 K ~ 7.5 KHz continuously Speed deviation based on changes in temp. Max. ±1% Idle Adjustment (Clockwise) 1,200 Hz or less Idle Adjustment (Counterclockwise) 4,100 Hz or less Performance...
  • Page 205 Components DWC-2000 Over speed Reset Crank Overspeed Crank Test Speed Gain Model : DWC-2000 Stability Input : DC24V Part No. Serial No. 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...
  • Page 206 GAC-ESD5550 6.00 (152) 5.25 (133) O 0.27 (7) C1 OFF SOFT COUPLING LEAD CIRCUIT OVERSPEED OVERNORS RESET TEST MERICA OVERSPEED SPEED CONTROL UNIT SPEED ESD5550 MODEL : GAIN MADE IN AGAWAM, MA U.S.A STABILITY STARTING SPEED FUEL RAMPING DEAD TIME CAUTION DROOP COMPENSATION...
  • Page 207 Description of Controller Terminology 1. Starting Fuel Controls the amount of starting fuel during the initial ignition. When rotated clockwise, the amount of fuel increases. 2. Speed Ramping Controls the time required to reach the maximum rpm. When rotated counterclockwise, the time required for reaching the rated rpm decreases.
  • Page 208 Wiring Please refer to the chart above for the basic electrical wiring. When connecting the actuator and battery to ter- minals A, B, E and F, the wire thickness must be at least 1.3 . If the wires are long, they must be thicker in order to reduce drops in voltage.
  • Page 209 (3) If the engine is running with load, the gain and stability must be adjusted finely. Generally, this should be done in an unloaded, stable state. CAUTION In the event that it continues to appear unstable or demands higher performance in spite of being adjusted, refer to the section on troubleshooting.
  • Page 210 CAUTION The generator set supplied by Doosan does not include a speed potentiometer for remote control. The consumer must install one themselves if they desire remote control. In order to obtain engine stability at a very low speed setting, a droop potentiometer can be used to obtain a small amount of droop.
  • Page 211 Troubleshooting 1. When the system does not work When the engine actuator does not work, you can deduce the fault by performing the following four-step voltage test. Be sure to check the polarity when performing measurements. Step Terminal Specifications Possible cause 1.
  • Page 212 2. System not working properly In the event that the system is not running properly, perform the following test. Item Details Specifications Engine 1. Do not run the engine 1. The actuator will move to the position for overspeeds 2. Apply a DC power supply to maximum fuel supply.
  • Page 213 Control Unit (2) Components DWG-2013 Crank Over speed Starting Power Pick-up Crank Run Over speed Fuel Test Speed Ramping Idle Droop Speed Gain Stability Battery Speed Trim Droop Idle Frame Actuator Pick-up DV2213203B - 15 -...
  • Page 214 4. Regarding setting each Doosan engine to the average set range depending on the type of engine, the indications for the set range on the front of each adjustable resistor recommend the settings within the set range.
  • Page 215 Starting 1. The potentiometer’s guide range on the front of Fuel the case is the adjustment range applied to Doosan Infracore (Inc.) engines. Speed 2. When adjusting the potentiometer, use a flat- Ramping blade precision screwdriver of the right size.
  • Page 216 (2) Adjusts the initial engine speed. IMPORTANT After turning the initial speed switch ON again, use the idle potentiometer to adjust the speed to 800 rpm. Purpose of adjustment: Adjusting the initial amount of fuel for starting the engine and for the preheating function after starting the engine.
  • Page 217 8. Other adjustments (1) Adjusting the ON timing of the engine oper- ation (run) lamp. Crank Over Speed IMPORTANT Turn potentiometer counterclockwise engine operating speed until the engine run lamp turns on. In order to prevent the lamp from DV2213196C blinking (turning on/off when the load changes after setting the rated speed), turn...
  • Page 218 10) When the engine will not start (1) If there are no problems with the wiring connections  adjust all control values to the "factory setting." (Refer to DV2213211A)  Restart the engine. (2) If the problem is not resolved: There may be a problem with the controller hardware so replace the controller.
  • Page 219 External Wiring Connections • Refer to the wiring connection diagram to connect them. • All wiring must be over the specified 1.5 and be shielded. • When using shielded wiring, all shielded wires not indicated on the wiring connection diagram must be grounded to the frame.
  • Page 220 CAUTION Incorrectly connected wires or abnormal battery voltage can cause critical damage to the controller so be sure to inspect them before use. Mounting and Connecting the Magnetic Speed Sensor 1. The optimal gap between the magnetic speed sensor and ring gear is 0.45 mm. In order to achieve this, tighten the sensor until it makes contact with the ring gear, then turn it another 3/4 turns in the reverse direction to obtain a suitable gap.
  • Page 221 3. State of adjustment at time of factory release 300611-00683 Overspeed 1,725 rpm (based on 160 gear teeth) Run lamp Maximum CW Gain Mid-range (facing 12 o’clock) Stability Mid-range (facing 12 o’clock) Starting Fuel Full CW (Maximum Fuel) Speed Ramping Facing 9 o’clock Droop Full CCW (Minimum)
  • Page 222 300611-00685 Overspeed 2,070 rpm (based on 160 gear teeth) Run lamp Maximum CW Gain Mid-range (facing 12 o’clock) Stability Mid-range (facing 12 o’clock) Starting Fuel Full CW (Maximum Fuel) Speed Ramping Facing 9 o’clock Droop Full Full CCW (Minimum) E.M. Speed Adjustment (152 gear teeth) Speed Adjustment 3,800 Hz (1,500 rpm)
  • Page 223 Droop Parallel Operating Mode (Manual Parallel) • Definition of droop: A reduction in the speed setting following an increase in the load (No Load Speed - Full Load Rated Speed) 100 DROOP(%) = • Full Load Rated Speed • Purpose of droop: Droop is used with the purpose of load sharing in the parallel operating system among generators.
  • Page 224 System Troubleshooting (Instability) 1. Instability at rapid intervals (hunting): Applying SW D1 and D2 (1) The differential function activates when D1 is placed in the ON position. (2) This can increase the responsiveness to changes in speed (rpm), thereby enabling quicker response to changes in speed.
  • Page 225 When the System is Not Working In the event that the engine governor system is not working properly, you can deduce the cause by performing the test in the following chart. Here, (+) and (-) represent the polarities of the measuring instrument. Using the method in the chart below, if the test results are normal, there may be a problem in the actuator or the actuator wiring connections so the actuator must be inspected.
  • Page 226 Digital Speed Controller Product Overview and General Specification 1. Product information Digital speed controller (DSC-1000) is applicable to generator (vehicles and vessels) engines as a high performance embedded electronic control system designed based on PID control for fast and precise con- trol of engine speed with an enhanced micro controller unit (MCU) that minimizes analog circuits vulnera- ble to user environments.
  • Page 227 2. Product appearance Digital Speed Controller is made of a rigid aluminum case taking into account anti-shock, electromagnetic resistance and environmental protection. An embedded system containing graphic LCD and high perfor- mance MCU is inside the controller and a heat sink is located on the outside of the case for protection and precise control of actuator operating elements.
  • Page 228 3. Product specification Item Description 16-bit DSC dsPIC33FJ256 Graphic LCD 128*64 Display LED: 6 ea Keypad 8 Button Keys Output 3 Contact Points (a and b) Input RMS 3V (Min) Memory 128 Mb RS232 57600 bps Communication CAN (J1939)/250 kbps Rated Power DC 24V (12V ~ 30V) Current Consumption...
  • Page 229 4. Product system diagram System Configuration for Digital Speed Controller +10V Toolkit Cable Aux Input Speed Trim Idle Switch * All of the GND(Earth) Mark must to wiring to GND Droop Switch * CAN and R232 Communication Line must to concect with shield Cable EEX190001 5.
  • Page 230 Terminal I/O Type Terminal Functions Terminal K receives droop function selecting information. Droop Terminal L has a ground signal and the switch is connected to ter- Input (K, L) minals K and L. Once the terminal K is connected to the ground, droop starts to operate.
  • Page 231 6. Product dimension 4- 6 EDL11160004 - 33 -...
  • Page 232 Installation Digital Speed Controller should be connected to the pick-up sensor attached on the engine and the actuator. Speed trim, droop, idle and aux terminals can be used for additional functions in connection with surrounding circuits. Contact points a or b can also be used to operate external devices using crank, run and over speed functions.
  • Page 233 (2) Connecting to batteries Battery voltage is DC +24V and the battery is connected to the controller matching E (-) and F (+) with the respective polarities of the battery. E (-) is connected to (-) of the battery and F (+) to (+) of the bat- tery.
  • Page 234 2. Connecting to speed trim, droop, idle and other inputs (1) Speed trim, droop, idle and other inputs diagram Toolkit Cable RS232 5 4 3 2 1 9 8 7 6 Pin No. Description Pin No. Description +3.3V /MCLR PGC2 PGD2 +10 V External...
  • Page 235 (3) Connecting to droop The switch is connected to terminals K and L. Signals indicating whether droop function works or not serve as inputs to the controller by keeping K and L either open or close. Inputs can be done by toggle or converting switches.
  • Page 236 3. Connecting to crank, run, over speed and communication (1) Crank, run, over speed and communication connection diagram It is used to deliver operation information to external devices by activating contact point (a or b) when activat- ing crank, run or over speed functions. RS232 and CAN communication is connected to external PCs or hosts so that the controller can transmit system settings or operation information.
  • Page 237 (3) Connecting to run terminals Terminals 4, 5 and 6 are the ones for run output contact point and the contact point will be in operation when the controller activates the run function. The fifth crank contact point is a shared terminal while terminals 4 and 5 are for the contact point b and terminals 5 and 6 for the contact point a.
  • Page 238 Configuration and Operation The controller can be configured and operated by input keys according to the menus on the LCD display by selecting proper ones and assigning values in the selected menu to input control information to the system. Input information should immediately apply to the controller system once updated. 1.
  • Page 239 2. LCD display menu The overall menu tree of the controller is as follows: Menu Display MENU Low Battery Main Display Logo Display MENU MENU MENU MENU MENU LEFT RIGHT DOWN RPM Display Menu Display MENU Low Battery Main Display Logo Display MENU MENU...
  • Page 240 LED turns on in red where there are fault conditions. At this moment, the LCD display is not activated and Doosan logo will appear for 1 second followed by the operation display after pressing the LCD button.
  • Page 241 (2) LCD main menu display Displays main menu screen of the controller The main menu of the controller has 10 sub-menus. Main Menu of the Controller 1 to 2 EDL11160053 Engine type The controller can start operation once the initial system values are configured. Users can load preset values depending on types of the engines by selecting the type.
  • Page 242 System monitor It offers menu to monitor the controller operation. It shows values for Engine RPM, Valve Duty, Valve Current, Aux RPM Input, Pickup Voltage and Bat Voltage. (3) Engine type setup menu This menu offers function to configure setting values of the controller depending on types of the engines in advance and apply such preset values to the selected engine.
  • Page 243 Gear number Users can input the number of flywheel teeth in the engine to the controller so that the controller can calculate the accurate RPM depending on the values of the pick-up sensor from the engine. Starting fuel Users can designate the amount of fuels used when the engine starts to operate and the operat- ing current for the controller to activate the actuator changes based on these values.
  • Page 244 (5) PID gain setup menu Users can input Kp, Ki and Kd values as inputs to the PID control of the engine. Kp means proportional values while Ki means integral of the proportional values and Kd means differential of the proportional val- ues.
  • Page 245 (8) Alarm list menu This menu displays year, month, day, hour and minute for the errors in the controller and types of the faults in codes which are used in troubleshooting. EDL11160019 (9) Default setup menu When you cannot identify the type of the control engine by the controller, this menu offers the most common parameter setting values.
  • Page 246 3. Engine configuration (1) Engine type configuration Users can store control setting information depending on types of the engines in the internal memory of the controller. If you select your engine type, applicable parameters will be automatically configured accordingly. This feature is available for 16 different types of engines. Designated parameters by engine type (Configuration values by engine type) Gear Starting...
  • Page 247 Engine configuration procedure Step 1) Press Menu button of the control- ler and then you can see DRIVE UNIT MENU. Step 2) Select Engine Type by using Up and Down buttons in DRIVE UNIT MENU and then press Enter button. Step 3) Go to Engine Type Menu and EDL11160022 select your engine type using Up...
  • Page 248 Configuring set idle rpm Step 1) Press Menu button of the controller and then you can see DRIVE UNIT MENU. Step 2) Select System setup menu in DRIVE UNIT MENU using Up, Down, Left and Right buttons and then press Enter button. Step 3) Select SET IDLE RPM in SYSTEM SETUP menu and then press Enter button.
  • Page 249 Configuring cranking rpm Step 1) Press Menu button of the controller and then you can see DRIVE UNIT MENU. Step 2) Select System setup menu in DRIVE UNIT MENU using Up, Down, Left and Right buttons and then press Enter button. Step 3) Select CRANKING RPM in SYSTEM SETUP menu and then press Enter button.
  • Page 250 Configuring starting fuel Step 1) Press Menu button of the controller and then you can see DRIVE UNIT MENU. Step 2) Select System setup menu in DRIVE UNIT MENU using Up, Down, Left and Right buttons and then press Enter button. Step 3) Select STARTING FUEL in SYSTEM SETUP menu and then press Enter button.
  • Page 251 Configuring max current Step 1) Press Menu button of the controller and then you can see DRIVE UNIT MENU. Step 2) Select System setup menu in DRIVE UNIT MENU using Up, Down, Left and Right buttons and then press Enter button. Step 3) Select MAX CURRENT in SYSTEM SETUP menu and then press Enter button.
  • Page 252 Configuring droop gain Step 1) Press Menu button of the controller and then you can see DRIVE UNIT MENU. Step 2) Select System setup menu in DRIVE UNIT MENU using Up, Down, Left and Right buttons and then press Enter button. Step 3) Select DROOP GAIN in SYSTEM SETUP menu and then press Enter button.
  • Page 253 (Example for 7% droop) Assuming that RPM with no load is 1,800 and RPM with maximum load is 1,926 then the percentage will be 5%. It means that the generator output will be changed by 14.3% as the frequency changes by 1% due to the actuator control.
  • Page 254 N - load curr Step 1) Press Menu button of the controller and then you can see DRIVE UNIT MENU. Step 2) Select System setup menu in DRIVE UNIT MENU using Up, Down, Left and Right buttons and then press Enter button. Step 3) Select N - LOAD CURR.
  • Page 255 Configuring PID sampling time Step 1) Press Menu button of the controller and then you can see DRIVE UNIT MENU. Use Up, Down, Left and Right buttons to select PID gain setup menu and then press Enter button. Step 2) Use Up and Down buttons in PID GAIN SETUP to select SAMPLING TIME and then press Enter button.
  • Page 256 Step 4) Press YES and then the system message "PID AUTO SETUP MODE" will appear. As PID auto setup was initiated during the operation, PID auto tuning is already in progress. EDL11160038 Step 5) PID tuning repeats a process to obtain PID values and a window to indicate whether the pro- cess succeeded or failed will appear in several minutes (approx.
  • Page 257 (6) Alarm list Step 1) Press Menu button of the controller and then you can see DRIVE UNIT MENU. Use direction buttons to select Alarm List menu and then press Enter button. Step 2) Use Up, Down, Left and Right buttons in ALARM LIST menu to confirm the fault messages. EDL11160041 Alarm code table Alarm...
  • Page 258 (7) Actuator test The menu offers function to test whether there is any problem in operating load current of the actuator attached to the engine. It indicates voltage and current for on/off. (8) Default setup functions Step 1) Press menu button of the controller and then you can see DRIVE UNIT MENU. Use Up, Down, Left and Right buttons to select Default setup menu and then press Enter button.
  • Page 259 (10) LCD setup functions Step 1) Press Menu button of the controller and then you can see DRIVE UNIT MENU. Use Up, Down, Left and Right buttons to select LCD setup menu and then press Enter but- ton. Step 2) Use Up and Down buttons to select menus including LCD BRIGHTNESS and LCD CON- TRAST for adjustment and then press Enter button.
  • Page 260 4. How to operate (1) Operating sequence for digital speed controller Step 1) Supply DC +24V power to the battery terminals (E (-), F (+)) of the controller. Step 2) Configure parameter values required for selection of the engine type and control of the engine.
  • Page 261 Troubleshooting 1. Alarm list check Where there are problems in the system operation, you need to review the alarm list menu of the control- ler and then check the engine and the system in reference to the alarm codes. Alarm Alarm Alarm Condition Output Control...
  • Page 262 (-E, +F) of the battery. If the LED does not turn on, cut the power off and contact our A/S center for service request. Step 4) Check whether the power LED turns on and Doosan logo appears on the LCD display after sup- plying power to DC +24V input terminals (-E, +F) of the battery.

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