Page 1 950106-038007EN Operation & Maintenance Manual MARINE ENGINE V158TI, V180TI, V222TI, AD158TI, AD180TI, AD222TI...
Page 3 FOREWORD This manual is designed to serve as a reference for the operation & Maintenance of V158TI/180TI/222TI Marine engines and AD158TI/180TI/222TI marine generator engine united in one book. The former is explained for operation and the latter is described for maintenance like parts disassembly, maintenance &...
Page 4 Malfunctions resulting from incorrect operation by the user, delayed repairs, accidents, and natural ● disasters The contents of this operation and maintenance manual are the exclusive property of Doosan Infracore. Any unauthorized reproduction, printing and distribution thereof are strictly prohibited.
Page 5 CONTENTS 1. SPECIFICATION ......................... 1 1.1. Engine Specification ........................... 1 1.2. Engine Aspects ........................... 5 1.3. Engine Performance Curve ........................ 8 1.4. Engine Model & Serial Number ......................9 2. SAFETY REGULATIONS......................11 2.1. General Notes ..........................11 2.2. Regulations Designed to Prevent Accidents with Injury to Persons ..........11 2.3.
Page 6 7. MAIN PARTS MAINTENANCE ....................114 7.1. Lubricating System ......................... 114 7.2. Cooling System ..........................115 7.3. Fuel System ............................ 115 7.4. Turbo-charger ..........................139 8. TROUBLE SHOOTING ......................166  Appendix...
Page 7 1. SPECIFICATION 1.1. Engine Specification 1.1.1. V158TI Marine Engine Specification V158TI Model Units V158TIH V158TIM V158TIL 4 cycle, V-type, direct-injection, water cooled Engine type with wet-turbo charger & inter-cooler Rating output (B.H.P) PS(kW)/rpm 480(353)/1,800 540(397)/2,100 680(500)/2,300 Displacement 14,618 Cylinder number - bore (Ø) x stroke 8 - Ø128 x 142...
Page 8 1.1.2. V180TI Marine Engine Specification V180TI Model Units V180TIH V180TIM V180TIL 4 cycle, V-type, direct-injection, water cooled Engine type with wet-turbo charger & inter-cooler Rating output (B.H.P) PS(kW)/rpm 600(441)/1,800 650(478)/2,100 820(603)/2,300 Displacement 18,273 Cylinder number - bore (Ø) x stroke 10 - Ø128 x 142 Valve clearance at cold In / Ex...
Page 9 1.1.3. V222TI Marine Engine Specification V222TI Model Units V222TIH V222TIM V222TIL 4 cycle, V-type, direct-injection, water cooled Engine type with wet-turbo charger & inter-cooler Rating output (B.H.P) PS(kW)/rpm 720(530)/1,800 800(588)/2,100 1,000(736)/2,300 Displacement 21,927 Cylinder number - bore (Ø) x stroke 12 - Ø128 x 142 Valve clearance at cold In / Ex...
Page 10 1.1.4. AD158TI / AD180TI / AD222TI Model DV Series Units Spec. AD158TI AD180TI AD222TI 4 cycle, V-type, direct-injection, water cooled Engine type with wet-turbo charger & inter-cooler 410(302)/1,500 606(446)/1,500 485(357)/1,500 50 Hz (AD180TIF) (AD222TIF) (AD158TIF) PS(kW) Rating output (B.H.P) / rpm 480(353)/1,800 600(441)/1,800 720(530)/1,800...
Page 11 1.2. Engine Aspects Note : The images shown represent the standard model; they do not include all models. 1.2.1. Engine sectional view (Longitudinal → V222TI) EB2M1001 1. Cylinder head 4. Tappet 7. Oil pump 2. Cylinder head cover 5. Camshaft 8.
Page 12 1.2.2. Engine sectional view (Cross → V222TI) EB2M1002 1. Intake manifold 6. Exhaust manifold 11. Oil cooler 2. Breather assembly 7. Piston 12. Oil level gauge 3. Injection pump 8. Connecting rod 13. Oil filter 4. Injection pipe 9. Cylinder liner 14.
Page 13 1.2.3. Engine assembly (V222TI) EDV2218083 1. Crank pulley 7. Fresh water filler cap 13. Exhaust manifold 2. Fuel filter 8. Sea water pump 14. Turbocharger (wet) 3. Intercooler 9. Heat exchange ass′y 15. Sea water inlet pipe 4. Oil drain pump 10.
Page 14 1.3. Engine Performance Curve 1.3.1. V158TI Heavy Duty Medium Duty Light Duty Propulsion Curve Propulsion Curve Propulsion Curve Full Consumption Full Consumption Full Consumption 1000 1500 2000 1000 1500 2000 1000 1500 2000 Engine Speed (rpm) Engine Speed (rpm) Engine Speed (rpm) EDV2218086 1.3.2.
Page 15 1.4. Engine Model & Serial Number The engine serial number is inscribed on the engine as illustrated. This number is required when requesting warranty and ordering parts. It is also referred to as engine model and serial number because of their location. Note : The engine model name (V222TI) is Name Plate...
Page 16 Specification - 10 -...
Page 17 Do not touch the engine with bare hands when it is warm from operation risk of burns. ● Exhaust gases are toxic. Comply with the installation instructions for the installation of DOOSAN marine diesel engines which are to be operated in enclosed spaces. Ensure that there is adequate ventilation and air extraction.
Page 18 2.2.2. 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.
Page 19 ″just as good″. (4) In addition to the above, note the following points. ● Never let the engine run when dry, i.e. without lube oil, fuel or coolant. Use only DOOSAN approved service products. (engine oil, anti-freeze and anti-corrosion agent) ●...
Page 20 2.4. Regulations Designed to Prevent Pollution 2.4.1. Engine oil, filter element, fuel filter ● Take old oil only to an oil collection point. Take strict precautions to ensure that oil does not get into the drains or into the ground and sea. ●...
Page 21 3. COMMISSIONING AND OPERATION 3.1. Inspections before Operation 3.1.1. Lubricating oil a) The notches in dipstick must indicate the oil level between max. and min. permissible. b) The measurement of the oil level must be done on a even water line and in 10 min- utes after engine operating.
Page 22 3.1.3. Sea water pump Impeller of the sea water pump is a bronze type, therefore you should install the sea water strainer as right figure in order not to suck in any hard pieces and sharp scales. Install the sea water strainer in adequate size for the engine between kingston valve and sea water pump.
Page 23 3.1.7. Gauge panel Check the all gauges of the panel whether the function is in normal or not. Before operation your engine familiarize yourself with the instruments supplied with your boat. 1) Analog gauge panel ● Deluxe panel EDV2218013 1. Volt meter 5.
Page 24 ● Single panel / Dual panel EDV2218015 1. Tachometer 5. Monitor warning lamp 9. Key switch 2. Water temp. gauge 6. Push button 10. Panel 3. Oil pressure gauge 7. Rotary switch 4. Clutch oil press. gauge 8. Stop button ●...
Page 25 2) Digital gauge panel ● Circuit diagram EDV2218035 - 19 - Commissioning and operation...
Page 26 ● Front EDX1218005 1. LCD 3. Key switch 2. Function Keys 4. Start / stop button ● Rear EDX1218006 1. Power connector 6. Fuse 2. Signal connector 7. CCTV (Optional) 3. CAN 8. GPS (TBD) 4. Ext. buzzer 9. Built-in buzzer 5.
Page 27 3.1.8. Engine stop & warning devices V158TI/V180TI/V222TI gauge panel is equipped with an audible alarm to alert the operator to the following. 1) Engine stop device (Stop solenoid) ● When the engine oil pressure is less than 0.5 kg/cm ●...
Page 28 3.2. Starting 3.2.1. Operation 1 (Analog panel) After checking the warning lamps of the gauge panel and the NEUTRAL position of reduction gear control lever, turn the key switch to the START position to crank the engine, at once. Behavior - When the key switch is placed in the START position. After the engine is cranked, convert the key switch to the ACC position quickly.
Page 29 3.3.1. New engine break-in 20 hours All DOOSAN marine engines have been run for a short period of time as a final test at the factory. You must follow the Engine Break-In procedure during the first 20 hours of operation to ensure maximum performance and longest engine life.
Page 30 3.3.3. Next 8 hours During the next 8 hours, continue to operate at approximately three-fourths throttle or less (minimum planing speed). Occasionally reduce throttle to idle speed for a cooling period. During this 8 hours of operation it is permissible to operate at full throttle for periods of less than two minutes only 2 times. Note : Do not run engine at a constant rpm for prolonged periods of time during the break-in period.
Page 31 3.3.5. Operating after break-in 20 hours When starting a cold engine, always allow the engine to warm up gradually. Never run the engine at full throt- tle until the engine is thoroughly warmed up. And you′d better run the engine at three-fourths throttle (about 1,600 rpm) before initial 50 hours as possible. Be sure to check the oil level frequently during the first 50 hours of operation since the oil consumption will be high until the piston rings are properly seated.
Page 32 3.5. Check after Initial 50 Hours Operation. To insure your continued boating enjoyment, you should check as follows : ● Change engine oil and oil filter cartridge. ● Change fuel filter cartridge. ● Check coolant level. ● Check the tension of all drive belts. ●...
Page 33 3.7. Tuning the Engine The purpose of an engine tune-up is to restore power and performance that′s been lost through wear, corro- sion or deterioration of one or more parts or components. In the normal operation of an engine, these changes can take place gradually at a number of points, so that it′s seldom advisable to attempt an improvement in per- formance by correction of one or two items only.
Page 34 Commissioning and operation - 28 -...
Page 35 4. The use of proper tools or specified special tools is important to perform the efficient and reliable mainte- nance operation. 5. Use genuine DOOSAN parts necessarily. 6. Used cotter pins, gaskets, O-rings, oil seals, lock washer, self-lock nuts and rubber coated seal ring etc.
Page 36 4.2. Periodical Inspection & Maintenance In order to insure maximum, trouble-free engine performance at all times, regular inspection, adjustment and maintenance are vital before occurring any problems. ● Daily inspections in below figure should be checked every day. ● The following maintenance details should be executed thoroughly at regular internals. Every Every Every...
Page 37 4.3. Cooling System 4.3.1. Coolant level check and refill ● Replenish the deficient coolant in the expansion tank every day before running. The coolant must be changed at intervals of 1,200 hours operation or six months whichever comes first. If the coolant is being fouled greatly, it will lead engine overheat or coolant blow off from the expansion tank.
Page 38 4.3.2. Contamination check of coolant and quantity of anti-freeze ● We recommend the engine coolant for DOOSAN marine engines should be mixture of fresh water and additional agent (35 ~ 40% anti-freeze and 3 ~ 5% anti-corrosion agent). Check the quantity of anti-freeze every 600 hours. From time to time, refill the anti-freeze as much as required.
Page 39 (1) Compare the end pad ″a)″ color of % GLYCOL / FREEZEPOINT ( ) (End Pad) the strip with color blocks of a row at the upper part of the standard color chart (below of the letter ″GLYCOL/ -12 -15 -18 -21 -23 -29 -34 -43 -51 FREEZE POINT″).
Page 40 Ambient Fresh water (%) Anti-freeze (%) temperature (°C) Over -10 Any coolant loss due to engine operation must be replenished. But adding fresh water for coolant tends to lower the content of anti-freeze. Always replenish the coolant with a mixture of antifreeze and water, and keep the proper content of antifreeze (35 ~ 40%).
Page 41 If, in the case of a multiple belt drive, wear or differing tensions are found, always replace the complete set of the belts. Note : Always apply to DOOSAN genuine parts every replacement. 4.3.6. Thermostat The thermostat maintains a constant tempera- To heat exchanger ture of coolant (71 ~ 85°C) and improves ther-...
Page 42 ● Inspecting (1) Check the wax pallet and spring for damage. (2) Put the thermostat in a container of Thermometer water, then heat the water slowly and check temperature with a thermometer. If the valve lift is 0.1 mm (starting to Wood plate open) at temperature of 71°C and 8 mm or more (opening wide) at temperature...
Page 43 4.4. Lubrication System 4.4.1. Oil level ● The notches in dipstick must indicate the oil level between high and low permissible when the vessel is in the water that is at normal trim. ● The oil level should be checked at the hori- zontal position of the boat after waiting about 10 minutes since then the engine has been shut down.
Page 44 4.4.2. Exchanging of lubrication oil Engine oil and the oil filter is important factors affecting engine life. They affect ease of starting, fuel econ- omy, combustion chamber deposits and engine wear. Change the engine oil at 50 hours of operation at first and next exchange will be performed every 250 hours.
Page 45 Note : It is strongly advisable to use DOOSAN genuine oil filter cartridge for replacement. EFM2010I ● Lightly oil the O-ring and turn the oil filter until sealing face is fitted against the O-ring. Turn 3/4 ~ 1 turns further with the filter wrench.
Page 46 Right-hand filter cut out Continuous operation Left-hand filter cut out (both filter halves in operation) EDV2218091 Caution : Do not leave selector lever in any intermediate position because this would be liable to interfere with oil supply. 4.4.4. Oil centrifugal filter ●...
Page 47 4.5. Intake & Exhaust System 4.5.1. Cleaning & change of the air filter element The engine life and performance depends on the intake air condition greatly. A fouled air filter element result a decreased intake air amount leading the engine output decrease and finally may cause an engine malfunction.
Page 48 4.5.2. Inter-cooler Inter cooler depends on the intake air condition greatly. The fouled air pollutes and clogs the air fins of the inter cooler. As a result of this, the engine output is decreased and the engine malfunction may be occurred. Therefore always check weather the intake air systems like air filter element are worn or polluted.
Page 49 If the air compressor should be badly fouled, it is recommended that the wheel be allowed to soak in a vessel with solvent and to clean it then with a stiff non-steel brush. In doing so, take care to see that only the com- pressor wheel is immersed and that the turbocharger is supported on the bearing casing and not on the wheel.
Page 50 Fuel quality is an important factor in obtaining satisfactory engine performance, long engine life, and acceptable exhaust emission levels. DOOSAN engines are designed to operate on most diesel fuels mar- keted today. In general, fuels meeting the properties of ASTM designation D975 (grades 1-D and 2-D) have provided satisfactory performance.
Page 51 Fuel oil selection chart General Fuel ASTM No. 1 No. 2 DIN 51601 Classification test ASTM 1-D ASTM 2-D Gravity, (API #) D 287 40 ~ 44 33 ~ 37 0.815 ~ 0.855 Flash point D 93 100 (38) 125 (52) 131 (55) °...
Page 52 4.6.3. Water separator DOOSAN recommends the fuel water separa- Bleed screw tor to install between fuel tank and fuel injec- tion pump strongly. D out out C Condensation formed in a partially filled tank Stage 5 promotes the growth of microbial organisms...
Page 53 Bleeding of the fuel system Whenever fuel filter is changed or the engine is stopped cause of the fuel lack, the air of fuel line must be removed as follows. Bleed the fuel by manually operating the priming pump with fuel filter outlet joint bolt and injection pump bleeder screw loosened.
Page 54 4.7. Electric System 4.7.1. Warning lamp check Check the lamps of the gauge panel carefully whether the lamp is switch on or not while the engine is run- ning. If the oil warning lamp is switched on below 0.5 bar of the oil pressure and the water temp warning lamp is switched off over 95°C of water temperature, their function is normal.
Page 55 First of all detach the battery wire (-) and then the other wires and clean the wires. If the battery is refilled with the distilled water, refill it but DOOSAN batteries need not. And apply the grease on the surface of the wire terminals to protect corrosion.
Page 56 General information - 50 -...
Page 57 5. MAIN ACCESSORY PARTS 5.1. Reduction Gear Refer to ″reduction gear manual″ provided with engine separately for detail operation and maintenance of reduction & maintenance. 5.1.1. Construction and operation The reduction gear is used for high-speed engine and consists of 4 major components such as input shaft, gear shaft, output shaft, and housing.
Page 58 The hydraulic-type clutch is composed of forward main body, reverse main body, output shaft, and selector valve. The selector valve assembly installed on the external part is a device designed to control forward, neutral, and reverse movements and also it can be remote-controlled. The oil pumped up at the pump supplies hydraulic pressure for the clutch assembly, lubricating portions on gear and bearings, and cooling system.
Page 59 5.2. Front Power Take Off Refer to Service and Operation manual of AP Power Take Off company for detail operation and maintenance. 5.2.1. PTO Description and operation Below figure shows a section view of a typical multiple-plate PTO. A driveshaft(1) is carried in a cast iron housing(2). The tapered roller bearing(4) locates in the flywheel(5) (various types of bearing can be specified) to support the input end of the drive shaft.
Page 60 Release levers(11) carried on the pressure plate are connected to a release sleeve(12) by control links(13). The PTO is engaged by moving the lever(14) in the direction of the engine. The lever is attached to a cross- shaft(15) in the PTO housing and a release bearing yoke(16). As the lever moves toward the engine, the bearing yoke rotates with the cross shaft and moves the release bearing(17) and sleeve(12) to contact with the adjusting ring assembly(18).
Page 61 DOOSAN engines only apply to 11.5″ PTO size. Do not adjust the PTO too tightly. Loads above the maximum quoted can cause PTO component failure. ● Re-adjust PTO with adjusting ring if necessary.(Refer to PTO adjustment 5.2.2.) ● Recheck cross shaft torque.
Page 62 <Adjusting rings> EB2O5002 ● Relocate lock or socket screw, turning adjuster ring clockwise if required, to ensure engagement of the screw or lock in the nearest spline space. The socket screw should be tightened with a torque of 10- 13 Ibs.ft.(14 ~ 18 Nm) ●...
Page 63 (5) Lubrication point ● The release bearing is lubricated through a grease nipple on the PTO housing which is connected to the bearing by a flexible hose. The drive shaft output bearings are lubricated through a grease nipple located on the PTO housing just above the bearings. Internal drillings in the housing carry the grease to the bearings.
Page 64 5.2.3. Exploded view of typical 11-1/2″ ~ 14″ twin clutch PIVOT PIN PLAIN WASHERS & SPLIT PINS OR CIRCLIPS SPLIT PINS EB4O5002 Main accessory parts - 58 -...
Page 65 (Torque represents when there is no pro- peller load) Model Load(kW) Model Load(kW) V158TIE 1,500 V180TI 1,500 V158TI 1,500 V222TI 1,500 2) For small power The right figure is applicable to the drive arrangement in which the distance between Crank V-pulley, PTO pulley the end face of the engine pulley and the MAX.
Page 66 5.3. Propeller Selection Your dealer has chosen a propeller designed to deliver top performance and economy under 100% most conditions. To obtain the maximum per- centage of available horsepower (A), the engine RPM at Full Throttle should be in the specified Full Throttle Operating Rage (B).
Page 67 5.4. Electric System 5.4.1. Alternator 24V x 80A Terminal R Terminal B Terminal L EDV2218021 Battery + 0.5 MFD Regulator Relay Terminal Trio Diode Lamp Terminal EDV2218022 The alternator is fitted with integral silicon rectifiers. A transistorized regulator mounted on the alternator con- trols the alternator voltage evenly.
Page 68 Pack them as far as possible and dispose it as rubbish that is unable to use again. ● DOOSAN will not be responsible to the problems that might be raised by the disassembling and structural change of this product without consultation. Main accessory parts...
Page 69 5.4.3. Starter motor The starter motor is installed on the flywheel Circuit diagram housing. When the starting key switch is turned on, the starter motor pinion flies out and engages the ring gear of the flywheel. Then the main con- tact is closed, current flows, and the engine is started.
Page 70 Main accessory parts - 64 -...
Page 71 6. DISASSEMBLY AND ASSEMBLY OF MAJOR COMPONENTS 6.1. Disassembly 6.1.1. General precautions ● Maintenance operation should be carried out in a bright and clean place. ● Before disassembly, provide racks for arrangement of various tools and disassembled parts. ● Arrange the disassembled parts in the disassembly sequence and use care to prevent any damage to them.
Page 72 6.1.5. V-belt. Loosen the belt tension adjusting bolts, and remove the V-belt. EFM2002I 6.1.6. Alternator Remove the supporting guide piece for install- ing the alternator and the bracket bolts. Disassemble the alternator. EFM2003I 6.1.7. Vibration damper Remove the fixing bolts for crankshaft pulley in reverse order of assembly and disassemble the crankshaft pulley and vibration damper.
Page 73 ● Do not use again the cartridge removed after use. ● Remove the oil filter head fixing bolts and disassemble the filter head. EFM2006I 6.1.9. Cooling water pump ● Loosen the various hose clamps for the connections. ● Remove the cooling water discharging pipe and disassemble the thermostat.
Page 74 ● Disassemble the rubber hoses of the fuel supply and discharge. ● Remove the fuel filter fixing bolts and dis- assemble the filter. 6.1.12. Injection pipe ● Disassemble the injection pipe from the nozzle holder and fuel injection pump. ● Disassemble various fuel pipe and hose.
Page 75 6.1.14. Turbocharger ● Loosen the hose clamp for connecting the intake stake and tear down the air intake stake. ● Loosen the clamp for connecting the air intake manifold. ● Remove the hollow screw of the turbo- charger inlet & outlet pipe for lubricating, and tear the pipes down.
Page 76 6.1.17. Intake manifold ● Remove the manifold fixing bolts and detach the intake manifold from the cylin- der head. EFM2016I 6.1.18 Heat exchanger ● Remove the hoses and the pipes. ● Remove the cover bolts ● Remove the 4 fixing bolts from the lower plate.
Page 77 6.1.21. Cylinder head cover Remove the fixing bolts and tear the cylinder head cover down. EFM2020I 6.1.22. Nozzle holder ● By means of a special tool, loosen the noz- zle holder assembly and take it out. EFM2021I 6.1.23. Rocker arm ●...
Page 78 Note : Be careful not to damage the cylinder head face where its gasket contacts. 6.1.25. Oil pan ● Remove the fixing bolts and detach the oil pan. ● Remove the oil pan gasket and scrap it. EFM2024I 6.1.26. Oil pump ●...
Page 79 6.1.28. Front oil seal holder ● Remove the oil seal holder fixing bolts and tear it down. ● Remove the oil seal and gasket from the oil seal holder and scrap them. EFM2027I 6.1.29. Flywheel ● Remove the flywheel fixing bolts in the order of disassembling and detach the fly- wheel.
Page 80 6.1.31. Crankshaft ● Loosen the bolts from bearing caps. ● Dissemble the main bearing cap fixing bolts in order of assembling. ● Remove them in the same way of the cylin- der head bolts. ● Maintain the removed bearing caps in the order of cylinder number.
Page 81 6.2. Inspection 6.2.1. 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 82 (1) Cylinder head disassembly Note : Be careful for the cylinder head gasket contact face of the cylinder head not to be damaged. ● Remove the cotter pin pressing the Valve spring valve spring by means of a special tool. compressor EA0M4007 ●...
Page 83 ● If the measured value exceeds the maximum allowable limit, replace the cylinder head. <Lower face warp and height> Standard Limit War page 0.05 mm 0.2 mm or less EA6M2002 Thickness : t 113.9 ~ 112.9 mm (reference) 114.0 mm (3) Inspection and measurement of valve and valve guide a) Valve ●...
Page 84 b) Check of valve guide ● Insert the valve into valve guide and measure the clearance between valve and valve guide by the shaking degree of valve. If the clearance is bigger, measure the valve and then replace the more worn valve guide.
Page 85 ● The disassembly of valve seat cam be pulled out by means of a special Valve seat tool with the arc welding done at two insert points of valve seat rotating tool or valve seat. Cylinder head ● Regarding the valve seat assem- bling, shrink the valve seat by putting it in the dry ices for about 1 hour or so, and then press it into the cylinder...
Page 86 <Single spring perpendicularity regular - marine> Items Free length Inside 72.43 mm Intake/ Exhaust Outside 67.17 mm <Single spring perpendicularity regular - marine generator> Items Free length Intake/ Outside 61.9 mm Exhaust <Valve spring tension standard - marine> Spring Length Limit tension Items...
Page 87 e) Assembling cylinder head ● Clean the cylinder head thoroughly. ● Coat the valve stems and valve guides with engine oil and assemble the valves. ● Replace the valve stem seals with new ones and insert the stem seals to the valve guides of cylin- der head with a special tool.
Page 88 6.2.4. 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. EFM2091I 2) Inspection and measurement a) Rocker arm bracket...
Page 89 c) Tappet and push rod ● By means of outside micrometer, measure the outer diameter of tappet and replace the severe ones. Items Standard Limit (1) Unevenness (2) Crank (3) Normal (1) Unevenness (2) Crank (3) Normal Tappet 0.035 0.15 mm ~ 0.077 mm clearance (4) Abnormal...
Page 90 ● Measure the camshaft's axial end play, moving the camshaft gear by means of a driver. Items Standard Limit 0.24 ~ 0.9 mm 0.86 mm play ● If excessive end play, assemble it by EPM2017S means of other thrust washer. (2) Inspection and measurement ●...
Page 91 ● Clearance Between camshaft journal and body. Items Standard Limit 0.060 ~ Thust 0.240 mm 0.120 mm 0.130 ~ Middle 0.240 mm 0.180 mm ● Camshaft bearing replacement Replace the camshaft bearing with a special tool. Disassembly & assembly tool EF8OM058 ●...
Page 92 6.2.6. Crankshaft (1) Inspection and measurement ● Inspect for any scratch or damage 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 mag- netic powder and color check, and replace the cracked ones.
Page 93 ● There are kinds as above, and the crankshaft also can be used by " R " regrinding as above. " R " <“R part” standard value> Crank pin ′R′ : 4.0 -0.5 " R " " R " " R " Crank journal ′R′...
Page 94 a) How to utilize the cylinder gauge Assemble the main bearing at the cylinder block and after tightening the bearing cap at the specified torque, measure the inside diame- ter. ø 104.066 ~ Journal bearing standard diameter ø 104.115 mm Bearing cap Initial 30 kg.m + °...
Page 95 End play ● Assemble the crankshaft in the cylinder block. ● Install the dial gauge, and measure the end play of crankshaft by pushing the crankshaft to axial direction. Standard Limit 0.140 ~ 0.361 mm 0.4 mm EFM2050I 6.2.7. Piston (1) Piston disassembling ●...
Page 96 ● With the outside micrometer, measure the piston′s outside diameter the mea- suring position is 71.5 mm from the pis- ton lower end, and the direction of measurement must be perpendicular to the piston pin direction. ø127.739 ~ ø127.757 mm 71.5 mm Standard EA3M2045...
Page 97 <Piston ring gap> Division Standard Limit Top ring 0.30 ~ 0.50 mm 1.5 mm 2nd ring 1.10 ~ 1.30 mm 1.5 mm Oil ring 0.25 ~ 0.55 mm 1.5 mm Piston ring groove clearance. ● Assemble the piston ring at the piston. ●...
Page 98 (5) Connecting rod 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 abnor- mal, replace the connecting rod. Standard Limit 0.02 mm...
Page 99 6.2.8. Injection nozzle ● Set the nozzle assembly between the vise holder and disassemble it. ● Remove the nozzle nuts and disassemble the inner parts. Nozzle holder body ● Inspect the disassembled parts if there is Cap nut any damage, replace it. Adjusting shim ●...
Page 100 6.3. Engine Re-assembly 6.3.1. 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. ●...
Page 101 6.3.4. Oil spray nozzle ● Assemble the oil spray nozzle. ● Tighten the fixing bolts. 6.3.5. Tappet Coat the tappet wholly with clean oil and push in the tappet hole of the cylinder block. EAMD072S 6.3.6. 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 102 ● 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 engine oil, and after fitting the main bearing into the bearing cap and assemble it to the cylinder block making sure of the...
Page 103 6.3.8. Flywheel housing ● Coat the thrust washer fixing bolt with an adhesive and tighten it with specified torque. Torque 3.1 kg.m EFM2065I ● Coat the oil seal with lubricating oil and assemble it carefully not to be deviated or damaged by means of special tool.
Page 104 6.3.10. Flywheel ● Installation of flywheel ring gear With a gas burner, heat the ring gear evenly until heat expansion takes place, then install it using a hammer. Do not allow the temperature of the ring gear to exceed 200°C (390°F). EA0M4029 ●...
Page 105 6.3.12. Heat exchanger ● Assemble 4ea of fixing bolts. ● Assemble the heat exchange tube. 2-baffle side of the heat exchange tube should be installed upward. ● Assemble the cover bolts. Be careful to install O-ring and gasket properly. EFM2017I ●...
Page 106 ● Pushing the piston down, rotate the crank- shaft about 180° and fit the bearing cap to Top ring the connecting rod. ● 2nd ring After engaging 2 - 3 threads of bolts primar- ily rind then tighten them. Oil ring EA6M2006 <Connecting rod bolt tightening order>...
Page 107 When in assembling, take care not to hurt the oil seal by the crankshaft. Note : Without coating the oil seal with oil or lubricant, assemble it in the dry state. ● Tighten the fixing bolts in the zigzag method. 6.3.16.
Page 108 ● Install the oil pan and tighten the fixing bolts. T h e n take care not to squeeze out the gasket. ● Install the guide tube and insert the oil level gauge. 6.3.19. Cylinder head ● Blow the cylinder head bolt holes with com- pressed air to remove the foreign material cleanly.
Page 109 6.3.20. Nozzle Put the new seal ring in nozzle hole of the cyl- inder head and after inserting the nozzle assembly, tighten it to assemble However, coat the nozzle outer part with the stuck pre- venting agents and assemble it. EFM2090I 6.3.21.
Page 110 6.3.22. Valve clearance adjust procedure Method 1 1) Rotate the crankshaft so that #1. cylinder may be positioned at the compression TDC (Top Dead Cen- ter). Note : #1. Cylinder is located at the side where cooling water pump was installed. In case of 8/12 cylinder engine, #6.
Page 111 7) When a cylinder valve overlap, adjust the valve clearance cylinder of the compression TDC (Top Dead Center), as follow. * 8 cylinder engine (V158TI/AD158TI) Valve overlap cylinder No. Adjusting Valve Cylinder No. (In./Ex. Valve) * 10 cylinder engine (V180TI/AD180TI) Valve overlap cylinder No.
Page 112 6.3.24. Fuel injection pump ● Turn the crankshaft so as to let the cylinder No. 6 for V158TI, AD158TI, V222TI, AD222TI engines and the cylinder No. 7 for V180TI, AD180TI come to the overlap TDC (Top Dead Center). ● Rotate the crankshaft to reverse about 30°...
Page 113 <Oil quantity of the injection pump> V158TIE/V158TI V180TI V222TI 0.95 liter 1.1 liter 1.3 liter 6.3.25. Injection timing <How to check the injection timing> ● Check the current injection timing of the engine as follows before adjusting it but if the injection timing is wrong should do it.
Page 114 5) After confirmation that fastening bolts are completely tightened check the start point (injection timing degree) of fuel delivery setting once more if not right repeat it again as same as upper way. <Fuel injection timing degree> V158TI V158TI V180TI V222TI °...
Page 115 6.3.28. Oil centrifugal filter ● Assembling is done in the reverse order of disassembling and take care at the state of O-ring installation. ● At the engine operation, make sure the smooth operation and no oil leaks from all the engine connections. ●...
Page 116 6.3.31. Exhaust manifold ● Prior to assembling the exhaust manifold, attach the gasket firstly to the cover and elbow exhaust pipe and assemble them to the engine block tightening the bolts evenly as the right figure. EFM2084I ● Attach new gaskets to the exhaust mani- fold and then assemble the exhaust mani- fold with the fixing bolts.
Page 117 6.3.34. Fuel injection pipe ● Connect the fuel injection pipes to the fuel injection pump and the nozzle respectively and then assemble them by tightening nuts. ● Assemble the fuel return pipes by tighten- ing fixing nuts. EFM2087I 6.3.35. Fuel filter ●...
Page 118 6.3.37. Idle pulley ● Install the idle pulley. ● Connect the water pump, the crank and the idle pulleys with driving V-belts. ● Tighten eye bolt and nut. (10 mm ~ 15 mm or so pushing with a thumb). EFM2089I 6.3.38.
Page 119 6.4. Trial Test after Maintenance Because the sliding surfaces of a maintenance engine are not lapped enough, the oil film can be destroyed easily by overload or over-speed and the engine life-time may be shortened. Therefore the following things must be obeyed by all means. (Refer to 3.3) Up to the first 50 hours ●...
Page 120 Disassembly and assembly of major components - 114 -...
Page 121 7. MAIN PARTS MAINTENANCE 7.1. Lubricating System Lubricating oil pumped by the gear oil pump in the oil pan is filtrated in the oil filter. This filtrated oil passed on the oil cooler and next the main oil gallery of the cylinder block where is distributed to lubricate the various sliding parts, fuel injection pump, and turbo-charger etc also in order to ensure normal engine performance.
Page 122 7.2. Cooling System 7.2.1. Fresh water pump assembly Impeller Cover Spline shaft Mechanical seal Oppression Rubber seal Pump housing EDV2218164 7.3. Fuel System 7.3.1. Injection pump The components relating to the injection pump should be serviced at regular intervals as the plunger and delivery valve may be worn after a given length of time for use and cause the deterioration of the engine.
Page 123 1) V158TIH (1) Main data and specifications Model : PE8P120A520LV Injection pump : 65.11101-7680 Governor : RQV 300/900 Plunger : 2 418 455 188 Delivery valve : 2 418 552 039 ± 0.05 mm Pre-stroke : 4.50 ± 1 ° Injection timing : BTDC 15 Injection order...
Page 124 (3) Rack diagram 1000 1200 ENGINE SPEED (rpm) EB2M5001 (4) Boost compensator pressure 1000 1200 EB2M5002 Main parts maintenance - 118 -...
Page 125 2) V158TIM (1) Main data and specifications Model : PE8P120A520LV Injection pump : 65.11101-7680 Governor : RQV 300/900 Plunger : 2 418 455 188 Delivery valve : 2 418 552 039 ± 0.05 mm Pre-stroke : 4.50 ± 1 ° Injection timing : BTDC 16 Injection order...
Page 126 (3) Rack diagram ENGINE SPEED (rpm) EB2M5003 (4) Boost compensator pressure 1000 1200 1400 EB2M5004 Main parts maintenance - 120 -...
Page 127 3) V158TIL (1) Main data and specifications Model : PE8P120A520LV Injection pump : 65.11101-7680 Governor : RQV 300/900 Plunger : 2 418 455 188 Delivery valve : 2 418 552 039 ± 0.05 mm Pre-stroke : 4.50 ± 1 ° Injection timing : BTDC 18 Injection order...
Page 128 (3) Rack diagram 1000 1500 EDV2218074 (4) Boost compensator pressure 1000 1500 2000 2500 EDV2218075 Main parts maintenance - 122 -...
Page 129 4) V180TIH (1) Main data and specifications Model : PE10P120A520LV Injection pump : 65.11101-7681 Governor : RQV 300/900 Plunger : 2 418 455 188 Delivery valve : 2 418 552 039 ± 0.05 mm Pre-stroke : 4.50 ± 1 ° Injection timing : BTDC 16 Injection order...
Page 130 (3) Rack diagram 1000 1200 ENGINE SPEED (rpm) EDV2218058 (4) Boost compensator pressure 1000 1200 EDV2218071 Main parts maintenance - 124 -...
Page 131 5) V180TIM (1) Main data and specifications Model : PE8P120A520LV Injection pump : 65.11101-7681 Governor : RQV 300/900 Plunger : 2 418 455 188 Delivery valve : 2 418 552 039 ± 0.05 mm Pre-stroke : 4.50 ± 1 ° Injection timing : BTDC 18 Injection order...
Page 132 (3) Rack diagram 1000 1200 1400 ENGINE SPEED (rpm) EDV2218077 (4) Boost compensator pressure 1000 1200 EDV2218071 Main parts maintenance - 126 -...
Page 133 6) V180TIL (1) Main data and specifications Model : PE8P120A520LV Injection pump : 65.11101-7681 Governor : RQV 300/900 Plunger : 2 418 455 188 Delivery valve : 2 418 552 039 ± 0.05 mm Pre-stroke : 4.50 ± 1 ° Injection timing : BTDC 18 Injection order...
Page 134 (3) Rack diagram 1000 1500 EDV2218078 (4) Boost compensator pressure 1000 1500 2000 2500 EDV2218079 Main parts maintenance - 128 -...
Page 135 7) V222TIH (1) Main data and specifications Model : PE12P120A500LV Injection pump : 65.11101-7682 Governor : RQV 300/900 Plunger : 2 418 455 188 Delivery valve : 2 418 552 039 ± 0.05 mm Pre-stroke : 4.50 ± 1 ° Injection timing : BTDC 17 Injection order...
Page 136 (3) Rack diagram 1000 1200 ENGINE SPEED (rpm) EDV2218076 (4) Boost compensator pressure 1000 1200 EDV2218071 Main parts maintenance - 130 -...
Page 137 8) V222TIM (1) Main data and specifications Model : PE12P120A500LV Injection pump : 65.11101-7682 Governor : RQV 300/900 Plunger : 2 418 455 188 Delivery valve : 2 418 552 039 ± 0.05 mm Pre-stroke : 4.50 ± 1 ° Injection timing : BTDC 18 Injection order...
Page 138 (3) Rack diagram ENGINE SPEED (rpm) EDV2218072 (4) Boost compensator pressure 1000 1200 1400 EDV2218073 Main parts maintenance - 132 -...
Page 139 9) V222TIL (1) Main data and specifications Model : PE12P120A500LV Injection pump : 65.11101-7682 Governor : RQV 300/900 Plunger : 2 418 455 188 Delivery valve : 2 418 552 039 ± 0.05 mm Pre-stroke : 4.50 ± 1 ° Injection timing : BTDC 19 Injection order...
Page 140 (3) Rack diagram 1000 1500 EDV2218074 (4) Boost compensator pressure 1000 1500 2000 2500 EDV2218081 Main parts maintenance - 134 -...
Page 141 7.3.2. Fuel feed pump 1) General descriptions and construction The P-type injection pump is mounted with Priming K-ADS or KP type feed pump. These pump Priming pumps have the same basic construction pump and operation, and the general descriptions Check Check valve Check valve of the KP type pump are given below :...
Page 142 In addition, a strainer is fitted into joint bolt on the inlet side of the fuel feed pump to fil- trate any foreign substances possibly mixed in fuel. Strainer EB1M4003 2) Disassembly ● EQM4021S ● Clamp the feed pump with a vise and disassemble the plugs (30, 32), strainer (31) and gaskets (35, 36).
Page 143 4) Re-assembly ● Re-assembly operation is performed in reverse order of disassembly. All the gaskets must be replaced with new ones at re-assembly. 5) Testing ● Suction capacity test Connect one end of a hose to the inlet Outlet hose side of the feed pump and immerse the other end of it into the fuel tank as illus- Feed pump...
Page 144 7.3.3. Injection nozzle The injection nozzle assembly consists of the nozzle body and needle valve assembly. Pressurized fuel delivered from the fuel injection pump is sprayed into the combustion chamber past the injection nozzle at proper spray pressure and spray angle, then burnt completely to achieve effective engine performance. The fuel injected should necessarily be ignited immediately and combusted in a short period of time as too long a combustion period will prevent the high speedy operation of the engine and can cause serious engine knocking.
Page 145 3) Inspection and adjustment ● Assemble the nozzle in the nozzle tester and operate the nozzle tester 2 or 3 times to bleed air. After pressurizing it measure the nozzle pressure. New nozzle 300 +8 kg/cm Used nozzle 285 +8 kg/cm ●...
Page 146 7.4. Turbo-charger 7.4.1. Specification Model V158TIH V180TIH V222TIH Engine output (PS / rpm) 480 / 1,800 600 / 1,800 720 / 1,800 Turbo-charger model HX35M HX40M HX50M Maximum allowable exhaust gas temperature (Turbine inlet) Lubricating system Forced oil supply Model V158TIM V180TIM V222TIM...
Page 147 7.4.2. Construction of the turbo-charger 2 2 2 1 2 2 8 EAMC055S EDV2218017 1. Turbine housing 11. Bearing 21. Nut 2. V-vent 12. Thrust collar 22. Bolt 3. Wheel 13. Screw 23. Clamp 4. Piston ring 14. Thrust bearing 24.
Page 148 7.4.3. Inspection As the condition of turbocharger depends greatly on how well the engine is serviced, it is very important to maintain the engine in accordance with the specified maintenance procedure and pay particular attention to checking oil & air leaks, unusual sound on running. 1) Checking of the rotor for rotating condition The inspection of the rotor assembly for rotating condition should be performed by the degree of unusual sound on running.
Page 149 3) Precautions for reassembling the turbocharger onto the engine For re-assembly of the turbocharger or handling it after re-assembly operation, be sure to observe the fol- lowing precautions: Especially, pay attention to prevent foreign matters from entering the inside of the turbocharger. (1) Lubricating system ●...
Page 150 2) Center housing rotating assembly EA7M4005 3) Watercooled bearing housing (4) Optionally this can have additional water feed and drain plug fittings. EA7M4063 4) New compressor wheel lock nut (61) Holset have introduced a new compressor wheel lock nut which is to be all new WH1C/ E turbochargers.
Page 151 Caution : Always make sure the turbinewheel shaft end and the compressor wheel have alignment marks before disassembly of the CHRA. If no marks exist, scribe the shaft and compressor wheel (as shown) before removing the compressor wheel lock nut. Always check balance the rotor EDV2218096 before rebuild.
Page 152 HX50 : Loosen and remove the 8 bolts (59) lock washers (54) clamp plates (51). HX55 : Loosen and remove the compres- sor side V-band lock nut (62). EDV2218053 ● Gently remove the compressor cover (8), and if fitted, remove the O-ring seal (41). Caution : The compressor wheel blades can be easily damaged when the compressor...
Page 153 ● Locate Center Housing Rotating Assembly (CHRA) onto a 19 mm socket clamped in the jaws of a vice or a suitable fixture. Caution : Always make sure the turbine wheel shaft and the compressor wheel have alignment marks before disassembly EDV2218054 of the CHRA.
Page 154 ● Carefully remove and discard the piston ring seal(s) (13). - HX35(V158TI) : 1EA - HX50(V180TI/V222TI) : 2EA Caution : Care should be taken not to score the assembly turbine wheel shaft. EDV2218104 ● Remove the heat shield (38). EDV2218105 ●...
Page 155 - HX50 : Using two flat screwdrivers. EDV2218108 ● Remove the oil slinger (31). - HX35 EDV2218055 - HX50 EDV2218109 ● Remove and discard the piston ring seal (16). EDV2218110 - 149 - Main parts maintenance...
Page 156 <HX35> ● Remove and discard the oil baffle (33). EDV2218111 ● Remove and discard the O-ring seal (32). EDV2218112 ● Remove the thrust bearing (12). EDV2218113 <HX50> ● Remove and discard the O-ring seal (32). EDV2218114 Main parts maintenance - 150 -...
Page 157 ● Remove and discard the oil baffle (33). EDV2218115 ● Remove the thrust bearing (12). EDV2218116 ● Remove the thrust collar (36). EDV2218117 ● Using circlip pliers, remove and discard the two circlips (64) and the journal bearing (11) from the compressor end. EDV2218118 - 151 - Main parts maintenance...
Page 158 ● Turn the bearing housing over and repair the process. EDV2218057 7.4.6. Cleaning With the turbocharger completely dismantled for overhaul, soak all the components in a non-caustic metal cleaner to loosen deposits. Bead blast the turbine housing if chemicals do not clean sufficiently. On aluminium parts a bristle brush can be used.
Page 159 <Major components> ● Assembly turbine wheel (6) b) Inspect the piston ring groove walls for wear. - HX35 (V158TI) Turbine wheel piston ring groove 1.664 0.0665 (Min.) - HX50 (V180TI/ V222TI) EDV2218120 Turbine wheel piston ring groove Single ring (Min.) 1.664...
Page 160 Inspect the bore for wear or score mark on both the bearing and piston ring area. Also check all tapped holes are clean and free from dirt. Replace with new if any damage is found. - HX35 (V158TI) Bearing Housing EDV2218123 Bore (Min.) 15.885 0.6254...
Page 161 ● Oil seal plate (43) Inspect the seal bore, replace if scored or damaged. EDV2218126 ● Heat shield (38) Check and replace if the heat shield id dis- torted or if signs of rubbing or cracking are visible. EDV2218127 7.4.8. Assembly ●...
Page 162 Mark up each individual item to help ensure correct alignment during assembly. - HX35 (V158TI) Rotor balance g.mm oz. ins. limits (Max.) Turbine end 0.002 Compressor end 0.002 - HX50 (V188TI, V222TI) Rotor balance g.mm oz. ins. limits (Max.) Turbine end 0.003...
Page 163 ● Install the heat shield (38). EDV2218132 ● Install the two new piston ring seals (13) to the assembly turbine wheel (6). EDV2218133 ● Lubricate the shaft using clean engine oil. Caution : Align the piston ring seals (16) so the gaps are positioned 180°...
Page 164 ● Install the thrust collar (36). Caution : Align the balance mark on the thrust collar with that on the shaft. EDV2218136 ● Using clean engine oil, lubricate the thrust bearing (12). Install the thrust bearing. - HX35 EDV2218137 - HX50 EDV2218138 ●...
Page 165 <HX35> ● Using clean engine oil, lubricate the oil slinger (31) and install into the oil seal plate (43). EDV2218140 ● Install the oil baffle (33) into the oil seal plate (43). EDV2218141 ● Apply a small amount of engine oil to the oil seal plate (43) and place the O-ring seal (32) into position.
Page 166 ● Install the oil baffle (33) into the oil seal plate (43). EDV2218144 ● Using clean engine oil, lubricate the oil slinger (31) and install into the oil seal plate (43). EDV2218145 ● Install the oil seal plate (43) into the bearing housing (4).
Page 167 ● Using circlip plier, install the retaining ring (66). EDV2218148 ● Align the balance marks and install the compressor wheel (7). EDV2218149 ● Install the compressor wheel lock nut(61) and tighten to the torque value. Note : Left hand thread. in-lbs Torque value EDV2218150...
Page 168 <HX50> ● Locate the C.H.R.A. into the turbine hous- ing (5). Install the 3 clamp plates (88) and tighten the 6 bolts (57) to the torque value. in-lbs Torque value Bolts (57) If fitted, install v-band clamp (28) and tighten the v-band lock nut. in-lbs Torque value bolts (57)
Page 169 ● Loosely fit the V-band clamp. Lubricate and install the O-ring seal (41) if fitted. Install the compressor cover (8). Caution : The compressor wheel blades can be easily damaged when the compressor housing is installed. EDV2218155 ● HX50 HX50 HX55 Install the 2 clamp plates (51), eight lock washers (54) and tighten the 8 bolts (59) to...
Page 170 2) Checking of the rotor end play The radial and axial clearances of the rotor should check after every 2,000 hours operation. This precau- tion will enable measuring for any wear of axial clearance bearings to be detected in good time before serious damage is caused to the rotor and bearings.
Page 171 3) Precautions for reassembling the turbocharger onto the engine For re-assembly of the turbocharger or handling it after re-assembly operation, be sure to observe the fol- lowing precautions : Especially, pay attention to prevent foreign matters from entering the inside of the turbocharger. (1) Lubricating system ●...
Page 172 Main parts maintenance - 166 -...
Page 173 8. TROUBLE SHOOTING The following description summarizes the probable cause of and remedy for general failure by item. Immedi- ate countermeasures should be taken before a failure is inflamed if any symptom is detected. Hard to start the engine Fuel system admits air Bleed air (check feed pump) Detect the cause and remove clogs or Clogged fuel supply piping or clogged air...
Page 174 Insufficient output Driven machine normal? Hydraulic pressure source Change or reduce the propeller pitch Excess intake air resistance Clogged air cleaner Clogged intake air pipe Clean Clean Excess exhaust Clogged Clogged exhaust Clogged cylinder resistance muffler pipe head exhaust outlet Clean or replace Clean Fuel system...
Page 175 Overheating Driven unit normal? Hydraulic pressure source Set relief pressure of control valve Cooling Insufficient Sagged Broken or Clogged heat Incresed exhaust system cooling water V-belt worn V-belt exchanger pressure Add water Adjust Clean Clean Replace Pressure cap Clogged heat- Reduction in cool- Thermostat clogging and...
Page 176 Black smoke is produced. Driven machine normal? Hydraulic pressure source Set relief pressure of control valve Insufficient output Refer to “Insufficient output.” Fuel Improper fuel Replace Fuel pump Too early injection timing Excess injection volume Uneven injection volume Adjust or replace Adjust Adjust or replace Governor...
Page 177 Starter motor will not turn Except engine seizure and or output less power. trouble of driven machine Disconnection & Battery Grounding Disconnected Coupler faulty connection terminal termainal connection Repair Repair Repair Repair Battery Specific gravity Voltage Damaged battery Charging Replace Add electrolyte or charge Key switch...
Page 178 Battery is dead or not [During operation] chargeable. Poor charging Discharged Defective Discon- Coupler ON condition Battery Grounding switch wiring and nected connec- terminal terminal connection wiring tion Repair Repair Wiring Short-circuit Battery Battery Replace terminal Alternator Electric appliance Key switch Damaged Switch or rusted...
Page 179 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 torque 90° - Side bolt M12 × 1.5 10.9 Flywheel housing - Tightening bolt M12 ×...
Page 180 ● 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) Tightening torque (kg 0.15...
Page 181 ● Tightening torque for plug screw Allow- Compo- Specifica- Item Inspection item able Repair Remarks nent tions Limit ø Worn inside diameter of 111 ~ ø cylinder liner 111.022 There must be Difference in projection Cylinder Liner projection 0.03 ~ 0.08 ø...
Page 182 Allow- Compo- Item Inspection item Specifications able Repair Remarks nent Limit Replace the ø ø Piston pin O.D. 41.994 ~ piston pin Piston Replace if the ring Clearance between the wear exceeds 0.055 ~ 0.071 piston and bushing the specified amount Unevenly worn journal Repair it with a...
Page 183 Allow- Compo- Item Inspection item Specifications able Repair Remarks nent Limit Connecting rod free Replace 0.170 ~ 0.248 0.50 connecting rod play Clearance between Replace the connecting rod bearing 0.034 ~ 0.098 0.25 bearing and crank pin Install the Clearance between bearing and small end bush and 0.050 ~ 0.081...
Page 184 Allow- Compo- Item Inspection item Specifications able Repair Remarks nent Limit Intake - Free length of inside 72.43 mm spring Intake - Set length of inside 46.3 mm/ 32.8 mm spring (P1/P2) ± Intake - Load on inside spring 1.0 kg/ 16.0 kg/29.5 kg ±...
Page 185 Allow- Compo- Item Inspection item Specifications able Repair Remarks nent Limit ø 25.005 ~ Replace the ø Rocker arm bushing I.D. 25.083 ø 25.035 bushing ø Diameter of rocker arm 24.967 ~ Replace the ø 24.930 ø 24.990 shaft shaft Replace the Rocker arm oil gap 0.015 ~ 0.068...
Page 186 Allow- Compo- Item Inspection item Specifications able Repair Remarks nent Limit Axial clearance of oil pump 0.055 ~ 0.105 gear Replace the Clearance between gear gear or cover shaft and oil pump cover 0.032 ~ 0.077 hole Clearance between drive Replace the Oil pump gear bushing O.D.
Page 187 Governor Actuator Controller...
Page 189 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 190 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 191 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 192 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 193 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 194 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 195 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 196 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 197 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 198 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 199 (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 200 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 201 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 202 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 203 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 204 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 205 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 206 (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 207 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 208 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 209 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 210 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 211 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 212 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 213 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 214 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 215 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 216 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 217 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 218 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 219 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 220 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 221 6. Product dimension 4- 6 EDL11160004 - 33 -...
Page 222 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 223 (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 224 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 225 (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 226 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 227 (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 228 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 229 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 230 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 231 (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 232 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 233 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 234 (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 235 (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 236 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 237 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 238 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 239 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 240 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 241 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 242 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 243 (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 244 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 245 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 246 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 247 (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 248 (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 249 (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 250 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 251 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 252 (-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.
Page 253 Digital Panel for Marine Engines Service Manual Ver.1.0 Doosan Infracore HY-DP-MANUAL-001...
Page 254 ▶ Contents 1. General Information Product Information ---------------------------------------------------------- Components and Optional Accessories --------------------------------------- Product Specification ---------------------------------------------------------- 2. Product Installation Cautions ------------------------------------------------------------------------ Stationary Type ----------------------------------------------------------------- Mount Type --------------------------------------------------------------------- 3. Part Names, Operation and Settings Front Side --------------------------------------------------------------------- Back Side ---------------------------------------------------------------------- External Connection Terminals ------------------------------------------------ 3.3.1 Power Connector...
Page 255 ▶ Contents Spare Sensor ----------------------------------------------------------------- 3.10 Event Summary -------------------------------------------------------------- 3.11 System Booting and Functional Check -------------------------------------- 4. Multi Panel Structure Multi Panels ------------------------------------------------------------------- How to Install Multi Panels -------------------------------------------------- Multi Panel Settings --------------------------------------------------------- 5. Digital Panel Manager Digital Panel Manager --------------------------------------------------------- PC Communication Connection ---------------------------------------------...
Page 256 1. General Information 1.1 Product Information The name of the product model is a digital panel applicable to ships, generators and other various marine engines. The product is intended to improve problems of existing analog panels and allow users to check engine controls and conditions by means of a digital visualization product. It provides information in analog graphic gauges and digital displays for enhanced user experiences.
Page 257 1. General Information 1.3 Product Specification Digital Panel Specification Item Description Microprocessor • Cortex-A8, dsPIC33FJ256 Software • Windows CE 6.0 R2 • 10.2” Color TFT LCD Display • 800 * 480 (Pixels) • 16:9 • 256MB (Flash) Flash Memory • 8GB (MicroSD card) •...
Page 258 2. Product Installation 2.1 Cautions Unskilled personnel should read this manual before use.  Do not use or keep the product close to combustible sprays or inflammable.  Use soft and dry cloth to clean the monitor.  Turn off the product, pull out the harness cable and then contact our service center when you ...
Page 259 2. Product Installation 2.2 Stationary Type Stationary types are installed in the steering or engine room by using stationary brackets delivered with the product. ※ Mounting Hole Spec: M6 bolt Wave Washer Rotation Lock Fix Handle Fixing Hole Mounting Hole Bracket [Fig.
Page 260 2. Product Installation 2.3 Mount Type Mounting types are installed in a steering or engine room by using optional mounting brackets (2pcs). ※ Bolt Spec: ① M6 ② M8, Length - 12mm ② ① Mounting Bracket [Fig. 2-4] Mounting Type Diagram ▶...
Page 261 3. Part Names, Operation and Settings 3.1 Front Side ② ② Name Reference ① ② Function Keys Page 14 ① ③ Key Switch Page 12 ④ Start/Stop Button Page 13 ③ ④ [Table 3-1] [Fig. 3-1] 3.2 Back Side Name Reference ①...
Page 262 3. Part Names, Operation and Settings 3.3 External Connection Terminals External connection terminals are used for inputs and outputs of engine control signals and each sensor signals. 3.3.1 Power Connector Power connector supplies power and power signals. Pin Description Notes Alternator In Battery Voltage Battery (+) (DC 24V)
Page 263 3. Part Names, Operation and Settings 3.3.2 Signal Connector [Fig. 3-4] Pin Description Notes Pin Description Notes Exhaust Gas Temperature Spare Analog Input 3 Sensor 1 (+) Engine Water Temperature Pickup Sensor (+) Sensor Engine Oil Pressure Sensor *Engine Oil Temperature Sensor *Boost Air Pressure Sensor Sensor Valve...
Page 264 3. Part Names, Operation and Settings 3.3.3 CAN Communication Connector CAN harness (optional) connection • CAN1/CAN2: for multi panels • CAN3: PC communication, firmware download • CAN1 CAN2 CAN3 +12V Out +12V Out +12V Out CAN1_H CAN1_H CAN2_H CAN1_L CAN1_L CAN2_L [Fig.
Page 265 3. Part Names, Operation and Settings 3.3.6 USB Connector USB memory can be inserted for data backup. • [Fig. 3-8] 3.4 Fuse and Internal Buzzer 3.4.1 Fuse Shut down the power for overcurrent exceeding 6A • Press Press the fuse button for 10 seconds to restore fuse •...
Page 266 3. Part Names, Operation and Settings 3.6 Start/Stop Button Start/Stop button is used to start/stop control for the engine. 1) Press the button for more than 3 seconds while the key is ON, the engine will start (the button LED will flash when pressing the button).
Page 267 3. Part Names, Operation and Settings 3.7 Function Keys Function keys are used to adjust LCD brightness, stop alarming (mute), configure CCTV, Digit, Home and other settings, move to and select menus, and reset the system. ⑥ ① ⑦ ② ⑧...
Page 268 3. Part Names, Operation and Settings 3.7.1 Detailed Settings [Fig. 3-15] Detailed Settings ▶ Setting Functions and Descriptions Press button and then use button to move to functions to be changed. Press button to go back to gauge display (changes will be automatically saved). Function Description Function Key...
Page 269 3. Part Names, Operation and Settings 3.8 Display Structure Engine Oil Pressure Engine Speed Water Temperature Accumulated Engine Exhaust Gas Operation Temperature Hours Gearbox Oil Pressure Sensor Value (Digit) Sensor Check Light [Fig. 3-16] Gauge Display Battery Voltage Alarm Gauge display shows various gauge data including pick up (RMP) sensor, coolant temperature, •...
Page 270 3. Part Names, Operation and Settings 3.8.2 Engine Water Temperature It shows the coolant temperature in gauge and digital values. 1) It shows the temperature indicated by the gauge hand in digital values (blue) for better accuracy (however, it is available when the ‘DIGIT’...
Page 271 3. Part Names, Operation and Settings 3.8.5 Gearbox Oil Pressure It shows gearbox oil pressure in gauge and digital values. 1) It shows the pressure indicated by the gauge hand in digital values (blue) for better accuracy (however, it is available when the ‘DIGIT’...
Page 272 3. Part Names, Operation and Settings 3.8.8 Engine Alarm The alarm will be activated with buzzer beeping when problems for coolant temperature, engine oil pressure, gearbox oil pressure, charging, coolant level, fuel leakage and over speed are detected. ① ② ③...
Page 273 3. Part Names, Operation and Settings 3.9 Spare Sensor It identifies the status of spare sensor, product S/N, F/W version, and date/time. Press button of the function key to move to spare sensor page. Alarm On [Fig. 3-25] Spare Sensor and SW information Item Condition •...
Page 274 3. Part Names, Operation and Settings 3.10 Event Summary It shows the numbers of normal operations, normal stops, emergency stops and sensor errors together with dates of recent errors. Press button in spare sensor page to move to event summary page. [Fig.
Page 275 1) Insert the key into the key switch and rotate it to the right (ON). Key On 2) DOOSAN logo will appear for 17 seconds while the system is booting (refer to the image). ※ If the logo does not appear after rotating the key, Rotate it to the left (OFF) and then to the right (ON) ...
Page 276 4. Multi Panel Structure 4.1 Multi Panels Panels can be installed up to 4 units except Master in the ship and you can check the ship conditions and control those panels at any places of installation. [Fig. 4-3] Slave 3 [Fig.
Page 277 ※ In order to install multi panels, all the necessary cables should be ready in advance (use the cables with specification recommended by DOOSAN). (1) Connect the CAN1 terminal of the Master panel and the CAN1 terminal of the Slave 1 panel as shown in ①...
Page 278 4. Multi Panel Structure 4.3 Multi Panel Settings (1) Press button of the panel to be configured as Slave. (2) Move to ① when the setting screen appears (use button to move). (3) Press button to switch configuration between Master and Slave. (4) Configure the Master panel as described above.
Page 279 5. Digital Panel Manager 5.1 Digital Panel Manager Digital Panel Manager is a program that allows users to monitor the product conditions in real time with PC. You can configure sensor values of each sensor, engine model and over speed conditions. [Fig.
Page 280 5. Digital Panel Manager 5.3 Software Installation and Execution 1. Install Digital Panel Manager on your PC. 2. Run Digital Panel Manager. 3. Permission Cert – Manufacturer or research institute cert is required as shown in Fig. 5-3 to run it. ※...
Page 281 5. Digital Panel Manager 5. Configure the port connected to RS232 in Communication Port Settings. Communication Port Settings [Fig. 5-5] Communication Port Settings 6. When the panel is connected to RS232, COMx Connected at the bottom right corner will turn on in green.
Page 282 5. Digital Panel Manager 5.4 Display Structure and Detailed Functions 5.4.1 Menu Structure Descriptions of menus at the top left corner are as follows: [Fig. 5-7] Menu Structure Structure Description Open Load setting files Files Save Save settings as a file Exit Exit the program Transmit data settings in the current tab to the...
Page 283 5. Digital Panel Manager 5.4.2 Operation Record Files You can check the operation record files saved in the product (users are not allowed to use this function). 1. Menu → Advanced → Click Open Operation Record Files. [Fig. 5-8] Advanced Menu 2.
Page 284 5. Digital Panel Manager 3. The window in which you can check the operation records will be activated. You can see Files and Advanced Menu at the top left corner. [Fig. 5-10] Operation Record Menu [Fig. 5-12] Menu Advanced → [Fig.
Page 285 5. Digital Panel Manager 4. Click + on the alarm event list at the top left corner of the operation window. Click [Fig. 5-13] Activate Operation Record Window 5. The list of each sensor will be activated. In order to check the records of the sensor that you want to, click + on the list (where there are records, + will appear).
Page 286 5. Digital Panel Manager 6. When clicking the date of operation records by each sensor, you can see the graphs of those records. If you want to save those records in Excel files, select Advanced → Save current data in Excel files. [Fig.
Page 287 5. Digital Panel Manager ② Service Authentication – default setting (battery voltage control inactive) / Deactivate all tabs except event settings. Deactivate [Fig. 5-17] Service Authentication ③ End User Authentication – Deactivate all taps except start button action time (you can still check the current information).
Page 288 5. Digital Panel Manager 5.4.4 Default Settings It shows description about the default setting tab in the initial main screen. ※ End users can configure start button action time only. ⑩ ⑪ ① ⑤ ⑥ ② ⑦ Engine Model ③ ⑧...
Page 289 5. Digital Panel Manager 5. Digital Panel Manager 5.4.5 Event Settings It shows description about the event setting tab. ⑤ ① ⑥ ② ⑦ ③ ⑧ ⑨ ④ ⑩ [Fig. 5-20] Event Setting Screen Event Setting ① ON/OFF check for fuel leakage alarm (Default: off) ②...
Page 290 5. Digital Panel Manager 5.4.6 Sensor Value Mapping Tab You can configure sensor values in this tap with manufacture/research institute permission only. You can only check the settings with other permissions. Click each voltage value to change it. [Fig. 5-21] Sensor Tab [Fig.
Page 291 6. Maintenance 6.1 Maintenance To maintain the performance of the device, regular maintenance is required. Use soft cloth to clean the LCD without damaging it. 1) Clean the LCD after turning the power off. 2) Do not use cleaners with acids or ammonia. 3) Do not use neutral detergents to remove oil stains.
Page 292 7. Warranty and A/S Service 7.1 Warranty As this manual contains important contents related to safety, use and maintenance of the product. So please read this manual carefully and then use the product in a proper manner. Those who are not familiar with the product should keep this manual close to it. We are not responsible for human injuries or property damages caused by the following reasons: Where you use the product for purposes other than the ones described in this manual ...
Page 293 8. Appendix 8.1 List of Engine Models List of compatible engine models Number of Engine Rate Speed Over Speed Gear Teeth DB58TI L066TIH 2,200 115% 2,530 D1146 L136 2,200 115% 2,530 L136T 2,200 115% 2,530 D1146T L136TL 2,500 115% 2,875 D1146TI L136TI 2,200...

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Doosan V158TI Operation & Maintenance Manual

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Doosan V158TI Operation & Maintenance Manual

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