Table Of Contents - Doosan V158TI Operation & Maintenance Manual

Table of Contents

Symbols Used In The Manual3
Table Of Contents5
Engine Specification7
Engine Sectional View11
Engine Aspects11
Engine Assembly Diagram13
Engine Performance Curve14
Engine Model & Serial Number15
Safety Regulation17
General Notes17
Regulations Designed To Prevent Accidents With Injury To Persons17
Regulations Designed To Prevent Damage To Engine And Premature Wear19
Regulations Designed To Prevent Pollution20
Engine Oil, Filter Element, Fuel Filter20
Notes On Safety In Handling Used Engine Oil20
Commissioning And Operation21
Inspections Before Operation21
Cooling Water21
Sea Water Pump22
Intake & Exhaust Line22
Fuel Line22
Bottom Of The Engine Room22
Gauge Panel23
Dutch Panel23
Single Panel / Dual Panel24
Dual Panel24
Digital Gauge Panel Circuit Diagram25
Digital Gauge Panel View26
Engine Stop & Warning Devices27
Starting28
Engine Break-In29
New Engine Break-In 20 Hours29
Initial Two Hours Of Break-In29
Inspections After Starting31
Operating After Break-In 20 Hours31
Pressure Of Lubricating Oil31
Temperature Of Cooling Water31
Check After Initial 50 Hours Operation32
Operation In Winter32
Prevention Against The Freeze Of Cooling Water32
Prevention Against Excessive Cooling32
Tuning The Engine33
General Repair Instructions35
General Information35
Periodical Inspection & Maintenance36
Cooling System37
Coolant Level Check And Refill37
Contamination Check Of Coolant And Quantity Of Anti-Freeze38
Anti-Freeze39
Heat Exchanger And Cooling Line Cleaning40
Fresh Water Line Cleaning40
Check And Adjust Of V-Belt Tension41
Thermostat41
Replacing Thermostat And Precautions For Handling42
Lubrication System43
Oil Level43
How To Re-Mark The Oil Dipstick43
Exchanging Of Lubrication Oil44
Oil Drainage44
Recommend Of Lubricating Oil44
Replacement Of Oil Filter Cartridge45
Engine Oil Viscosity - Ambient Temperature45
Oil Centrifugal Filter46
Marine Gear Oil Change46
Cylinder Compression Pressure46
Intake & Exhaust System47
Cleaning & Change Of The Air Filter Element47
Inter-Cooler48
Turbo-Charger Cleaning48
Fuel System49
Priming Pump Strainer Cleaning49
Fuel Tank Cleaning & Checking49
How To Select Fuel Oil50
Fuel Oil Selection Chart51
Water Separator52
Fuel Filter Exchanging52
Checking The Fuel Injection Timing53
Injection Nozzle Maintenance53
Bleeding Of The Fuel System53
Electric System54
Warning Lamp Check54
Valve Clearance54
When The Engine Is Not Used Long Time54
When The Engine Is Sunk55
Main Accessory Parts57
Reduction Gear57
Front Power Take Off59
Pto Description And Operation59
How To Use Pto60
Checking Engagement Load60
Pto Adjustment61
Adjusting Rings62
Facing Check (Pto)62
Lubrication Point63
Exploded View of Typical 11-1/2" ~ 14" Twin Clutch64
Front Power Take-Off (F.p.t.o)65
Propeller Selection66
Alternator67
Starter Motor69
Disassembly And Assembly Of Major Components71
Cylinder Block Inspection81
Cylinder Liner Measurement81
Cylinder Head Inspection81
Cylinder Head Disassembly82
Distortion Of Cylinder Head Bottom Face82
Check Of Valve Guide84
Valve Seat84
Valve Spring Check85
Squareness Of Valve Spring86
Assembling Cylinder Head87
Rocker Arm Inspection88
Camshaft Inspection89
Crankshaft Inspection92
Run Out Of Crankshaft93
Inspection On Crankshaft Bearing93
How To Utilize The Cylinder Gauge94
How To Utilize Plastic Gauge94
Piston Inspection95
Piston Disassembling95
Piston Ring & Ring Groove Inspection96
Piston Pin Inspection97
Connecting Rod Inspection98
Piston Reassembling98
Injection Nozzle Inspection99
Engine Re-Assembly100
Flywheel Housing103
Tacho Sensor103
Flywheel104
Oil Cooler104
Heat Exchanger105
Starting Motor105
Piston105
Connecting Rod Bolt Tightening Order106
Front Oil Seal Holder106
Vibration Damper107
Oil Pump107
Oil Pan107
Cylinder Head108
Nozzle109
Rocker Arm109
Valve Clearance Adjust Procedure110
Cylinder Head Cover111
Fuel Injection Pump112
Injection Timing113
Flywheel Housing Cover114
Fresh Water Pump115
Intake Manifold115
Exhaust Manifold116
Turbocharger116
Fuel Injection Pipe117
Fuel Filter117
Idle Pulley118
Trial Test After Maintenance119
Main Parts Maintenance121
Lubricating System Maintenance121
Oil Pump Maintenance121
Cooling System Maintenance122
Fresh Water Pump Assembly122
Fuel System Maintenance122
Injection Pump Maintenance122
Rack Diagram124
Boost Compensator Pressure124
Fuel Feed Pump141
Fuel Feed Pump Disassembly And Inspection142
Fuel Feed Pump Testing143
Injection Nozzle144
Turbo-Charger Specification146
Construction Of The Turbo-Charger147
Inspection Of The Turbo-Charger148
Turbo Charge Identification149
Turbocharger Disassembly151
Turbocharger Cleaning158
Assembly Turbine Wheel159
Turbine Housing159
Compressor Housing160
Bearing Housing160
Compressor Wheel160
Oil Slinger160
Turbocharger Assembly161
Checking Of The Rotor For Rotating Condition169
Checking Of The Rotor End Play170
Precautions For Reassembling The Turbocharger Onto The Engine171
Troubleshooting173
Hard To Start The Engine173
Insufficient Output174
Overheating175
Black Smoke Is Produced176
White Smoke Is Produced176
Starter Motor Will Not Turn Or Output Less Power177
Hydraulic System Will Not Operate Or To Slow Function177
Battery Is Dead Or Not Chargeable178
Standard Table Of Tightening Torque179
Standard Bolt Tightening Torque Table180
Tightening Torque For Plug Screw181
Governor Actuator189
Outside View And Main Components Of Governor191
Control Unit192
Specifications194
Description Of Controller Terminology197
Controller Wiring198
How To Adjust The Engine Performance (For New Controllers)198
Adjusting The Starting Fuel199
Setting The Idle Rpm199
Droop Operation199
Auxiliary Input200
Auxiliary Supply200
Remote Speed Adjustment200
Control Unit Components203
Installing (Mounting) The Controller And Cautions204
Description Of Control Mode Items204
Adjustment (Tuning) Order And Method205
External Wiring Connections209
Mounting And Connecting The Magnetic Speed Sensor210
Adjusting The Speed Externally210
Droop Parallel Operating Mode (Manual Parallel)213
Accessory Input (Automatic Parallel)213
Controller Lamp Display (Diagnosis) Functions213
Digital Speed Controller216
Product Appearance217
Product Specification218
Product System Diagram219
Product I/O Signals219
Product Dimension221
Installation222
Connecting To The Engine222
Operating Sequence For The Controller223
Connecting To Speed Trim, Droop, Idle And Other Inputs224
Connecting To Crank, Run, Over Speed And Communication226
Configuration And Operation228
Input Keys228
Lcd Display Menu229
Lcd Displays After Powered On230
Lcd Main Menu Display231
Engine Type Setup Menu232
Pid Gain Setup Menu234
Pid Auto Setup Menu234
Date/Time Setup Menu234
Alarm List Menu235
Default Setup Menu235
System Info Menu235
Engine Configuration236
Designated Parameters By Engine Type236
Configuring Set Idle Rpm238
Configuring Set Over Speed238
Configuring Cranking Rpm239
Configuring Gear Number239
Configuring Starting Fuel240
Configuring Speed Ramping240
Configuring Max Current241
Configuring Low Battery241
Configuring Droop Gain242
Droop Function242
Pid Gain Setup Configuration244
Configuring Pid Sampling Time245
Pid Auto Setup Value Configuration245
Date/Time Value Configuration246
Alarm List247
Alarm Code Table247
Default Setup Functions248
System Info Functions248
Lcd Setup Functions249
System Monitor Functions249
Operating Sequence For Digital Speed Controller250
Controller Troubleshooting251
Digital Panel For Marine Engines253
Digital Panel Components And Optional Accessories256
Product Information256
Digital Panel Specifications257
Digital Panel Installation258
Product Installation258
Cautions258
Installing Stationary Type Digital Panel259
Installing Mounting Type Digital Panel260
Digital Panel Part Names, Operation And Settings261
Front Side261
Back Side261
External Connection Terminals262
Power Connector262
Signal Connector263
Can Communication Connector264
External Buzzer Connector264
Cctv Connector264
Fuse And Internal Buzzer (Digital Panel)265
Key Switch (Digital Panel)265
Usb Connector265
Start/Stop Button (Digital Panel)266
Function Keys (Digital Panel)267
Detailed Settings (Digital Panel)268
Display Structure (Digital Panel)269
Engine Speed (Tachometer)269
Engine Oil Pressure269
Exhaust Gas Temperature269
Gearbox Oil Pressure269
Battery Voltage269
Check Sensor Light269
Engine Water Temperature270
Engine Alarm272
Engine Stop272
Spare Sensor273
Event Summary274
System Booting And Functional Check (Digital Panel)275
Multi Panel Structure276
How To Install Multi Panels277
Multi Panel Settings278
Digital Panel Manager279
Pc Communication Connection279
Software Installation And Execution280
Display Structure And Detailed Functions (Digital Panel)282
Menu Structure282
Operation Record Files (Digital Panel)283
Setting Functions By Permission Level286
Default Settings (Digital Panel)288
Event Settings (Digital Panel)289
Sensor Value Mapping Tab (Digital Panel)290
Maintenance (Digital Panel)291
Troubleshooting (Digital Panel)291
Warranty And A/S Service292
Warranty292
A/S Service Information292
Appendix293
List Of Engine Models293