Doosan GV158TIC Operation & Maintenance Manual
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Doosan GV158TIC Operation & Maintenance Manual

Doosan GV158TIC Operation & Maintenance Manual

Gas generator engine
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950106-058010EN
Operation &
Maintenance Manual
GAS GENERATOR ENGINE
GV158TIC, GV180TIC, GV222TIC

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Summary of Contents for Doosan GV158TIC

  • Page 1 950106-058010EN Operation & Maintenance Manual GAS GENERATOR ENGINE GV158TIC, GV180TIC, GV222TIC...
  • Page 3 FOREWORD This manual is designed to serve as a reference for DOOSAN Infracore (here after DOOSAN) customers and distributors who wish to gain basic product knowledge on DOOSAN GV158TIC, GV180TIC, GV222TIC natural gas engines. These economical and high-performance natural gas engines (GV158TIC 8 cylinders), (GV180TIC 10 cylinders), (GV222TIC 12 cylinders) are 4 strokes and V-type have been so designed and manufactured to be used for the generator &...
  • 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 unautho- rized reproduction, printing and distribution thereof are strictly prohibited.

  • Page 5: Table Of Contents

    CONTENTS 1. Safety Regulations & Engine Specifications ........1 1.1.
  • Page 6 6. Engine Installation ............143 6.1.

  • Page 7: Safety Regulations & Engine Specifications

    1. Safety Regulations & Engine Specifications 1.1. General Notes Day-to-day use of power engines and the service products necessary for running them presents no prob- lems if the persons occupied with their operation, maintenance and care are given suitable training and think as they work.
  • Page 8 1.2.1. Avoid heating near pressurized fluid lines Wear welding goggles and gloves when ● welding or using an acetylene torch. Insure a that metal shield separated the ● acetylene and oxygen which must be chained to a cart. Do not weld or heat areas near fuel tanks ●...
  • Page 9 1.2.3. During commissioning, starting and operation This is the safety alert symbol. When you see this symbol in this manual, be alert to the potential for ● personal injury. Carefully read all safety message in this manual and on your safety signs. Be sure new equipment ●...
  • Page 10 (1) If faults occur, find the cause immediately and have it eliminated in order to prevent more seri- ous of damage. (2) Use only genuine DOOSAN spare parts. DOOSAN will accept no responsibility for damage resulting from the installation of other parts which are supposedly "just as good".
  • Page 11 1.2.7. To prevent pollution (1) Engine oil, filter elements, fuel filters 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. The ● drinking water supply could be contaminated.
  • Page 12 4. The use of proper tools and special tools where specified is important to efficient and reliable service operation. 5. Use genuine DOOSAN's parts necessarily. 6. Used cotter pins, gaskets, O-rings, oil seals, lock washer and self-lock nuts should be discarded and new ones should be prepared for installation as normal function of the parts can not be maintained if these parts are reused.

  • Page 13: Engine Specifications

    1.3. Engine Specifications 1.3.1. Specifications Engine Model GV158TIC GV180TIC GV222TIC Items Water-cooled, 4 cycle Vee type Engine type Turbocharger & intercooled Ignition system Spark plug ignition Combustion chamber type Open dish type Used fuel NG (Natural Gas) Fuel supply system...
  • Page 14 Engine Model GV158TIC GV180TIC GV222TIC Items Ignition type One coil per cylinder (no waste spark) Spark plug Iridium / Platinum electrode plug Ignition system Spark plug gap 0.3 ~ 0.4 Ignition coil Inductive coil pack Ignition timing adjustment Controlled by ESC and ICM...
  • Page 15 (1,800 rpm) (408 PS) (367 PS) (330 PS) 50 Hz 230 kW 207 kW (1,500 rpm) (313 PS) (281 PS) GV158TIC 60 H z 270 kW 243 kW (1,800 rpm) (367 PS) (330 PS) 50 Hz 319 kW 290 kW...

  • Page 16: Engine Assembly

    1.4. Engine Assembly Note: The images shown represent the standard model; they do not include all models. 1.4.1. Engine sectional view (longitudinal) EE3OM001 1. Crank shaft pulley 11. Turbo charger 2. Connecting rod 12. Flywheel 3. Piston 13. Flywheel housing 4.
  • Page 17 1.4.2. Engine sectional view (cross) EE3OM002 1. Oil level gauge 8. Intake manifold 2. Oil filter 9. Spark plug 3. Oil cooler 10. Cylinder head 4. Exhaust manifold 11. Cylinder block 5. Cylinder head cover 12. Oil drain pump 6. Throttle valve 13.
  • Page 18 1.4.3. Engine assembly views (1) GV158TIC EE3OM003 1. Alternator 11. Gas fuel mixer 2. Oil cooler & oil cooler 12. Lifting hook 3. Cooling water pump 13. Inter cooler 4. Water outlet 14. Ignition coil 5. Gas pressure regulator 15. Intake manifold 6.
  • Page 19 (2) GV180TIC EE3OM004 1. Alternator 11. Gas fuel mixer 2. Oil cooler & oil cooler 12. Lifting hook 3. Cooling water pump 13. Inter cooler 4. Water outlet 14. Ignition coil 5. Gas pressure regulator 15. Intake manifold 6. Throttle valve 16.
  • Page 20 (3) GV222TIC EE3OM005 1. Alternator 10. Inter cooler 2. Oil filter & cooler 11. Ignition coil 3. Cooling water pump 12. Turbo charger 4. Water outlet 13. Exhaust elbow 5. Gas pressure regulator 14. Crank shaft pulley 6. Throttle valve 15.

  • Page 21: Technical Information

    They are also referred to as engine model and serial number because of their loca- Engine tion. serial number EE3OM006 Engine serial No. (example1: GV158TIC) ● EEZOD 4 00001 Serial No. Production year (2004) Engine model Engine serial No. (example1: GV180TIC) ●...

  • Page 22: Diagnostic Display Module (Cpu - 95)

    RESET ALAR M ENTER EE3OM008 2.3. Engine Characteristic The DOOSAN GV158TIC, GV180TIC, GV22TIC natural gas engine is an overhead valve, turbocharged, water-to-air charge cooled, electronically controlled engine. 2.3.1. Design characteristic Spark-ignited by the spark plug. ● Electric engine control through the ECM (Engine Control Module) system.
  • Page 23 When combined with a gaseous fuel like natural gas, it allows greatly reduced emissions compared to diesel, plus high efficiencies and excellent high-performance. The GV158TIC, GV180TIC, GV222TIC engine is an integrated package featuring computer ● controlled electronic engine system by the engine speed controller. This system controls fuel, ignition and speed, and has engine protection features.
  • Page 24 2.3.5. Ignition control module : ICM This digital ignition system has been ● designed for application on nature gas fueled engines. This system is offers a variety of ● advanced control, emissions reduction, primary and spark diagnostics, self diagnostic serial communications and engine protection features.
  • Page 25 2.3.8. Engine timing Camshaft, oil pump and hall-effect sensor are driven by a gear train arranged at the flywheel end. ● Hall-effect sensor gear (Z=51) Drive gear of hall-effect sensor Camshaft gear (Z=51) (Z=86) Crankshaft gear (Z=43) Oil pump gear (Z=7) Oil pump drive gear Oil pump gear...
  • Page 26 Engine oil should be changed at the specified intervals. Oil in the oil filter cartridge should be ● changed simultaneously. First oil change After 50 hr operation GV158TIC Engine model GV180TIC Every 200 hr GV222TIC Technical Information...
  • Page 27 ● Engine oil capacity In oil pan Total Engine model Max. Min. (lit) (lit) (lit) GV158TIC GV180TIC GV222TIC Engine oil viscosity - ambient temperature SAE 5W - 30 SAE 10W - 30 Ambient -40 C -20 C 20 C 40 C...
  • Page 28 O-ring is fitted against the seal face. And then turn it in addition by 3/4 ~ 1 EFM2010I turns further with hand or the filter wrench. Note: It is strongly advisable to use DOOSAN genuine oil filter cartridge for replacement. Technical Information - 22 -...
  • Page 29 For the improper control might give the fatal damage to the cooling water pump and cylinder liners, detail care is needed. Since GV158TIC, GV180TIC, GV222TIC (Engine of D28 base engine) cylinder liner is wet type, par- ● ticularly the cooling water control should be applied thoroughly.
  • Page 30 How to use the cooling water test kit ● (1) When the cooling water temp. of engine is in the range of 10 ~ 55°C, loosen the plug for cooling Water discharge and fill the plastic cup about a half. Note: In taking the cooling water sample, if the water in auxiliary tank were taken, it is hard to measure the accurate density.
  • Page 31 2.3.17. V - belt Use a V-belt of specified dimensions, and ● replace if damaged, frayed, or deterio- rated. Check the V-belt for belt tension. If belt ● tension is lower than the specified limit, adjust the tension by relocating the alter- nator, (specified deflection: 10 ~ 15 mm when pressed down with thumb) EE3OM017...
  • Page 32 2.3.20. Valve clearance adjust procedure Adjust the valve clearance. ● - When disassembling the engine or cylinder head. - When there is excessive noise in the valve connection. - When the engine runs abnormally even if the fuel injection system is normal. Adjusting sequence of valve clearance (1 type) ●...
  • Page 33 7) When a cylinder valve overlap, adjust the valve clearance cylinder of the compression TDC (Top Dead Center), as follow. 8 Cylinder engine (GV158TIC) Valve overlapping on cylinder (Intake & Exhaust valve) Adjusting valves on cylinder (Intake &...
  • Page 34 2.3.21. Cylinder compression pressure Stop the engine after warming up, and ● take out the spark plug. EFM1004I Install the special tool (compression ● gauge adapter) at the spark plug hole, and connect the compression pressure gauge there. Standard value 16 kg/cm over Limit value...
  • Page 35 2.3.22. Spark plug Remove spark plug. Clean threads by ● hand with brush and solvent. Clean any deposits from electrode and ● Inspect insulator area. Measure the spark plug distance at elec- ● trode position. (A) Replace spark plug if necessary. ●...
  • Page 36 2.3.23. Battery Inspect for any leakage of electrolytic solution owing to battery crack, and replace the battery in case ● of poor condition. Inspect for amount of electrolytic solution, and replenish if insufficient. ● Measure the gravity of electrolytic solution, if less than specified value (1.12 ~ 1.28), replenish. ●...
  • Page 37 2.3.25. Alternator The alternator is fitted with integral silicon rectifiers. A transistorized regulator mounted on the alter- ● nator body interior limits the alternator voltage. The alternator should not be operated except with the regulator and battery connected in circuit to avoid damage to the rectifier and regulator. 24V X 45A Ignition Lamp terminal...
  • Page 38 2.3.26. Starting motor The sliding-gear starter motor is flanged to the rear of the flywheel housing on the left-hand side. As ● parts of every engine overhaul, the starter pinion and ring gear should be cleaned with a brush dipped in fuel and then a coat of grease should be applied again. 24V x 7.0kW M5 X 0.8 Bolt M10 X 1.25 Bolt...
  • Page 39 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 ●...

  • Page 40: Diagnosis And Remedy

    2.4. Diagnosis and Remedy The following description summarizes the probable cause of and remedy for general failure by item. ● Immediate countermeasures should be taken before a failure is inflamed if any symptom is detected. ● Inspect the electrical parts problem by the display module. ●...
  • Page 41 2. Engine Overheated Operating state 1. Overload 2. Radiator core clogged Cooling system Check coolant level Normal Too low Replenish Check fan belt tension, wear or damage etc. Inspect cooling water leakage Repair. Normal Replace External Internal Retighten. Engine Check fresh Replace Replace disassembly...
  • Page 42 3. Output insufficient Engine Generator set Inspect by display module diagnostic tool Inspect gas fuel filter Others Polluted Inspect air cleaner Normal Repair . Normal Repair . Replace Replace Inspect air leakage Inspect ignition timing Check valve clearance of air piping line Normal Adjust Normal...
  • Page 43 4. Oil pressure lowered Check if oil pressure Check oil amount gauge indicates wrongly Normal To low Check cooling temperature Use recommened oil (replenish) Too high Normal Refer to engine overheat Inspect oil quality Normal Check oil Water mixed in oil Improper relief valve Replace with...
  • Page 44 5. Fuel Consumption Excessive Cause according to use conditions 1. Overload 2. Generator set Inspect nature gas leakage Normal Nature gas leakage Retighten. Inspect ignition timing Replace Normal Adjust Inspect ignition system (ICM, Harness, Ignition coil, spark plug, boots etc.) Inspect compressed pressure Check valve...
  • Page 45 6. Oil Consumption Excessive Cause according to use conditions 1. Excessive oil infusing 2. Continuous operation in low speed or extremely cold state Inspect oil leakage Inspect air cleaner Clean. Replace Normal Oil leakage Check oil quality External Internal Retighten. Check compressed Replace pressure...
  • Page 46 8. Battery Discharge Battery Wiring, Switch Alternator Inspect cut wire Check fan belt Check electrolytic shorts and loose tension & damage liquid amount connections Repair. Replace Battery room Battery self Battery over Normal damage discharge charging Electrolytic liquid`s standard Replace Charging Inspect alternator voltage regulator...
  • Page 47 Condition Causes Remedies 1) Starting difficult (1) Compression pressure Valve's poor shut, stem distortion Repair or replace ● Valve spring damage Replace valve spring ● Cylinder head gasket's leak Replace gasket ● Adjust Wear of piston, piston ring or liner ●...
  • Page 48 Condition Causes Remedies (3) Piston, piston pin &piston ring Piston clearance increase as the wear Replace piston & piston ring ● of piston and piston ring progresses Wear of piston or piston pin ● Replace Stuck piston ● Replace piston Piston insertion poor ●...

  • Page 49: Engine Inspection

    2.5. Engine Inspection 2.5.1. Stopping engine Cut off the main circuit breaker of the generator control panel. After checking the engine for any ● unusual condition at the idling speed, then press the stop button to stop the engine. 2.5.2. General engine inspection cycle In order to insure maximum, trouble-free engine performance at all times, regular inspection, adjust- ●...
  • Page 50 2.5.3. Use of original parts for repair and replacement For engine is being mechanically harmonized with many parts, only when the original parts that the ● manufacture recommends to use is used, the engine trouble would be preventively maintained and capable to keep up the maximum performances.

  • Page 51: Disassembly And Reassembly Of Major Components

    3. Disassembly and Reassembly of Major Components 3.1. Engine Disassembly Engine parts' disassembly procedures are as follows; ● 3.1.1. General precautions For the various tool storage before disassembly and parts storage after disassembly, the shelf for ● parts is prepared. At the time of disassembly and reassembly, do the work with the naked and clean hand, and also ●...
  • Page 52 3.1.4. Cooling water Remove the cooling water drain plug ● from the cylinder block and oil cooler, various pipes, etc. and let the cooling water discharge into the prepared ves- sel. EE3OM023 EE3OM024 3.1.5. V-belt. Loosen the V-belt tension adjusting bolts, ●...
  • Page 53 3.1.7. Intercooler Tear down the various hoses and air ● pipes from the inter cooler. Remove the intercooler fixing bolts and ● tear it down. EFM2014I EE3OM026 3.1.8. Turbocharger and gas fuel mixer Loosen the gas hose and air cleaner ●...
  • Page 54 3.1.9. Exhaust manifold Remove the exhaust manifold fixing bolts ● and tear the manifold from the cylinder head. Caution: Be careful not to drop the manifold because it is very heavy. EFM2015I 3.1.10. Intake manifold & throttle valve Remove the throttle valve fixing bolts and ●...
  • Page 55 Remove the oil filter head fixing bolts and ● disassemble the filter head. Oil filter catridge Oil filter head EE3OM029 3.1.13. Cooling water pump Loosen the various hose clamps for the ● Thermostat connections. Water pump Remove the cooling water discharging ●...
  • Page 56 Remove the oil cooler insert fixing bolts, ● and then disassemble the cooler insert. Oil cooler Oil cooler cover EE3OM032 3.1.15. Starting motor Remove the starting motor fixing nuts and ● disassemble the starting motor. EFM2008I 3.1.16. Timing drive & sensor Remove the timing drive fixing bolts and ●...
  • Page 57 3.1.18. Cylinder head cover Remove the fixing bolts and tear the cyl- ● inder head cover down. EFM2020I 3.1.19. Spark plug By means of a long impact tool, loosen ● the spark plug and take it out. EE3OM035 3.1.20. Rocker arm Remove the rocker arm bracket fixing ●...
  • Page 58 Note: Be careful not to damage the cylinder head face where its gasket contacts. 3.1.22. Vibration damper Remove the fixing bolts for crankshaft ● pulley in reverse order of assembling and disassemble the crankshaft pulley and vibration damper. EFM2004I 3.1.23. Oil pan Remove the oil pan fixing bolts and sepa- ●...
  • Page 59 3.1.25. Piston Remove the connecting rod cap bolts in ● the reverse order of assembling and fol- low the similar method as in the cylinder head bolt removal. Tapping the upper and lower connecting ● rod caps lightly with an urethane ham- mer, separate them and take the bear- ings out.
  • Page 60 Remove the flywheel ring gear. ● - Heat the ring gear evenly with a gas burner (up to 200°C) to invite volumet- ric expansion. - Tapping around the edges of the ring gear with a hammer and brass bar to remove it.
  • Page 61 Note: Do not mingle with the metal bearings and bearing caps randomly. To prevent mixing, temporarily assemble the metal bearings to the corresponding bearing caps in turn. 3.1.30. Camshaft and tappet Pull out the tappets from the cylinder ● block. Remove the camshaft being careful not to ●...

  • Page 62: Measurement And Inspection Of Major Parts

    3.2. Measurement and Inspection of Major Parts 3.2.1. Cleaning and inspection of cylinder block Clean the cylinder block and inspect it for any crack or damaged. ● Inspect the oil passage and water passage for any clog and erosion. ● By performing the hydraulic test, inspect for any leaks.
  • Page 63 3.2.4. Spark plug Remove spark plug. Clean threads by ● hand with brush and solvent. Clean any deposits from electrode and ● inspect insulator area. Measure the spark plug distance at elec- ● trode position. (A) Correct or replace the spark plug if nec- ●...
  • Page 64 2) Distortion Measure the flatness degree (any dis- ● tortion) of cylinder head. Even beyond the limit value of maintenance, it may be corrected by grinding. (if more than limit value of use, replace it.) Standard Limit Warpage 0.05 mm or less 0.2 mm EA3M2031 EA6M2002...
  • Page 65 Inspect the scratch and wear of valve ● stem seal contacting face, and if nec- essary correct with the grinding paper but if severe replace it. If valve head thickness (A) becomes ● less than 1.6 mm for intake and 1.3 mm for exhaust, replace the valve.
  • Page 66 3.2.7. Valve spring Inspect the outlook of valve spring and if ● necessary replace it. By means of spring tester, measure the ● tension and free length. Measure the perpendicularity of valve ● spring. In case that the measured value exceeds ●...
  • Page 67 3.2.8. Valve spring Clean the cylinder head thoroughly. ● Coat the valve stems and valve guides ● Valve cotter 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 cylinder head with a spe- Stem seal cial tool.
  • Page 68 3.2.9. Rocker arm 1) Rocker arm disassembling 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 rocker arm bracket Measure the outer diameter of rocker...
  • Page 69 3.2.10. Tappet and push rod By means of outside micrometer, mea- ● sure the outer diameter of tappet and replace the severe ones. (1) Unevenness (2) Crank (3) Nomal Standard Limit Tappet clearance 0.035 ~ 0.077 mm 0.15 mm By inspecting the tappet surface that con- Abnormal ●...
  • Page 70 Measure the camshaft's axial end ● play, moving the camshaft gear by means of a driver. Standard Limit End play 0.24 ~ 0.86 mm 0.9 mm If excessive end play, assemble it by ● means of other thrust washer. EPM2017S 2) Inspection and measurement With inspecting the cam surface for ●...
  • Page 71 5) Cam bearing diameter Measure the camshaft bush inside ● diameter with cylinder gauge and by Camshaft bearing comparing the inside and outside diameters (after press-fit bearing fabri- cated) with the following standard, replace if abnormal. (mm) Standard Limit ø ø...
  • Page 72 3.2.12. Crank shaft 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 bear- ing. Inspect for any crack by means of ●...
  • Page 73 There are 4 kinds as above, and the ● " R " crankshaft also can be used by regrinding as above. " R " <"R part" standard value > (a) Crank pin "R part" : 4.0 -0.5 " R " "...
  • Page 74 (a) How to utilize the cylinder gauge Assemble the main bearing at the cyl- ● inder block and after tightening the bearing cap at the specified torque, measure the inside diameter. Journal bearing ø1 04.066 ~ ø1 04.115 mm nominal diameter Bearing cap bolt Initial 30 kg.m...
  • Page 75 5) End play Assemble the crankshaft in the cylin- ● der 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 3.2.13.
  • Page 76 2) Piston inspection With naked eyes, inspect the piston ● for any wear, crack and scratch and particularly inspect carefully at the ring grooves for any wear. With the outside micrometer, measure ● the piston's out side diameter the measuring position is 71.5 mm from 71.5mm the piston lower end, and the direction of measurement must be perpendicu-...
  • Page 77 4) Piston side clearance Assemble the piston ring at the piston. ● Measure the each ring's side clear- ● Feeler gauge ance and if the measured value exceeds the limit value, replace rings or piston. <Piston side clearance> Limit Division Specified value value EA0M4032...
  • Page 78 7) Connecting rod Inspect and measure the bigger end ● bearing hole and the smaller end bearing hole with respect to the paral- lelness and if abnormal, replace the rod. Standard Limit Feeler gauge 0.02 mm 0.2 mm EA0M4034 8) Piston reassembling After heating the piston at the piston ●...
  • Page 79 Measure the valve opening temperature ● and the valve full opening temperature and inspect if the valve lift is more than 8 mm and if abnormal, replace it. Opening Full opening temperature temperature 300738 -00159 71°C 85°C 300738-00161 83°C 95°C - 73 - Disassembly and Reassembly of Major Components...

  • Page 80: Engine Reassembly

    3.3. Engine Reassembly 3.3.1. Preparation and precaution before and after engine reassembly Clean all the parts thoroughly and also clean thoroughly by blowing into each passage of oil and ● cooling water. Disposition the various special and general tools for assembling in order. ●...
  • Page 81 3.3.3. Oil spray nozzle Tighten the oil injection nozzle flange with ● hollow screws. Assemble the oil injection nozzle with the ● fixing bolts. Hollow screw 7 kg.m Torque Fixing bolt 1.2 kg.m 3.3.4. Tappet Coat the tappet wholly clean oil and push ●...
  • Page 82 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 ●...
  • Page 83 3.3.6. Camshaft Coat the cam bush of cylinder block and ● camshaft with engine oil. Assemble the cam bush and camshaft for ● Crankshaft gear them not to be damaged. Assemble the crankshaft gear and the ● camshaft gear making sure that the gear marks both gears...
  • Page 84 After fitting the flywheel housing holes to ● the guide pins and engage temporarily 2 ~ 3 threads of fixing bolts, and according to the tightening order (zigzag method) tighten them in the specified torque. M12 x 1.5 10 kg.m Torque 7.5 kg.m 3.3.8.
  • Page 85 3.3.9. Front oil seal holder After placing the oil seal in the oil holder ● hole properly, press it in with a mandrel. (Be careful for oil seal must not be dam- aged.) Attach a gasket at the oil seal holder. ●...
  • Page 86 By means of a special tool, insert the pis- ● ton rings and adjust the angles between Top ring the ring gaps at 120°. 2nd ring Push in the piston with hands or wooden ● bar into cylinder. (Be careful for piston Oil ring and rings not be damaged.) Pushing the piston down, rotate the...
  • Page 87 3.3.11. Oil pump Put the oil pump at the place to be ● installed on the cylinder block. Attach a gasket at the surface of oil pump ● where the pressure regulating valve is to installed and place the regulating valve on a gasket.
  • Page 88 3.3.13. Oil pump Clean thoroughly the gasket that is pro- ● jecting at the junction parts of front oil seal holder and flywheel housing of cylin- der block' s lower face with a scraper. In the process of gasket removal, be ●...
  • Page 89 Tighten the cylinder head bolts to the ● Intake side(Spark plug) specified torque according to step by step. However, prior to tightening the bolts, ● with a long steel rule, the parallelness between the cylinder heads must be adjusted. Exhaust side EFM2077I <...
  • Page 90 3.3.16. Spark plug Put the spark plug hole of cylinder head ● and after inserting the spark plug assem- bly into it, tighten to assemble. Torque 2.5 ~ 3.0 kg.m EE3OM035 3.3.17. Rocker arm Coat the push rod with engine oil and put ●...
  • Page 91 Until the end of it reach on trigger magnet ● Assemble the sensor and reverse rotate (CCW) the timing sen- angle sor for 255° (gap 1.0 mm) and then fix lock nut. 0.7 ~ 1.0 mm Timing sensor gap (178° ~ 255°) Tolerance limit EE3OM045...
  • Page 92 2) Adjust ignition timing angle Remove the effect-hole sensor drive ● gear cover. Correct start of effect-hole sensor set- ● ting by turning the drive gear flange in the oblong holes of the drive gear. Mark sure after every adjustment that ●...
  • Page 93 3.3.22. Cylinder head cover Attach a new gasket on the surface of cyl- ● inder head where the cover is to be installed. Assemble the cylinder head cover by ● tightening the fixing bolts. Insert the oil filler cap. ● Torque 2.2 kg.m EFM2020I...
  • Page 94 Rotate (CCW) the Magnetic pick-up sen- ● sor for 270°(gap 1.0 mm) and fix lock nut. Flywheel Tolerance limit is 27°.(gap ±0.1 mm) ● Housing Tolerance limit EPM2031I 3.3.25. Oil cooler Attach a gasket on the surface in the oil ●...
  • Page 95 3.3.26. Oil filter Attach the oil filter gasket on the oil ● cooler. Install the filter head on the oil cooler and ● then tighten bolts in a diagonal sequence. Oil filter catridge Torque 4.4 kg.m Oil filter head EE3OM029 Lubricate the cartridge gasket and spin ●...
  • Page 96 3.3.28. Starting motor Install stud bolts at the bolt holes on the ● flywheel housing for installing the starter. Insert the starter into the fly wheel hous- ● ing and tighten the fixing bolts. Torque kg.m EFM2008I 3.3.29. Turbocharger Attach a gasket to the exhaust elbow and ●...
  • Page 97 3.3.30. Gas fuel mixer Attach a gasket to the intake elbow and ● assemble the gas fuel mixer with fixing Gas fuel mixer bolts. At the same method as above, both sides ● are assembled. Caution: Check assembled after the all engine parts install and tighten fuel line.
  • Page 98 3.3.32. Ignition coil & gas pressure regulator Attach a bracket to the intake manifold ● Gas pressure and assemble the gas pressure regulator regulator with fixing bolts. Assemble the ignition coil and high volt- ● age cable. Caution: Check assembled after the all engine Ignition coil parts install and tighten fuel line.

  • Page 99: Starting And Trial Operation

    3.4. Starting and Trial Operation 3.4.1. Preparations for breaking-in Fill of new engine oil through the oil filler cap. ● When measuring the oil level with the oil level gauge with the engine mounted, the oil level must ● indicate about 10 mm above the max. line. Connect water hoses and fill up cooling water.
  • Page 100 Refer to following table. Engine oil capacity Recommend oil Engine model In oil pan Sulfated ash Total (lit) API No. content Max. (lit) Min. (lit) GV158TIC GV180TIC SAE 15W40 Bellow 0.5% GV222TIC Disassembly and Reassembly of Major Components - 94 -...

  • Page 101: Speed Controller Setting

    3.5. Speed Controller Setting 3.5.1. Installation checks Do the checks in the order indicated. Terminal numbers in this chapter refer to the speed controller. (4.3. Speed controller) 1) Check that all electrical connections are correctly made and terminal screws tightened, the magnetic pickup is properly installed and the jam nut tightened, and the fuel valve and drain line are securely fastened and correctly installed.
  • Page 102 3.5.2. Initial pre-start settings In case the newly installed the speed controller does not control engine speed, be prepared to bellows sequence. 1) Rated speed If RATED SPEED was not set with a signal generator, set the RATED SPEED potentiometer to min- imum (fully counterclockwise).
  • Page 103 3) If the engine is hunting at a rapid rate, slowly decrease the GAIN (turn the potentiometer counter- clockwise) until performance is stable. 4) If the engine is hunting at a slow rate, increase the STABILITY (turn the potentiometer clockwise) until the engine stabilizes.
  • Page 104 13)Decrease the IDLE SPEED (turn the potentiometer counterclockwise) until the desired idle speed is reached. It may be necessary to adjust the idle dynamics to maintain stability as speed is lowered. 14)Dynamic adjustment a) Gain is too high and stability too low. There are secondary overshoots on transients and large overshoots on starts (under damped) Load Load...
  • Page 105 d) Stability too high, long time to settle to rated speed (over damped) Setting Time Speed EE3OM055 15)If idle dynamics were selected on initial start-up, it will now be necessary to set rated dynamics. Load the engine, then select rated dynamics. 16)Engine response will change as the engine warms up.

  • Page 106: Display Module

    3.6. Display Module 3.6.1. Display module system The Display module, typically mounted in an engine control panel or other enclosure off the engine, offers users comprehensive display and control functionality. It features a two-line, backlit, alphanu- meric display, in conjunction with a front accessible, sealed membrane keypad and gives users access to critical operating, setup, and diagnostic information.
  • Page 107 3) This diagnostic is flagged when zero gear tooth pulses are between two reset pulses. An open, shorted, or damaged magnetic pickup cable is typically the GT PICK-UP FAULT source of this fault. MISSING PULSES EGV2218005 4) Diagnostic faulted when too many gear tooth pulses are received without detec- tion of reset pulse.
  • Page 108 3.6.3. Patented primary and secondary diagnostic 1) Indicates ignition system detected an open circuit on output "A"; usually the result of faulty wiring or a failed coil. PRIMARY OPEN EGV2218008 2) A short circuit condition detected on out- put "B"; may be the result of an improp- erly wired coil or a short to ground inside the conduit.
  • Page 109 5) No secondary spark on output "E"; indi- cates disconnected secondary lead or voltage demand exceeding the coiPs out- put. NO SEC. SPARK EGV2218012 6) Output "F" is indicating that its monitored spark voltage demand is dramatically lower than the average of the cylinders. This indicates potentially an overly rich LO FROM ENGINE air/fuel mixture, a short in the secondary...
  • Page 110 3.6.4. Understanding the home screen 1) The READY message is displayed when the ignition is ready for the engine to crank for starting. READY 0 rpm 15.0 mA 10.0˚ Btdc EGV2218015 2) Once theengine begin sturning, the SYNCING message is displayed while the ignition system verifies signals from the engine pickups.
  • Page 111 5) The WARNING message will supersede all of the above home screens if a diagnostic warning con- dition is present. When a diagnostic warning exists, a View Diagnostics message will flash on the bottom line of the display. (a) The Ignition Module will continue to operate under a warning condition while alerting the operator of a potential problem in several ways: by turning on the Alarm LED in the Ignition Module and by changing the state of the Alarm Out switch (switch opens).
  • Page 112 L4B160 FS100#001 UNIT 791950-16 EGV2218025 - H : Represents the engine model (H:GV158TIC, J:GV180TIC, L:GV222TIC) Date configured Time configured - 4 : 4-cycle engine - A : Represents the altronic pattern code 10 - 01 - 95 12 : 00...
  • Page 113 3.6.5. Ignition state checks 1) The last setup screen permits the operator to enter an ignition test mode. This test mode can fire all outputs in rotation, or individual outputs at a slow rate. This feature can be used to troubleshoot pri- mary wiring and operation.
  • Page 114 3.6.6. Ignition control module diagnostics 1) A diagnostic fault represents the most severe classification of problems. The presence of a diagnos- tic fault will inhibit the ignition from firing. When a fault is detected several things will occur: (a) The ignition will stop firing. (b) The Fire Confirm Out switch will open.
  • Page 115 4) Acknowledgment of the alarm results in the following until a reset is commanded or until another fault or warning may occur. a) The Alarm Out switch will return to its closed position. b) The Alarm LED will flash to indicate that an alarm is present but acknowl- edged.
  • Page 116 b) When too many gear-tooth pluses are seen without a reset pluses. GT PICK-UP FAULT MISSING PULSES EGV2218005 c) When there are no hall-effect pickup pluses or when the pick-ups are not synchronized. HE PICK-UP FAULT MISSING / / NO - SYNC EGV2218007 d) When too many or to few gear-tooth pluses...
  • Page 117 f) When the check-sum of microproces- sor firmware cannot be verified. Unit requires service. BOTTOM BOARD uP CHECKSUM FAILED EGV22180037 - 111 - Disassembly and Reassembly of Major Components...

  • Page 118: Diagnosis And Remedies Of Trouble Causes

    3.7. Diagnosis and Remedies of Trouble Causes Prior to asking for repair, please check the following items ● Generated Problem Inspection Items Inspecting Position Backward of gauge panel Confirm connector that connects electric ● wiring to gauge panel if it is correctly connected Starting failure, starting motor Confirm connection of electric wiring and...

  • Page 119: Electrical Equipment

    4. Electrical Equipment 4.1. Gas Fuel Circuit EE3OM056 - 113 - Electrical equipment...

  • Page 120: Electrical Wiring Diagram

    4.2. Electrical Wiring Diagram EE3OM057 Electrical equipment - 114 -...

  • Page 121: Speed Controller

    4.3. Speed Controller 4.3.1. Speed controller description The Speed Controller is designed to provide basic isochronous speed control for gas engines. ● Engines with mechanical loads and generator loads are handled equally well. ● 152.4 133.35 4-O5.94 FLO-TECH SPEED EE3OM058 - 115 - Electrical equipment...
  • Page 122 4.3.2. Speed controller circuit FLOTECH SPEED CONTROL EE3OM059 Shield wires to be twisted pairs with shield grounded at one end only. ● No. 18AWG or 20AWG standard wire. Must be as short as possible. 50ft. maximum wire length ● for 20AWG wire. 80ft. maximum wire length for 18AWG wire. Use 24 volt system.

  • Page 123: Ignition Controller

    4.4. Ignition Controller 4.4.1. Ignition controller circuit Spark plug Ignition coil CPU-95 "G" lead-shutdown, instrument power & oscilloscope diagnostics *Hall-effect Display module cycle sensor RS485 serial data link & power Hall-effect pickup to line- 24 Vdc power up with magnet coincident with reset pickup lined-up Note: with reset pin on compression...
  • Page 124 4.4.2. DC power hookup of ignition system Regulator Battery CPU-95 UNIT Alternator Switch rating Battery charger Battery 10A min Fuse rating Power supply Power supply spec: 5A continuous EE3OM061 Operating voltage requirements ● Starting 20 VDC min. Running 24 ~ 28 VDC Dimensions of cable ●...
  • Page 125 Dimensions of cable ● * If multiple units are powered from a source located in a separate building, Determine the wire size required between the power source and the engine room. Create a common power hookup point in the engine room, Then use determine the wire size required from this common point to each ignition module.
  • Page 126 2)Display module circuit Use shielded 2 conductor cable or twisted pair MISC. input: Colse to Auxiliary terminal acivate selected feature User 4-conduct shielded cable for 2-wire transmitter power & RS-485 connections. Connect shield in ignition module Power module (See "A") 24Vdc supply POWER COMMUNICATIONS...

  • Page 127: Ignition Control Module

    4.5. Ignition Control Module 4.5.1. Ignition control module views 19-PIN CONNECTOR Fuse 1/2" CONDUITFITTINGS EEprom Microprocessor EE3OM065 4.5.2. Ignition control circuit PANEL OUT COMMUNICATIONS MAGN. PICKUPS 4-CYCLE PU POWER To pickups USER INPUT, CLOSE TO STOP IGNITION. NOTE RECOMMEND ALTRONIC 4-CONDUCTOR CABLE 503194-500 10 A fuse...
  • Page 128 4.5.3. Ignition harness connector Connector pin no. of ignition harness Cylinder GV158TIC GV180TIC GV222TIC EE3OM067 Ignition harness connector Off to GND 4.5.4. Ignition harness connector Engine model Firing order GV158TIC 1-5-7-2-6-3-4-8 GV180TIC 1-6-5-10-2-7-3-8-4-9 GV222TIC 1-12-5-8-3-10-6-7-2-11-4-9 4.5.5. Engine cylinder no. Cylinder no.
  • Page 129 4.5.6. Ignition system EE3OM069 - 123 - Electrical equipment...
  • Page 130 Electrical equipment - 124 -...

  • Page 131: Maintenance Of Major Parts

    5. Maintenance of Major Parts 5.1 Turbocharger 5.1.1. Main data and specification Generator engine GV158TI GV180TI GV222TI Turbocharger model HOLSET HX35 Rated revolution (rpm) 80,000 80,000 60,000 Intake air quality (m /sec) 0.28 0.35 0.43 Compression efficiency (%) 75.0 Compression ratio 1.66 Weight 14 kg...
  • Page 132 5.1.3. Construction Make sure that servicing should be performed at the professional maintenance shop as authorized by HOLSET or DOOSAN Company. 27,30,31 EFM3001I 1. Turbine shaft 15. Seal plate 2. Thrust bush 16. Thrust bearing 3. Oil shut off 17. Journal bearing 4.
  • Page 133 5.1.4. General information The engine output depends upon the supplied fuel quantity and the engine efficiency. In order to ● transform into the effective work of engine by burning the supplied fuel fully, the sufficient air to burn the fuel should be supplied to the cylinder. Therefore, the engine output is essentially determined by the size of the cylinder, and for if the air is ●...
  • Page 134 5.1.6. How to handle the engine 1) Precautions for operation of the engine Operation following items must be observed at the starting, operation and stop of engine. Operation Caution Reason At starting 1) Inspect oil quantity 2) After confirming that oil pressure rises 2) If engine is started quickly, of course by starting engine with starter (until the beginning with every parts of engine, for...
  • Page 135 Operation Caution Reason At stop 1) At stopping the engine, perform the idling 1) After heavy load operation, if the engine operation for 5 min. and then stop it. were stopped suddenly, the heat would be conducted to bearing parts from red hot turbine wings that would result in burning the oil to cause the stuck bear- ing metal and revolving shaft.
  • Page 136 5.1.8. Periodical servicing The turbocharger assembly must be inspected periodically. 1) Rotating condition of the rotor and checking tips Inspection on the revolving state of rotor is performed according to abnormal noises. ● In case of using an acoustic bar, touch the turbocharger housing with a tip of bar and raise the ●...
  • Page 137 c) In case that the end plays to axial and circumference directions, replace or repair the tur- bocharger. 3) Overhaul and cleaning points Be sure to dismantle the turbocharger from the engine before cleaning. ● Also, make sure to seal the oil inlet and outlet with tape or similar. ●...
  • Page 138 5.1.9. Trouble cause diagnosis and remedy Condition Causes Remedies 1.Exhaust gas 1) Air cleaner elements clogged Replace or clean excessive 2) Air Inlet port clogged Inspect or repair 3) Air leaks from air intake system Inspect or repair 4) Turbocharger impossible to rotate due to Overhaul and repair or replace stuck 5) Turbine wing's contact...

  • Page 139: Lubricating System

    5.2 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 lubri- cate the various sliding parts and turbocharger etc also in order to ensure normal engine performance.

  • Page 140: Cooling System

    5.3. Cooling System The engine has a liquid-cooling system. The water pump is a maintenance-free impeller pump driven ● by v-belts from the crankshaft pulley. Ø40 Ø12 EXHAUST MANIFOLD Ø55 AIR VENT Ø48.6 TIRBO CHARGER THERMOSTAT CYLINDER BLOCK Ø45 BY PASS Ø67 FRESH WATER PUMP Ø12...

  • Page 141: Thermostat

    5.4. Thermostat 5.4.1. General descriptions and main data The thermostat maintains a constant tem- ● To radiator perature of coolant (90 - 95°C) and improves thermal efficiency of the engine by preventing heat loss. Namely, when the temperature of coolant ●...
  • Page 142 5.4.3. Replacing thermostat and precautions for handling Precautions for handling ● The wax pallet type thermostat does not react as quickly as bellows type one to a variation of tem- perature of coolant. Such relatively slow reaction is mainly due to the large heat capacity of the wax pellet type thermostat.

  • Page 143: V-Belts

    5.5. V-Belts The tension of the belts should be checked after every 2,000 hours of operation. ● 5.5.1. Change the belts if necessary If in the case of a multiple belt drive, wear or differing tensions are found, always replace the com- ●...
  • Page 144 70 kg 60 kg 20.2 mm 75 kg 70 kg 60 kg *: Adopted in GV158TIC, GV180TIC, GV222TIC engine 5.5.5. Tensioning and changing belts Loosen fixing bolts and nuts. ● Adjust the alternator until belts have cor- ● rect tensions.

  • Page 145: Air Intake System

    5.6. Air Intake System 5.6.1. Maintenance (Only when engine is switched off) Empty the dust bowl regularly. The bowl should never be filled more than halfway with dust On slipping off the two clamps, the dust bowl can be removed. Take off the cover of the dust bowl and empty.
  • Page 146 5.6.3. Changing filter element By compressed air (wear goggles) ● - For the purpose, the air gun should be fitted with a nozzle extension which is bent 90° at the discharge end and which is long enough to reach down inside to the bottom of the element.
  • Page 147 Checking the filter cartridge ● - Before reinstalling the cartridge, it must be checked for damage e.g. to the paper pleats and rubber gaskets, or for bulges and dents etc. in the metal jacket. - Cracks and holes in the paper pleating can be established by inspecting the cartridge with a flashlight.
  • Page 148 Maintenance of major parts - 142 -...
  • Page 149 6. Engine Installation 6.1. Installing The center alignment of engine and Generator set is the most important factor for the extension of ● performance and life. Although aligning the center perfectly and accurately requires only few minutes, it is able to prevent unnecessary mechanical trouble at the future. 6.1.1.
  • Page 150 6.2. Inspection Prior to Installation 6.2.1. Inspection prior to installation Measure the correctness of flywheel and flywheel housing. Prior to inspection, clean the flywheel ● and flywheel housing. 1) Measuring flywheel housing Measure the flywheel housing surface ● and install the dial gauge (1/1,000) at Dial gauge the flywheel so as to be vertical to the flywheel housing, and let the gauge...
  • Page 151 4) Measuring pilot bore of flywheel Install the gauge as below so as for ● the gauge stem to contact to the pilot Dial gauge bore of the surface to be installed. Flywheel The eccentrics of the pilot bore of fly- ●...
  • Page 152 Engine installation - 146 -...
  • Page 153 Appendix Standard table of tightening torque ● Specification Screw Strength Tightening torque Cylinder block bearing cap - main bolt M18 x 2 12.9 Initial 30 kg.m + rotating angle 90° - side bolt M12 x 1.5 10.9 11.2 Flywheel housing - tightening bolt M12 x 1.5 10.9...
  • Page 154 * SUM22L 11.0 16.0 20.0 35.0 STS304 11.0 16.0 20.0 35.0 *: Adopted in DOOSAN engine 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)
  • Page 155 Engine assembly tolerance ● (Unit: mm) Items Specifications Remark Cylinder Inside dia. of liner forced in joint part (upper part) ø145.800 ~ ø145.840 ø145.8 H7 block Inside dia. of liner forced in joint part (lower part) ø144.500 ~ ø144.540 ø144.5 H7 Inside dia.
  • Page 156 (Unit: mm) Items Specifications Remark Connecting Con rod small end inside diameter (w/o bush) ø50.600 ~ ø50.630 ø50.6 H7 Con rod bush's diameter ø50.670 ~ ø50.700 Tighteness 0.04 ~ 0.10 Con rod large end part's inside diameter ø95.000 ~ ø95.022 ø95 H6 Con rod bearing spread (MIBA) 95.5 ~ 97.0...
  • Page 157 (Unit: mm) Items Specifications Remark Flywheel Ring gear assembly part's outside diameter ø432.490 ~ ø432.645 Ring gear inside diameter ø432.000 ~ ø432.200 Overlap 0.290 ~ 0.645 Heat fitting temp. (°C) 200 ~ 230 Allowable shaking amount after assembly Outside diameter after reassembly used ring ø114.980 ~ ø115.015 Cylinder Head gasket thickness (after tightening bolts)
  • Page 158 (Unit: mm) Items Specifications Remark Timing Rocker arm bush's inside diameter ø25.005 ~ ø25.035 When assembled Rocker arm bearing journal's diameter ø24.967 ~ ø24.990 Bearing's clearance 0.015 ~ 0.068 Push rod's shaking Valve tappet ass'y part's inside dia. of block ø20.000 ~ ø20.021 Push rod's outside diameter ø19.944 ~ ø19.965...
  • Page 159 GV158TIC Engine assembly ● 1018 236.5 996.5 AIR C OOLER COOLING WATER IN & OUTLE Ø75 256.1 66.7 GAS INLET PT 2-11 196.1 ENGINE COOLING WATER OUTLET 39.6 Ø75 25.4 ENGINE COOLING WATER INLET Ø75 16.7 8-M12x1.5 Depth2 2 12-M10 Depth20 AIR COOLER COOLING WATER IN &...
  • Page 160 GV180TIC Engine assembly ● 236.5 1176 1154.5 66.7 Air cooler cooling 354.1 water in & outle t 39.6 PT 2-11 25.4 Gas inlet Engine cooling 16.7 water outlet Engine cooling water inlet 8-M12x1.5 12-M10 Tap depth 22 Tap depth20 Power train 236.5 Air cooler cooling water in &...
  • Page 161 GV222TIC Engine assembly ● 1334 236.5 1312.5 401.5 GAS INLET PT 1-1/4 355.5 66.7 AIR COOLER COOLING WATER IN & OUTLE Ø75 ENGINE COOLING WATER OUTLET 39.6 Ø75 25.4 ENGINE COOLING WATER INLET 16.7 Ø75 8-M12x1.5 Depth22 12-M10 Depth20 AIR COOLER COOLING WATER IN & OUTLE 1053.5 236.5 Ø75...
  • Page 162 - 156 - Appendix...

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