Related Manuals for Doosan DP222L Series
Summarization of Contents
1. General introduction
General Information
Provides general information about the manual and engine.
Danger, warning, caution, and note
Details safety classifications and their meanings for user safety.
General Instructions
Outlines basic principles for engine operation and safety.
2. Operation and maintenance
Starting and stopping of the engine
Step-by-step guide for safely starting and stopping the engine.
Break-in period of the engine
Details the critical initial period for new or overhauled engines.
Operation in winter
Specific procedures for operating the engine in cold weather conditions.
Inspection and repair of the engine
Guidelines for inspecting and repairing various engine components.
3. Performance and specifications
Engine specifications and performance
Detailed technical specifications and performance data for the engines.
Exterior view drawing of the engine
Visual diagrams of engine components from different views.
Gross Engine Output
Table detailing engine output (PS and kW) for prime and standby conditions.
4. Regular inspection
General information
Importance and methods for performing regular engine inspections.
Routine Inspection
Daily checks to be performed by the operator before running the engine.
Regular inspection table
Comprehensive table outlining inspection and replacement intervals for engine parts.
General Conditions
General guidelines for maintaining engine performance and preventing accidents.
Cooling system
General Information
Overview of the engine's water-cooling system and its function.
Coolant standards
Recommended coolant mixture and additive details for optimal performance and protection.
Capacity of coolant
Specifies the coolant capacity for different engine models.
Checking the Coolant
Procedures for checking coolant level, concentration, and quality.
Lubrication system
General Information
Explains the role of engine oil in lubrication, cooling, and engine protection.
Engine oil standards
Details recommended engine oil specifications based on viscosity and classification.
Engine Oil Capacity
Table showing the recommended engine oil capacity for different engine models.
Checking the Engine Oil
Step-by-step guide for checking engine oil level and condition.
Fuel system
General Information
Overview of the fuel system and the importance of cleanliness and proper fuel.
Fuel Standards
Specifies fuel quality requirements and recommendations for optimal engine performance.
Water (Moisture) in diesel fuel
Explains the causes and effects of water in diesel fuel.
Specifications
Fuel system specifications for different engine models.
Failure Diagnosis
Table listing common fuel system problems, causes, and troubleshooting steps.
Fuel injection pump
General information about the fuel injection pump and its governor.
Intake/exhaust system
General Information
Overview of the intake and exhaust system's role in engine performance.
Air Filter
Description of the air cleaner and factors affecting its service interval.
Disassembly of air filter
Procedures for disassembling the air filter assembly.
Cleaning of the Air Filter Element
Methods for cleaning the air filter element.
Changing the air filter element
Steps for replacing the air filter element.
Turbocharger
Maintenance overview for the turbocharger.
Routine check and serving the turbocharger
Regular checks for intake, exhaust, fuel, and lubrication systems affecting turbocharger.
Disassembly and cleaning a turbocharger
Procedure for disassembling and cleaning the turbocharger.
Cylinder block/head
Valve Clearance
Importance and conditions for adjusting valve clearance.
Adjusting the Valve Clearance
Detailed method for adjusting valve clearance.
Tightening Cylinder Head Bolt
Procedures for retightening cylinder head bolts after initial use or repair.
Cylinder Compression Pressure
Steps for measuring and interpreting cylinder compression pressure.
Electric system
General information
Overview of electrical system components and functions.
Specification
Electrical specifications for alternator, starter, and battery.
Electrical Wiring diagram
Diagram illustrating the engine's electrical system connections.
Switches and sensors
Details on temperature switches, sensors, and magnetic pick-up units.
Starter
General information, specifications, and views of the starter motor.
Alternator
General information, views, wiring diagram, and specifications of the alternator.
Others/driving system
General Information
Overview of crankshaft, connecting rod, and piston features.
Crankshaft
Procedures for inspecting and measuring crankshaft journals, pins, and warpage.
Piston
Steps for piston disassembly, assembly, inspection, and ring groove checks.
Connecting rod
Inspection procedure for connecting rod parallelism.
Engine Timing
Diagram illustrating engine timing gear relationships.
5. About the engine
Marking system of units
Explains conversion methods between SI and US units.
Tightening torque
Detailed specifications for tightening torque of various engine parts and bolts.
Tightening Torque of Main Parts
Torque values for critical engine components like cylinder block and flywheel.
Tightening Torque of General Bolts
Torque specifications for standard bolts based on strength classification.
Engine Disassembly
Procedure of Disassembling an Engine
Step-by-step procedure for disassembling the engine.
Engine Assembly
Procedure of Assembling Engine
Step-by-step procedure for assembling the engine.
6. Cooling system
General information
Overview of the engine's water-cooling system and its function.
Specifications
Detailed coolant capacity and temperature specifications for different engine models.
Failure Diagnosis
Table listing common cooling system problems, causes, and troubleshooting steps.
Thermostat
General Information
Explains the function of the thermostat in maintaining engine temperature.
Check of the thermostat
Procedures for checking and verifying the thermostat's operation.
7. Lubrication system
General information
Explains the role of engine oil in lubrication, cooling, and engine protection.
Specifications
Details oil capacity, pressure, and specification for different engine models.
Failure Diagnosis
Table listing common lubrication problems, causes, and troubleshooting steps.
8. Fuel system
General information
Overview of the fuel system and the importance of cleanliness and proper fuel.
High Sulfur content in diesel fuel
Guidelines on fuel sulfur content and its impact on engine life and maintenance.
Water (Moisture) in diesel fuel
Explains the causes and effects of water in diesel fuel.
Specifications
Fuel system specifications for different engine models.
Failure Diagnosis
Table listing common fuel system problems, causes, and troubleshooting steps.
Fuel injection pump
General information about the fuel injection pump and its governor.
9. Intake/exhaust system
General information
Overview of the intake and exhaust system's role in engine performance.
Specifications
Technical specifications for intake and exhaust systems, including turbocharger models and output.
Function
Explanation of how the turbine and compressor components of the turbocharger work.
Failure Diagnosis
Table listing common intake/exhaust system issues, causes, and troubleshooting.
How to Maintain Turbocharger
Guidelines for proper engine operation to maintain turbocharger health.
Special inspection of turbocharger
Procedures for checking turbocharger rotor radial and axial clearance.
10. Cylinder block/head
General Information
Introduction to the cylinder block and cylinder head construction.
Specifications
Technical specifications for cylinder block and head components like valve system and lash.
Cylinder block
Procedures for checking the cylinder block and measuring cylinder liners.
Cylinder head
Procedures for assembly and checking the cylinder head.
Valve
Information on valve dimensions, wear limits, and related components.
Rocker arm
Procedures for rocker arm disassembly, checking, and assembly.
Tappet and push rod
Checks for tappet clearance, visual inspection, and push rod warpage.
Camshaft
Procedures for checking camshaft end play, lobe height, bearing diameter, and run-out.
11. Electric system
General information
Overview of electrical system components and functions.
Specification
Electrical specifications for alternator, starter, and battery.
Electrical Wiring diagram
Diagram illustrating the engine's electrical system connections.
Switches and sensors
Details on temperature switches, sensors, and magnetic pick-up units.
Starter
General information, specifications, and views of the starter motor.
Alternator
General information, views, wiring diagram, and specifications of the alternator.
12. Others/driving system
General Information
Overview of crankshaft, connecting rod, and piston features.
Crankshaft
Procedures for inspecting and measuring crankshaft journals, pins, and warpage.
Piston
Steps for piston disassembly, assembly, inspection, and ring groove checks.
Connecting rod
Inspection procedure for connecting rod parallelism.
Engine Timing
Diagram illustrating engine timing gear relationships.
Governor Actuator Controller
Product Overview and General Specification
Introduction to the digital speed controller and its features.
Product features
List of key features of the digital speed controller.
Appearance and Installation
Visual representation of the governor actuator installation.
Operating Principles
Explanation of how the governor system controls engine speed.
Product Specifications
General specifications
Key operating parameters and specifications for GN11 and GN12 models.
Mechanical specifications
Mechanical details including product dimensions, weight, and material.
Outside view and main components of governor
Diagram and description of the governor's external view and key components.
Control Unit (1)
Description of Functions
Detailed explanation of the controller's functions and capabilities.
Specifications
Performance
Performance characteristics including speed range, droop, and stability settings.
Terminal Sensitivity
Sensitivity specifications for various controller terminals.
Speed Switch Adjustment Range
Range for adjusting speed switch settings.
Environmental Conditions
Operating environment requirements like temperature and humidity.
Input Power
Power requirements and consumption details for the controller.
Reliability
Information on vibration resistance and testing standards.
Components
DWC-2000
Diagram and labeling of the DWC-2000 controller components.
GAC-ESD5550
CAUTION
Important installation and wiring precautions for the ESD5550 controller.
Description of Controller Terminology
Glossary of Controller Terms
Glossary of terms used in the controller's interface and functions.
Wiring
External Wiring Connections
Guidelines for connecting external components to the controller.
Mounting and Connecting the Magnetic Speed Sensor
Proper mounting and connection of the speed sensor.
Adjusting the Speed Externally
Methods for remotely adjusting engine speed using potentiometers.
Troubleshooting
When the System is Not Working
Step-by-step voltage testing for system faults.
System not working properly
Troubleshooting for engine overspeeding and actuator issues.
Control Unit (2)
Components
Diagram and labeling of the control unit (DWG-2013) components.
Installation
Installing (Mounting) the Controller and Cautions
Critical precautions for installing the controller, including EMC and environmental factors.
Description of Control Mode Items
Explanation of various control mode items and their functions within the controller.
Connecting to the engine
Diagrams and instructions for connecting the controller to the engine and its components.
Operating sequence for the controller
Step-by-step operational sequence and LED indicators for the controller.
Connecting to speed trim, droop, idle and other inputs
Diagrams and instructions for connecting speed trim, droop, and idle controls.
Connecting to crank, run, over speed and communication
Wiring diagrams for crank, run, over speed indicators and communication interfaces.
Configuration and Operation
Input keys
Description of the controller's input keys and their functions.
LCD display menu
Overview of the controller's LCD menu structure and navigation.
System monitor
Menu for monitoring controller operation and engine parameters.
Engine type setup menu
Procedure to configure controller settings based on engine type.
System setup menu display of the controller
Overview of system setup options like RPM, fuel, and battery settings.
PID gain setup menu
How to input and configure PID gain parameters (Kp, Ki, Kd).
PID auto setup menu
Procedure for automatic designation of PID parameters for engine control.
Date/Time setup menu
How to set the controller's date and time for logging and fault management.
Alarm list menu
How to view and interpret alarm codes for troubleshooting.
Default setup functions
Procedure to reset controller configuration to factory default values.
System info functions
Accessing controller information like serial number and software version.
LCD setup functions
How to adjust LCD brightness and contrast.
Configuring starting fuel
How to set the fuel amount for engine start and preheating.
Configuring speed ramping
How to adjust the time for reaching rated speed from idle.
Configuring droop gain
How to adjust droop percentage for parallel generator operation.
Droop Function
Explanation of droop function calculation and purpose.
F - load curr
How to set maximum actuator current for full load generator operation.
N - load curr
How to set actuator current for generator with no load.
PID gain setup configuration
How to configure PID gain parameters (Proportional, Integral, Derivative).
Configuring PID sampling time
How to set the sampling time for PID calculations.
PID auto setup value configuration
Procedure for automatic PID tuning.
Date/Time value configuration
How to set the controller's date and time.
Troubleshooting
Alarm list check
Guide to reviewing alarm codes for system troubleshooting.
System checks and measures
Procedures for checking system connections and controller functions.
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