User Manuals: Doosan AD158TI Marine Generator Engine

Manuals and User Guides for Doosan AD158TI Marine Generator Engine. We have 1 Doosan AD158TI Marine Generator Engine manual available for free PDF download: Operation & Maintenance Manual

Doosan AD158TI Operation & Maintenance Manual

Doosan AD158TI Operation & Maintenance Manual (295 pages)

Brand: Doosan | Category: Engine | Size: 27 MB

Table of Contents

Symbols Used in the Manual
3
Table of Contents
5
Engine Specification
7
Engine Sectional View
11
Engine Aspects
11
Engine Assembly Diagram
13
Engine Performance Curve
14
Engine Model & Serial Number
15
Safety Regulation
17
General Notes
17
Regulations Designed to Prevent Accidents with Injury to Persons
17
Regulations Designed to Prevent Damage to Engine and Premature Wear
19
Regulations Designed to Prevent Pollution
20
Engine Oil, Filter Element, Fuel Filter
20
Notes on Safety in Handling Used Engine Oil
20
3 Commissioning and Operation

21
- Inspections before Operation
  21
  - Cooling Water
    21
  - Sea Water Pump
    22
  - Intake & Exhaust Line
    22
  - Fuel Line
    22
  - Bottom of the Engine Room
    22
  - Gauge Panel
    23
  - Dutch Panel
    23
  - Single Panel / Dual Panel
    24
  - Dual Panel
    24
  - Digital Gauge Panel Circuit Diagram
    25
  - Digital Gauge Panel View
    26
  - Engine Stop & Warning Devices
    27
- Starting
  28
- Engine Break-In
  29
  - New Engine Break-In 20 Hours
    29
  - Initial Two Hours of Break-In
    29
- Inspections after Starting
  31
- Check after Initial 50 Hours Operation
  32
- Operation in Winter
  32
  - Prevention against the Freeze of Cooling Water
    32
  - Prevention against Excessive Cooling
    32
- Tuning the Engine
  33
- General Repair Instructions
  35
4 General Information

35
- Periodical Inspection & Maintenance
  36
- Cooling System
  37
- Lubrication System
  43
  - Oil Level
    43
  - How to Re-Mark the Oil Dipstick
    43
  - Exchanging of Lubrication Oil
    44
  - Oil Drainage
    44
  - Recommend of Lubricating Oil
    44
  - Replacement of Oil Filter Cartridge
    45
  - Engine Oil Viscosity - Ambient Temperature
    45
  - Oil Centrifugal Filter
    46
  - Marine Gear Oil Change
    46
  - Cylinder Compression Pressure
    46
- Intake & Exhaust System
  47
- Fuel System
  49
  - Priming Pump Strainer Cleaning
    49
  - Fuel Tank Cleaning & Checking
    49
  - How to Select Fuel Oil
    50
  - Fuel Oil Selection Chart
    51
  - Water Separator
    52
  - Fuel Filter Exchanging
    52
  - Checking the Fuel Injection Timing
    53
  - Injection Nozzle Maintenance
    53
  - Bleeding of the Fuel System
    53
- Electric System
  54
- Warning Lamp Check
  54
- Valve Clearance
  54
- When the Engine Is Not Used Long Time
  54
- When the Engine Is Sunk
  55
5 Main Accessory Parts

57
- Reduction Gear
  57
- Front Power Take off
  59
  - PTO Description and Operation
    59
  - How to Use PTO
    60
  - Checking Engagement Load
    60
  - PTO Adjustment
    61
  - Adjusting Rings
    62
  - Facing Check (PTO)
    62
  - Lubrication Point
    63
  - Exploded View of Typical 11-1/2″ ~ 14″ Twin Clutch
    64
  - Front Power Take-Off (F.P.T.O)
    65
- Propeller Selection
  66
- Alternator
  67
- Electric System
  67
- Starter Motor
  69
6 Disassembly and Assembly of Major Components

71
- Cylinder Block Inspection
  81
- Cylinder Head Inspection
  81
- Cylinder Liner Measurement
  81
- Cylinder Head Disassembly
  82
- Distortion of Cylinder Head Bottom Face
  82
- Check of Valve Guide
  84
- Valve Seat
  84
- Valve Spring Check
  85
- Squareness of Valve Spring
  86
- Assembling Cylinder Head
  87
- Rocker Arm Inspection
  88
- Camshaft Inspection
  89
- Crankshaft Inspection
  92
- Inspection on Crankshaft Bearing
  93
- Run out of Crankshaft
  93
- How to Utilize Plastic Gauge
  94
- How to Utilize the Cylinder Gauge
  94
- Piston Disassembling
  95
- Piston Inspection
  95
- Piston Ring & Ring Groove Inspection
  96
- Piston Pin Inspection
  97
- Connecting Rod Inspection
  98
- Piston Reassembling
  98
- Injection Nozzle Inspection
  99
- Engine Re-Assembly
  100
  - Flywheel Housing
    103
  - Tacho Sensor
    103
  - Flywheel
    104
  - Oil Cooler
    104
  - Heat Exchanger
    105
  - Piston
    105
  - Starting Motor
    105
  - Connecting Rod Bolt Tightening Order
    106
  - Front Oil Seal Holder
    106
  - Oil Pan
    107
  - Oil Pump
    107
  - Vibration Damper
    107
  - Cylinder Head
    108
  - Nozzle
    109
  - Rocker Arm
    109
  - Valve Clearance Adjust Procedure
    110
  - Cylinder Head Cover
    111
  - Fuel Injection Pump
    112
  - Injection Timing
    113
  - Flywheel Housing Cover
    114
  - Fresh Water Pump
    115
  - Intake Manifold
    115
  - Exhaust Manifold
    116
  - Turbocharger
    116
  - Fuel Filter
    117
  - Fuel Injection Pipe
    117
  - Idle Pulley
    118
- Trial Test after Maintenance
  119
7 Main Parts Maintenance

121
- Lubricating System Maintenance
  121
- Oil Pump Maintenance
  121
- Cooling System Maintenance
  122
- Fresh Water Pump Assembly
  122
- Fuel System Maintenance
  122
- Injection Pump Maintenance
  122
- Rack Diagram
  124
- Boost Compensator Pressure
  124
- Fuel Feed Pump
  141
- Fuel Feed Pump Disassembly and Inspection
  142
- Fuel Feed Pump Testing
  143
- Injection Nozzle
  144
- Turbo-Charger Specification
  146
- Construction of the Turbo-Charger
  147
- Inspection of the Turbo-Charger
  148
- Turbo Charge Identification
  149
- Turbocharger Disassembly
  151
- Turbocharger Cleaning
  158
- Assembly Turbine Wheel
  159
- Turbine Housing
  159
- Compressor Housing
  160
- Bearing Housing
  160
- Compressor Wheel
  160
- Oil Slinger
  160
- Turbocharger Assembly
  161
- Checking of the Rotor for Rotating Condition
  169
- Checking of the Rotor End Play
  170
- Precautions for Reassembling the Turbocharger Onto the Engine
  171
- Troubleshooting
  173
- Hard to Start the Engine
  173
- Insufficient Output
  174
- Overheating
  175
- Black Smoke Is Produced
  176
- White Smoke Is Produced
  176
- Starter Motor will Not Turn or Output Less Power
  177
- Hydraulic System will Not Operate or to Slow Function
  177
- Battery Is Dead or Not Chargeable
  178
- Standard Table of Tightening Torque
  179
- Standard Bolt Tightening Torque Table
  180
- Tightening Torque for Plug Screw
  181
- Governor Actuator
  189
- Outside View and Main Components of Governor
  191
- Control Unit
  192
- Specifications
  194
- Description of Controller Terminology
  197
- Controller Wiring
  198
- How to Adjust the Engine Performance (for New Controllers)
  198
- Adjusting the Starting Fuel
  199
- Setting the Idle Rpm
  199
- Droop Operation
  199
- Auxiliary Input
  200
- Auxiliary Supply
  200
- Remote Speed Adjustment
  200
8 Troubleshooting

201
- Control Unit Components
  203
- Description of Control Mode Items
  204
- Installing (Mounting) the Controller and Cautions
  204
- Adjustment (Tuning) Order and Method
  205
- External Wiring Connections
  209
- Adjusting the Speed Externally
  210
- Mounting and Connecting the Magnetic Speed Sensor
  210
- Accessory Input (Automatic Parallel)
  213
- Controller Lamp Display (Diagnosis) Functions
  213
- Droop Parallel Operating Mode (Manual Parallel)
  213
- Digital Speed Controller
  216
- Product Appearance
  217
- Product Specification
  218
- Product I/O Signals
  219
- Product System Diagram
  219
- Product Dimension
  221
- Connecting to the Engine
  222
- Installation
  222
- Operating Sequence for the Controller
  223
- Connecting to Speed Trim, Droop, Idle and Other Inputs
  224
- Connecting to Crank, Run, over Speed and Communication
  226
- Configuration and Operation
  228
- Input Keys
  228
- LCD Display Menu
  229
- LCD Displays after Powered on
  230
- LCD Main Menu Display
  231
- Engine Type Setup Menu
  232
- Date/Time Setup Menu
  234
- PID Auto Setup Menu
  234
- PID Gain Setup Menu
  234
- Alarm List Menu
  235
- Default Setup Menu
  235
- System Info Menu
  235
- Designated Parameters by Engine Type
  236
- Engine Configuration
  236
- Configuring Set Idle Rpm
  238
- Configuring Set over Speed
  238
- Configuring Cranking Rpm
  239
- Configuring Gear Number
  239
- Configuring Speed Ramping
  240
- Configuring Starting Fuel
  240
- Configuring Low Battery
  241
- Configuring Max Current
  241
- Configuring Droop Gain
  242
- Droop Function
  242
- PID Gain Setup Configuration
  244
- Configuring PID Sampling Time
  245
- PID Auto Setup Value Configuration
  245
- Date/Time Value Configuration
  246
- Alarm Code Table
  247
- Alarm List
  247
- Default Setup Functions
  248
- System Info Functions
  248
- LCD Setup Functions
  249
- System Monitor Functions
  249
- Operating Sequence for Digital Speed Controller
  250
- Controller Troubleshooting
  251
- Digital Panel for Marine Engines
  253
- Digital Panel Components and Optional Accessories
  256
- General Information
  256
- Product Information
  256
  - Digital Panel Specifications
    257
  - Product Specification
    257
  - Cautions
    258
  - Digital Panel Installation
    258
  - Product Installation
    258
    
    Installing Stationary Type Digital Panel
    259
    
    Installing Mounting Type Digital Panel
    260
  - Back Side
    261
  - Digital Panel Part Names, Operation and Settings
    261
  - Front Side
    261
  - External Connection Terminals
    262
  - Power Connector
    262
  - Signal Connector
    263
  - CAN Communication Connector
    264
  - CCTV Connector
    264
  - External Buzzer Connector
    264
    
    Fuse and Internal Buzzer (Digital Panel)
    265
    
    Key Switch (Digital Panel)
    265
  - USB Connector
    265
    
    Start/Stop Button (Digital Panel)
    266
    
    Function Keys (Digital Panel)
    267
    
    Detailed Settings (Digital Panel)
    268
  - Battery Voltage
    269
  - Check Sensor Light
    269
  - Display Structure (Digital Panel)
    269
  - Engine Oil Pressure
    269
  - Engine Speed (Tachometer)
    269
  - Exhaust Gas Temperature
    269
  - Gearbox Oil Pressure
    269
    
    Engine Oil Pressure
    270
    
    Engine Water Temperature
    270
    
    Exhaust Gas Temperature
    270
    
    Battery Voltage
    271
    
    Check Sensor Light
    271
    
    Gearbox Oil Pressure
    271
  - Engine Alarm
    272
  - Engine Stop
    272
  - Spare Sensor
    273
  - Event Summary
    274
  - System Booting and Functional Check (Digital Panel)
    275
  - Multi Panel Structure
    276
  - How to Install Multi Panels
    277
  - Multi Panel Settings
    278
  - Digital Panel Manager
    279
  - PC Communication Connection
    279
  - Software Installation and Execution
    280
  - Display Structure and Detailed Functions (Digital Panel)
    282
  - Menu Structure
    282
  - Operation Record Files (Digital Panel)
    283
  - Setting Functions by Permission Level
    286
    
    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
  - A/S Service Information
    292
  - Warranty
    292
  - Warranty and A/S Service
    292
Appendix

293
- List of Engine Models
  293

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