Doosan PU222TI Manuals

Manuals and User Guides for Doosan PU222TI. We have 1 Doosan PU222TI manual available for free PDF download: Operation & Maintenance Manual

Doosan PU222TI Operation & Maintenance Manual

Doosan PU222TI Operation & Maintenance Manual (166 pages)

GENERATOR DIESEL ENGINE, POWER UNIT DIESEL ENGINE

Brand: Doosan | Category: Engine | Size: 11 MB

Table of Contents

Table of Contents
3
1 Safety Regulations & Engine Specifications

4
2 Technical Information

22
- Engine Model and Serial Number
  22
- Engines Characteristic
  23
  - Oil Gallery Cooling Type Piston
    23
  - Engine Block
    24
  - Piston / Connecting Rod / Crank Assembly
    24
  - Engine Timing
    24
  - Valves
    24
  - Engine Lubrication
    25
  - Engine Cooling System
    26
  - Oil Cooler
    26
  - Fuel System
    27
  - Fuel Oil Selection Chart
    28
  - Injection Pump
    29
  - Faults
    29
  - Bleeding the Fuel System
    29
  - Fuel Lift Pump
    29
  - Replacement of Fuel Filter
    30
  - Injector Maintenance
    30
  - Removal, Dismantling and Cleaning
    31
  - Note for Cleaning Nozzles
    31
  - Operating Pressure
    31
  - Installation
    32
  - Fan Belt
    32
  - Engine Oil
    32
  - Turbo Charger
    33
  - Intercooler
    34
  - Cooling System
    34
  - Filling-In of Coolant
    35
  - Draining of Coolant
    36
  - Cooling Water
    36
  - Amount of Anti-Freeze in Winter
    37
  - Fuel Filter
    38
  - Air Cleaner
    38
  - Valve Clearance Adjust Procedure
    38
  - Adjusting Sequence of Valve Clearance
    39
  - 8 Cylinder Engine (P158LE/PU158TI)
    39
  - 10 Cylinder Engine (P180LE/PU180TI)
    39
  - 12 Cylinder Engine (P222LE/PU222TI)
    39
  - Cylinder Compression Pressure
    40
  - Injection Nozzle
    40
  - Fuel Injection Pump
    41
  - Battery
    41
  - Air Removal of Fuel System
    41
  - Fuel Supply Pump
    41
  - Electrical Equipment
    42
  - Alternator
    42
  - Starting Motor
    43
  - Starter Motor
    43
- Troubleshooting
  44
  - Engine Starting Impossible
    44
  - Engine Overheated
    45
  - Output Insufficient
    46
  - Oil Pressure Lowered
    47
  - Fuel Consumption Excessive
    48
  - Oil Consumption Excessive
    49
  - Battery Discharge
    50
- Operation Tip
  54
- Periodic Inspection Cycle
  54
3 Disassembly and Reassembly of Major Components

55
- Engine Disassembly
  55
  - Oil Level Gauge
    55
  - Vibration Damper
    56
  - Oil Filter Assembly
    56
  - Cooling Water Pump
    57
  - Injection Pipe
    57
  - Oil Cooler Assembly
    58
  - Exhaust Manifold
    59
  - Intake Manifold
    59
  - Flywheel Housing Cover
    59
  - Cylinder Head Cover
    60
  - Nozzle Holder
    60
  - Rocker Arm
    60
  - Cylinder Head
    61
  - Oil Pan
    61
  - Oil Pump
    61
  - Piston
    62
  - Front Oil Seal Holder
    62
  - Flywheel
    62
  - Flywheel Housing
    63
  - Crankshaft
    63
  - Camshaft and Tappet
    64
  - Oil Spray Nozzle
    64
  - Cylinder Liner
    64
- Inspection
  65
  - Cylinder Block
    65
  - Cylinder Liner Measurement
    65
  - Cylinder Head Disassembly
    66
  - Inspection and Measurement of Cylinder Head
    66
  - Distortion at the Lower Face
    67
  - Inspection and Measurement of Valve and Valve Guide
    67
  - Lower Face Warp and Height
    67
  - Valve Guide
    68
  - Valve Seat
    68
  - Valve Seat Thickness
    69
  - Valve Seat Angle
    69
  - Valve Spring
    70
  - Perpendicularity Regular
    70
  - Assembling Cylinder Head
    70
  - Rocker Arm Bracket
    71
  - Tappet and Push Rod
    72
  - Rocker Arm Reassembling
    72
  - Camshaft
    73
  - Axial End Play
    73
  - Visual Check
    73
  - Cam Lobe Height
    73
  - Cam Bearing Diameter
    74
  - Clearance
    74
  - Camshaft Bearing Replacement
    74
  - Camshaft Run-Out
    74
  - Journal and Pin Diameter
    75
  - Crankshaft Journal Outside Diameter
    75
  - Crankshaft Pin Outside Diameter
    75
  - “R Part” Standard Value
    76
  - Run out of Crankshaft
    76
  - Inspection on Crankshaft Bearing and Connecting Rod Bearing Inspection
    76
  - How to Utilize the Cylinder Gauge
    76
  - How to Utilize Plastic Gauge
    77
  - End Play
    77
  - Piston Disassembling
    78
  - Inspection & Measurement of the Piston
    78
  - Measurement of Cylinder Bore
    79
  - Piston Ring and Ring Groove
    79
  - Gap Clearance
    79
  - Piston Ring Gap
    79
  - Piston Side Clearance
    80
  - Piston Pin
    80
  - Outside Diameter
    80
  - Piston Pin and Connecting Rod Bush Clearance
    80
  - Connecting Rod
    81
  - Distortion and Parallel
    81
  - Amounts of Wear
    81
  - Piston Reassembling
    81
  - Water Temperature Inspection
    82
- Engine Reassembly
  84
  - General Preparation
    84
  - Tappet
    85
  - Bearing Cap Bolt’s Tightening Order
    86
  - Tacho Sensor
    88
  - Connecting Rod Bolt Tightening Order
    90
- Breaking-In
  101
4 Commissioning and Operation

102
- Preparations
  102
- Starting
  102
- Running in
  103
- During Operation
  103
- Shutting down
  103
- Maintenance and Care
  104
  - Oil Level
    104
  - Oil Drainage
    104
  - Recommend of Lubricating Oil
    105
  - Refilling with Oil
    105
  - Engine Oil Viscosity - Ambient Temperature
    105
  - Lubricating Oil Filter
    106
  - Renewal of Filter Cartridges
    107
5 Maintenance of Major Components

108
- Fuel Injection System
  108
  - Governor System for Generator Engine
    108
  - Integral Actuator
    108
  - Speed Control Unit for Governor System
    109
  - Specification
    111
  - DWG-2000 Wiring and Outline
    112
  - Application and Installation Information
    113
  - Wiring
    113
  - Adjustments
    113
  - Before Starting Engine
    113
  - Start Engine
    114
  - Governor Speed Setting
    114
  - Governor Performance
    114
  - Starting Fuel Adjustment
    114
  - One of Two Methods of Operation for the DWC-2000 May Now be Selected
    115
  - Idle Speed Setting
    115
  - Speed Droop Operation
    115
  - Accessory Input
    116
  - Accessory Supply
    116
  - Wide Range Remote Variable Speed Operation
    116
  - Variable Speed Range Potentiometer Value
    116
  - OVERSPEED Shutdown Setting
    117
  - RUN Ramp Turn-On Speed Setting
    117
  - CRANK Ramp Turn-On Speed Setting
    117
  - System Inoperative
    117
  - Unsatisfactory Performance
    118
  - Insufficient Magnetic Speed Sensor Signal
    118
  - Electromagnetic Compatibility (EMC)
    119
  - Instability
    119
  - Injection Pump Calibration
    120
  - P158LE Series Engine
    120
  - P180LE Series Engine
    121
  - P222LE Series Engine
    122
  - Rack Diagram
    124
  - Boost Compensator Pressure
    124
- Cooling System
  129
  - Thermostat
    130
  - General Descriptions and Main Data
    130
  - Diagnostics and Troubleshooting
    131
  - Replacing Thermostat and Precautions for Handling
    131
- Lubricating System
  132
  - General Descriptions
    132
  - Oil Filter
    133
- Turbo Charger
  134
  - Turbine
    136
  - Compressor
    136
  - Bearing
    136
  - Sealing at Compressor Shaft
    136
  - Precautions at Engine
    138
  - Routine Inspection and Maintenance
    139
  - Intake Air
    139
  - Exhaust System
    139
  - Periodic Inspection and Maintenance
    140
  - Revolving State and Inspection Points of Rotor
    140
  - End Play Inspecting Points of Rotor
    140
  - Axial Direction End Play
    140
  - Overhaul and Cleaning Points
    141
  - Precautions in Assembling Engine
    141
  - Air Intake System
    141
  - Trouble Cause Diagnosis and Remedy
    142
  - Inspection Prior to Installation
    143
  - Measuring Flywheel Housing
    143
  - Measuring Bore of Flywheel
    143
  - Measuring Deformation of Flywheel Installing Surface
    143
  - Measuring Pilot Bore of Flywheel
    144
  - Bed Rail
    144
  - Supporting
    144
  - Aligning Center
    145
  - Installing Fuel System
    145
  - Example of Fuel System Installation
    145
  - Changing Filter Element
    146
- Air Cleaner
  146
  - Cleaning Filter Elements
    147
  - By Compressed Air
    147
  - By Washing
    147
  - Knocking out Dirt by Hand
    147
- Tightening Cylinder Head Bolts
  148
- V-Belts
  150
  - Testing by Hand
    150
  - Measuring Tension
    150
  - Tensioning and Changing V-Belt
    151
  - Tensioning Forces on the Tester
    151
6 Special Tool List

152
Appendix

154

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