Doosan P158LE, P180LE, P222LE, PU158TI, PU180TI, PU222TI User Manual

P158LE Series Operation & Maintenance

65.99897-8076C Operation & Maintenance Manual GENERATOR DIESEL ENGINE P158LE / -1 / - 2 / -S / -III P180LE / -1 / -S / -II P222LE / -1 / -S / -II POWER UNIT DIESEL ENGINE PU158TI PU180TI PU222TI

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FOREWORD

FOREWORD This manual is designed to serve as an instruction for Diesel generator engine and Power Unit engine of DOOSAN series (P158LE /P180LE /P222LE, PU158TI/ PU180TI/ PU222TI). The engines are 4 strokes, 2 valves per cylinder, V-type, and direct injection mode and thus, are also satisfying with various features required as generator and power unit engine such as quiet operation, economical fuel consumption, durability in high speed operation and so forth. We are very confident that these engine series are quite superior to any high speed engines in economy and administration of periodic inspections and maintenance should be observed. Readers are desired to know for efficiency.

However, high performance and long life cycle will be accomplished when a proper handling and your reference that those kinds of maintenance matters are explained here in detail by means of figures and diagrams. In this manual, the following symbols are used to indicate the type of service operations to be performed.

Removal Adjustment Installation Cleaning Disassembly Pay close attention-Important Reassembly Tighten to specified torque Align the marks Use special tools of manufacturer's Directional Indication Lubricate with oil Inspection Lubricate with grease Measurement If you have any question or recommendation in connection with this manual, please do not hesitate to contact our head office, dealers or authorized service shops near by your location for any services. For the last, the contents of this instruction manual may be changed without prior notice for some quality improvement. Thank you. Doosan Infracore Co., Ltd. Jan. 2008

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CONTENTS

CONTENTS 1. Safety Regulations & Engine Specifications 1.1. Safety regulations ............................................................................................................................... 1 1.2. Engine Specification ........................................................................................................................... 5 1.3. Engine Assembly .............................................................................................................................. 11 2. Technical Information 2.1. Engine Model and Serial Number ..................................................................................................... 19 2.2.

Engines Characteristic ...................................................................................................................... 20 2.3. Troubleshooting ................................................................................................................................ 41 2.4. Operation tip ..................................................................................................................................... 51 3. Disassembly and Reassembly of Major Components 3.1. Engine Disassembly ......................................................................................................................... 52 3.2.

Inspection ......................................................................................................................................... 62 3.3. Engine Reassembly .......................................................................................................................... 81 3.4. Breaking-In ....................................................................................................................................... 98 4. Commissioning and Operation 4.1. Preparations ..................................................................................................................................... 99 4.2.

Starting ............................................................................................................................................. 99 4.3. Running in ...................................................................................................................................... 100 4.4. During operation ............................................................................................................................. 100 4.5. Shutting down ................................................................................................................................. 100 4.6.

Maintenance and Care ................................................................................................................... 101 5. Maintenance of Major Components 5.1. Fuel Injection System ..................................................................................................................... 105 5.2. Cooling System .............................................................................................................................. 126 5.3. Lubricating System ......................................................................................................................... 129 5.4.

Turbo Charger ................................................................................................................................ 131 5.5. Installation ...................................................................................................................................... 140 5.6. Air Cleaner ...................................................................................................................................... 143 5.7. Tightening Cylinder Head Bolts ...................................................................................................... 145 5.8.

V-belts ............................................................................................................................................ 146 6. Special Tool List ................................................................................................................................. 149 z Appendix z Parts & After Service Center z Worldwide Network

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1.1. Safety regulations

1. Safety Regulations & Engine Specifications 1.1. Safety Regulations 1.1.1. General notes Handling diesel engines and the necessary resources is no problem when the personnel commissioned with operation and maintenance are trained accordingly and use their common sense. This summary is a compilation of the most important regulations, These are broken down into main sections which contain the information necessary for preventing injury to persons, damage to property and pollution. In addition to these regulations those dictated by the type of engine and its site are to be observed also. IMPORTANT :

If despite all precautions, an accident occurs, in particular through contact with caustic acids, fuel penetrating the skin, scalding from oil, antifreeze being splashed in the eyes etc, consult a doctor immediately. 1.1.2. Regulations designed to prevent accidents 1) During commissioning, starting and operation z Before putting the engine into operation for the first time, read the operating instructions carefully and familiarize yourself with the “critical” points, If you are unsure, ask your DHI representative.

z For reasons of safety we recommend you attach a notice to the door of the engine room prohibiting the access of unauthorized persons and that you draw the attention of the operating personal to the fact that they are responsible for the safety of persons who enter the engine room. z The engine must be started and operated only by authorized personnel. Ensure that the engine z When the engine is running, do not get too close to the rotating parts. Wear close-fitting clothing. cannot be started by unauthorized persons. z Do not touch the engine with bare hands when it is warm from operation risk of bums. z Exhaust gases are toxic.

Comply with the instructions for the installation of DHI Diesel engines which are to be operated in enclosed spaces. Ensure that there is adequate ventilation and air z Keep vicinity of engine, ladders and stairways free of oil and grease. Accidents caused by slipping extraction. can have serious consequences. Safety Regulations & Engine Specifications - 1 -

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