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Doosan DX22 User Manual
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950106-106013EN
DX22
GENERATOR ENGINE
Operation &
Maintenance Manual
2
Table of Contents
Table of Contents
5
Introduction
7
General Information
9
Danger, Warning, Caution, and Notes
10
General Information
10
General Precautions
11
Cautions for Starting the Engine
11
Cautions for Inspections and Maintenance
11
General Information
12
Other Safety Instructions and Environmental Pollution
12
Engine Care
13
Use of Genuine Parts
13
Preventing Damage and Wear
13
GTL (Gas to Liquids)
14
Handling Engine Oil
14
Preventing Pollution
14
HVO (Hydro Treated Vegetable Oil)
14
2. Operation and Maintenance
15
Operation and Maintenance
15
During Operation
17
Immediately after Starting the Engine
17
Preparing to Start
17
Starting and Stopping the Engine
17
When Starting the Engine
17
When Stopping
17
Breaking in New Engines
18
Engine Break-In
18
General Information
18
Inspection after Starting the Engine
18
Inspection Items
18
Operation after Break-In Period
18
Coolant Temperature
19
Engine Oil
19
Engine Oil Pressure
19
Engine Speed (Rpm)
19
Preventing Engine Overcooling
19
Prevention of Coolant Freezing
19
Running the Engine in Winter
19
Running the Primary Fuel Filter (Oil-Water Separator) Heater
19
Checking Engine Parts after Prolonged Operation
20
Engine Inspections and Maintenance
20
Turbocharger Inspections and Maintenance
20
Exhaust System
21
Fuel System Inspections and Maintenance
21
Intake System
21
Lubrication System
21
3. Performance and Specifications
23
Performance and Specifications
23
Engine Specifications
25
Engine Specifications and Performance
25
Engine Power
27
Outside Drawing of the Engine
28
Structural Diagram
28
Left/Right Sectional View
29
Top View
30
Engine Code and Production Number
31
Engine Serial Number
31
Numbers Stamped on the Engine
31
4. Regular Inspections
33
Regular Inspections
33
Daily Inspections
35
General Information
35
General Conditions
36
Maintenance Schedule
36
Allowable Fuel under Warranty
37
Cautions for Using Biodiesel
37
Cautions for Using Biodiesel in Different Types of Generators
37
Coolant Capacity
38
Coolant Inspections
38
Coolant Specifications
38
Cooling System
38
General Information
38
Measuring the Coolant Concentration
39
Add Coolant
40
Replacing Coolant
40
Cleaning the Cooling Circuit
41
Coolant
41
General Information
42
Lubrication System
42
Engine Oil Specifications
43
Adding Engine Oil
44
Checking Engine Oil
44
Engine Oil Capacity
44
Adding Engine Oil
45
Bleeding Fuel Delivery Lines
46
Fuel Filter
46
Fuel Lines Connected to the Engine
46
Fuel Specifications
46
Fuel System
46
Fuel Tank
46
General Information
46
Hand Priming Pump and Connecting Adapter
46
Primary Fuel Filter, Connecting Adapter, Fuel Heater, Service Tool
46
Engine Low-Pressure Fuel Lines
47
Cleaning the Air Filter
48
General Information
48
Intake/Exhaust System
48
Cleaning the Air Cleaner Element
49
Replacing the Air Cleaner Element
49
Adjusting the Valve Clearance
50
Cylinder Block/Head
50
Adjusting Sequence of Valve Clearance
51
Battery
52
Electrical System
52
Belt Tension
53
Other/Driving System
53
5. General Engine Information
55
General Engine Information
55
Method of Indicating Units
57
Unit Conversion Methods
57
Tightening Torque
58
Tightening Torque of Main Parts
58
Tightening Torque of General Bolts
59
Tightening Torque of Hollow Screws (Four Holes)
60
Tightening Torque of Plug Screws
60
Engine Disassembly
61
Order of Engine Disassembly
61
Engine Assembly
71
Order of Engine Assembly
71
6. Cooling System
93
Cooling System
93
Overview
95
Overview and Specifications
95
Specifications
96
Cautions for Replacing and Handling the Thermostat
97
General Information
97
Inspection
97
Thermostat
97
Causes of Faults and Troubleshooting
98
Air Heater (Optional)
99
Circuit Diagram
99
Operating Conditions
99
Lubrication System
101
Overview and Specifications
103
8. Fuel System
105
Fuel System
105
General Information
107
Caution
108
Fuel System Components
108
Fuel Tank
108
Fuel Lines Connected to the Engine
109
Hand Priming Pump and Connecting Adapter
110
Three-Way Valve
110
Primary Fuel Filter, Connecting Adapter, Fuel Heater, Service Tool
112
Engine Fuel Inlet/Outlet Ports
121
Low-Pressure Fuel Pump
123
Secondary Fuel Filter
124
High-Pressure Fuel Pump
125
Common Rail
126
High-Pressure Fuel Pipe
126
Injectors, High-Pressure Fuel Connectors
128
9. Intake/Exhaust System
129
Intake/Exhaust System
129
General Information
131
Specifications
131
Structure
131
Turbocharger
131
Function
132
Overview
132
Failure Diagnosis
133
Handling the Turbocharger
135
Check Items During Turbocharger Disassembly and Assembly
137
Inspecting the Turbocharger
138
10. Cylinder Block/Head
141
General Information
143
Cylinder Block
144
General Inspection of the Cylinder Block
144
Assembling the Cylinder Head
145
Cylinder Head
145
Inspecting the Cylinder Head
146
General Information
147
Inspecting the Valve Guide
147
Inspecting Valves
147
Valves
147
Inspecting the Valve Seat
148
Inspecting the Valve Spring
149
Assembling the Rocker Arms
150
Checking and Measuring the Assemblies
150
Disassembling the Rocker Arms
150
Rocker Arms
150
Inspecting the Tappet Visually
151
Pushrod Deflection
151
Tappet and Pushrod
151
Tappet Clearance
151
Camshaft
152
Camshaft Play
152
Checking and Measuring the Camshaft
152
Replacing the Camshaft Bearing
153
11. Electrical System
155
Electronic Components
157
Circuit Diagram
159
General Information
159
Engine Connectors
160
Engine Control Unit (ECU) Engine Connectors
164
Electronic Control Unit
167
Switches and Sensors
167
Ambient Temperature Sensor
171
Boost Pressure and Temperature Sensor
171
Camshaft Speed Sensor
171
Common Rail Pressure Sensor
171
Coolant Temperature Sensor
171
Crankshaft Speed Sensor
171
Engine Oil Pressure and Temperature Sensor
171
Engine Control Unit (ECU)
172
Engine Control Unit (ECU) Connectors
172
Engine Control Unit (ECU) Input/Output
173
Engine Control Unit (ECU) Operating Conditions
174
Outside Drawing
175
TMS 3.0 (Option)
175
Front PIN Map
176
TMS 3.0 TYPE a (LTE) Module (EG25-G) Specification
177
Schematic Diagram
178
General Information
180
Starter Motor
180
Circuit Diagram
181
Alternator
182
General Information
182
Circuit Diagram
183
12. Other/Driving System
185
General Information
187
Crankshaft
188
Inspecting the Crankshaft
188
Inspecting the Crankshaft Bearings and Connecting Rod Bearings
189
Disassembling Pistons
191
Pistons
191
Inspecting and Measuring
192
Injector Protrusion
194
Injectors
194
Engine Timing
195
Miscellaneous
195
Timing Gear Train
196
13. Installation Guidelines
199
Fuel Line Installation Information
201
Fuel Lines
201
Pre-Filter Specifications
202
Hand Priming Pump Specifications
203
Installation with Pre-Filter
204
WIF (Water in Fuel) Sensor
205
Heater
206
Engine Wire Harness Connector Information
207
5
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Doosan DX22 Specifications
General
Number of Cylinders
4
Fuel Type
Diesel
Aspiration
Naturally Aspirated
Fuel System
Direct Injection
Cooling System
Water-cooled
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