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General| Aspiration | Turbocharged, Intercooled |
|---|---|
| Fuel System | Direct Injection |
| Cooling System | Water-cooled |
| Lubrication System | Forced lubrication |
| Engine Model | Doosan GV158TIC |
General guidelines for safe operation, maintenance, and care of power engines.
Precautions for handling highly flammable and explosive natural gas to avoid injury.
Safety measures when welding or using torches near fuel lines and tanks.
Procedure to safely vent natural gas pressure from an engine.
Safety alerts and precautions during engine commissioning, startup, and operation.
Safety guidelines for carrying out maintenance and care procedures on the engine.
Safety instructions for authorized personnel performing checking, setting, and repair work.
Guidelines to prevent engine damage and premature wear through proper parts and maintenance.
Procedures and precautions to prevent environmental pollution from engine fluids and waste.
Health precautions and safe handling practices for used engine oil.
General instructions and precautions to be followed during engine repair operations.
Detailed technical specifications for GV158TIC, GV180TIC, and GV222TIC engines.
Table of detailed technical specifications for various engine models.
Engine power output data for various models under different operating conditions.
Details on engine assembly and component views.
Longitudinal sectional view of the engine, illustrating key components.
Cross-sectional view of the engine, showing internal parts.
Assembly views of the GV158TIC engine, detailing component locations.
Assembly views of the GV180TIC engine, detailing component locations.
Assembly views of the GV222TIC engine, detailing component locations.
Information on locating and identifying engine models and serial numbers for warranty and parts.
Description and cautions for using the diagnostic display module system.
Key engine characteristics, including design features and natural gas properties.
Key design features of the natural gas engines, including ignition and control systems.
Characteristics and benefits of natural gas as a clean and economical fuel.
Explanation of the spark-ignited engine system and its integration with the speed controller.
Function and application of the Engine Speed Controller (ESC) for isochronous speed control.
Features of the digital ignition system designed for natural gas engines.
Description of the cylinder block construction, liners, and cylinder heads.
Details on the construction and materials of pistons, connecting rods, and crankshafts.
Diagram illustrating the gear train for engine timing components.
Description of how overhead valves are actuated via camshaft components.
Explanation of the engine's force-feed lubrication system and oil flow.
Description of the oil cooler's location and type within the lubrication system.
Instructions for checking and changing engine oil, including capacity and recommended types.
Procedure for changing engine oil and oil filter, emphasizing importance for engine life.
Steps for replacing the oil filter cartridge, recommending genuine parts.
Overview of the engine's liquid-cooling system and water pump.
Guidelines for selecting and maintaining cooling water, including antifreeze and rust prevention.
Instructions for checking and adjusting V-belt tension and replacement.
Function and maintenance of the air cleaner to ensure proper combustion air purity.
Information on the water-to-air intercooler and its importance for intake air condition.
Step-by-step procedure for adjusting valve clearance, including engine configurations.
Procedure and specifications for measuring cylinder compression pressure.
Instructions for removing, cleaning, inspecting, and installing spark plugs.
Inspection procedures for battery leakage, electrolyte level, and gravity.
Notes on turbocharger inspection, maintenance, and cleaning of impellers.
Information on the alternator's features, maintenance, and circuit protection.
Description of the starting motor and its protection against moisture.
General precautions for using the engine, battery handling, and disposal.
Troubleshooting guide covering various engine problems, causes, and remedies.
Troubleshooting guide for engine starting failures, covering various causes and remedies.
Diagnostic flowchart for engine overheating issues, including cooling system and thermostat checks.
Troubleshooting guide for insufficient engine output, covering fuel, air, and ignition system issues.
Diagnostic steps for low oil pressure, including checks for oil amount, quality, and relief valve.
Troubleshooting for excessive fuel consumption, considering overload, ignition timing, and compression.
Diagnostic guide for excessive oil consumption, covering oil leakage and internal wear issues.
Troubleshooting for engine knocking, focusing on combustion, fuel quality, and ignition timing.
Diagnostic steps for battery discharge issues, including checks on the battery, wiring, and alternator.
Guidelines for regular engine inspection, adjustment, and maintenance procedures.
Procedure for safely stopping the engine using the main circuit breaker.
Schedule and guidelines for regular engine inspection, adjustment, and maintenance.
Importance of using genuine DOOSAN parts for repair and replacement to ensure performance.
General procedures and precautions for disassembling engine components.
Essential precautions for tool storage, cleanliness, and handling parts during disassembly.
Step for removing the oil level gauge as part of disassembly.
Procedure for draining engine oil using the oil drain pump lever.
Procedure for draining cooling water from the engine block and oil cooler.
Steps for loosening V-belt tension adjusting bolts and removing the V-belt.
Instructions for removing ignition coils and gas pressure regulators.
Steps for detaching hoses and air pipes from the intercooler and removing it.
Procedures for disconnecting hoses and bolts to remove the turbocharger and gas fuel mixer.
Instructions for removing the exhaust manifold, noting its weight.
Steps for removing the throttle valve and intake manifold from the engine.
Procedure for removing the alternator, including supporting pieces and bolts.
Instructions for disassembling the oil filter cartridge, advising against reuse.
Steps for removing hose clamps, discharging pipe, and disassembling the water pump.
Procedure for draining cooling water and disassembling the oil cooler and its housing.
Instructions for removing the starting motor.
Steps for removing timing drive fixing bolts and disassembling the timing drive and sensor.
Instructions for separating the side cover and disassembling the flywheel housing cover.
Procedure for removing the cylinder head cover by unscrewing fixing bolts.
Method for loosening and removing spark plugs using a long impact tool.
Steps for removing the rocker arm assembly and push rods.
Procedure for loosening and removing cylinder head bolts and gasket.
Instructions for removing the crankshaft pulley and vibration damper.
Steps for removing the oil pan and its gasket.
Procedure for removing oil suction pipe, relief valve bolts, and oil pump.
Method for removing connecting rod cap bolts, bearings, and piston assembly.
Instructions for removing the oil seal holder and its gasket.
Steps for removing flywheel fixing bolts and the flywheel itself.
Procedure for removing flywheel housing bolts and the oil seal.
Steps for removing bearing caps, bolts, and lifting the crankshaft.
Instructions for removing tappets and the camshaft carefully.
Procedure for removing oil spray nozzle fixing bolts and the nozzles.
Method for removing the cylinder liner using a special tool (extractor).
Procedures for measuring and inspecting major engine components.
Instructions for cleaning and inspecting the cylinder block for cracks, passages, and leaks.
Procedure for measuring cylinder liner inner diameters and checking against wear limits.
Steps for disassembling the cylinder head, including gasket contact surface care.
Reiteration of spark plug removal/installation and measurement, plus torque specs.
Detailed inspection for cylinder head damage, distortion, and testing methods.
Procedures for inspecting valve stem diameter, wear, and valve guide clearance.
Inspection of valve springs, including tension, free length, and perpendicularity measurements.
Instructions for cleaning cylinder head, assembling valves, and installing valve springs.
Steps for disassembling and inspecting rocker arms and their brackets for wear.
Procedures for measuring tappet diameter, inspecting tappet surface, and checking push rods.
Methods for measuring camshaft axial end play, inspecting cam surface, and lobe height.
Inspection and measurement of crankshaft journals and pins, including wear and diameter checks.
Procedures for disassembling, inspecting, and measuring pistons, rings, and grooves.
Inspection of thermostat wax case, spring, and operating temperature.
Step-by-step procedures for reassembling engine components.
General preparation and precautions for engine reassembly, including cleaning and lubrication.
Steps for replacing O-rings, coating joint parts, inserting cylinder liners, and leak testing.
Instructions for tightening oil injection nozzle flange and assembling with fixing bolts.
Procedure for coating tappets with oil and inserting them into the cylinder block.
Steps for heating wear rings, assembling main bearings, and mounting the crankshaft.
Instructions for coating camshaft components with oil and assembling crankshaft and camshaft gears.
Procedure for coating thrust washer bolts, assembling oil seal, and attaching flywheel housing gasket.
Steps for installing flywheel ring gear, assembling pilot bearing, and mounting the flywheel.
Instructions for placing and pressing the oil seal into the holder and attaching the gasket.
Procedure for aligning piston assemblies, fitting bearings, and coating with oil.
Steps for installing the oil pump, attaching gaskets, and tightening fixing bolts.
Instructions for assembling the vibration damper by tightening crankshaft pulley and fixing bolts.
Steps for cleaning gaskets, installing oil pan, and inserting oil level gauge.
Procedure for identifying valve marks and assembling valve stem seals with valve guides.
Steps for cleaning bolt holes, positioning cylinder head assembly, and ensuring gasket alignment.
Instructions for inserting and tightening spark plugs into the cylinder head.
Procedure for coating push rods with oil and assembling rocker arms, adjusting valve clearance.
Steps for attaching O-rings, installing timing drive, and mounting the timing sensor.
Procedure for checking and adjusting ignition timing angle and sensor positioning.
Instructions for attaching gasket to flywheel housing cover and tightening fixing bolts.
Steps for attaching gaskets and assembling intake manifold and gas regulator.
Procedure for attaching new gasket and assembling cylinder head cover.
Instructions for assembling exhaust manifold with gaskets, cover, and elbow pipe.
Steps for moving lock nut and rotating magnetic pick-up sensor for proper positioning.
Procedure for attaching gasket, tightening oil cooler, and assembling the oil cooler assembly.
Instructions for attaching oil filter gasket, installing filter head, and tightening cartridge.
Steps for attaching gasket, assembling cooling water pump, thermostat, and pipes.
Procedure for installing stud bolts and inserting the starter into the flywheel housing.
Instructions for assembling turbocharger with gaskets on exhaust elbow and oil pipes.
Steps for attaching gasket to intake elbow and assembling the gas fuel mixer.
Instructions for assembling intercooler fixing bracket, intercooler, hoses, and pipes.
Procedure for attaching bracket, assembling gas pressure regulator, ignition coil, and high voltage cable.
Steps for assembling alternator bracket, supporting plate, alternator, and connecting V-belts.
Procedures for starting and operating a new engine, including break-in guidelines.
Steps for preparing a new engine for initial operation, including oil, water, and system checks.
Guidelines for operating a new engine during the break-in period to ensure longevity.
Key points to monitor during engine break-in, such as oil level and warning lamps.
Steps for setting up and adjusting the engine speed controller.
Checks to perform before starting the engine after installing the speed controller.
Initial settings for the speed controller's potentiometers before starting the engine.
Procedures for adjusting governor settings for stable engine operation after initial startup.
Overview and functionality of the engine display module.
Overview of the display module's functionality, interface, and access to operating information.
Examples of typical diagnostic messages displayed by the system, like overspeed and faults.
Explanation of the different messages displayed on the home screen (READY, SYNCING, FIRING, STALLED).
Procedure for entering ignition test mode to check and adjust ignition outputs.
Interpretation of diagnostic faults and warnings from the ignition control module.
Schematic diagram illustrating the engine's gas fuel circuit components and flow.
Detailed electrical wiring diagram showing connections for various engine systems.
Description and circuit details of the engine speed controller.
Description of the Speed Controller's purpose in providing isochronous speed control for gas engines.
Information on the ignition controller, its circuit, and power hookup.
Circuit diagram and functional descriptions of the ignition controller and display module.
Guidelines for DC power hookup of the ignition system, including voltage requirements and cable dimensions.
Information on display module features, dimensions, and circuit connections.
Views and circuit details of the ignition control module.
Visual views of the ignition control module, showing connectors and dimensions.
Detailed circuit diagram for the ignition control module, including inputs, outputs, and safety notes.
Pin assignments for the ignition harness connector for different engine models.
Engine firing order specifications for various engine models.
Diagrams showing cylinder numbering for different engine configurations.
Schematic of the engine ignition system, showing coils, spark plugs, and grounds.
Information on turbocharger maintenance, specifications, and troubleshooting.
Key data and specifications for the turbocharger models used with the engines.
Explanation of the turbocharger's operating principle, including turbine and compressor functions.
Exploded view showing the construction of the turbocharger and its components.
General information on how engine output relates to air supply and the concept of turbocharging.
Detailed description of the functions of the turbine, compressor, bearing, and sealing at the compressor shaft.
Precautions for engine operation, including starting, immediate post-start, and during operation.
Guidelines for routine inspection and maintenance of the air intake, exhaust, and lubricating systems.
Procedures for periodic servicing of the turbocharger, including rotor inspection and clearance measurement.
Table diagnosing common turbocharger troubles, their causes, and remedies.
Information on the engine's lubricating system.
Specifications for the lubricating system, oil pump, and filter types.
Diagram and description of the oil pump components and their function.
Overview of the engine's liquid-cooling system.
Diagram and description of the cooling water pump's construction and components.
Information on the thermostat's function, specifications, and inspection.
Description of the thermostat's function in maintaining coolant temperature and its specifications.
Procedure for inspecting the thermostat's wax pallet, spring, and valve lift.
Precautions for handling and replacing the thermostat, emphasizing slow coolant changes.
Table for diagnosing and troubleshooting cooling system issues like overheating and leaks.
Information on V-belt maintenance, checking, and tensioning.
Guideline for replacing multiple belts if wear or tension differences are found.
Instructions for checking V-belts for cracks, oil, wear, and overheating.
Method for testing V-belt tension by finger pressure and using a tension tester.
Step-by-step guide for measuring V-belt tension using a tester.
Procedure for adjusting V-belt tension by moving the alternator and changing belts.
Maintenance procedures for the engine's air intake system.
Maintenance procedures for the air intake system, including emptying the dust bowl.
Steps for removing and changing the air filter element, ensuring cleanliness.
Methods for cleaning air filter elements using compressed air or washing.
Importance of center alignment for engine and generator set performance and life.
Guidelines for using steel bed rails and the impact of their strength on alignment.
Use and secure fixing of supporting brackets during engine installation.
Critical factors for engine and generator center alignment, including flange surface adjustments.
Procedures for inspecting the flywheel and housing before installation.
Procedures for measuring flywheel and housing correctness, including surface and bore measurements.
Method for measuring the flywheel housing surface error using a dial gauge.
Procedure for measuring the eccentricity of the flywheel housing bore.
Method for measuring the deformation of the flywheel installing surface with a dial gauge.
Procedure for measuring the pilot bore of the flywheel for eccentricity.
Table listing assembly tolerances for various engine components like cylinder block and liners.
Standard table for tightening torque values for various screws and bolts.
Table detailing tightening torques for plug screws based on diameter and pitch.
Tightening torque values for hollow screws based on material and thread size.
Standard table for bolt tightening torque based on diameter, pitch, and strength grade.
Detailed engine assembly tolerances for pistons, rings, pins, and connecting rods.
Detailed engine assembly tolerances for connecting rods and crankshaft components.
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