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P222LE -II
Doosan P222LE -II User Manual
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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
65.99897-8076C
2
Table of Contents
Default Chapter
3
Table of Contents
3
1 Safety Regulations & Engine Specifications
4
General Notes
4
Regulations Designed to Prevent Accidents
4
During Maintenance and Care
5
When Carrying out Checking, Setting and Repair Work
5
Notes on Safety in Handling Used Engine Oil
6
Regulations Designed to Prevent Damage to Engine and Premature Wear
6
Regulations Designed to Prevent Pollution
6
General Repair Instructions
7
Health Precautions
7
Engine Specification
8
Specification for Generator Engine
8
Specification for Power Unit Engine
9
Engine Power for Generator
10
Engine Performance Curve
11
PU158TI Engine
11
PU180TI Engine
12
PU222TI Engine
13
Engine Assembly
14
Engine Sectional View (Longitudinal)
14
Engine Sectional View (Cross)
15
Engine Assembly Views
16
PU158TI: Power Unit Engine
16
PU180TI : Power Unit Engine
17
PU222TI : Power Unit Engine
18
P158LE : Generator Engine
19
P180LE : Generator Engine
20
P222LE : Generator Engine
21
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
Standard Table of Tightening Torque
154
Standard Bolt Tightening Torque Table
155
Tightening Torque for Plug Screw
156
P158LE : Generator Engine Assembly
160
P180LE : Generator Engine Assembly
161
P222LE : Generator Engine Assembly
162
PU158TI : Power Unit Engine Assembly
163
PU180TI : Power Unit Engine Assembly
164
PU222TI : Power Unit Engine Assembly
165
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Doosan P222LE -II Specifications
General
Engine Model
P222LE-II
Aspiration
Turbocharged
Fuel System
Direct Injection
Fuel Type
Diesel
Engine Type
4-Cycle Diesel
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