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Doosan PU222TI User Manual

Doosan PU222TI
165 pages
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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

Table of Contents

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Doosan PU222TI Specifications

General IconGeneral
Engine ModelPU222TI
Number of Cylinders6
Compression Ratio17.5 : 1
Fuel SystemDirect Injection
AspirationTurbocharged
Cooling SystemWater-cooled
Lubrication SystemForced Feed
Emission ComplianceTier 3
Max Torque800 Nm @ 1400 RPM

Summary

Safety Regulations & Engine Specifications

Safety Regulations

General notes and regulations to prevent accidents during operation and maintenance.

Regulations designed to prevent damage to engine and premature wear

Guidelines to prevent engine damage and ensure longevity and proper operation.

General repair instructions

General guidelines and precautions for performing service and repair operations safely and effectively.

Engine Specification

Specification for generator engine

Technical specifications for Doosan generator engines, including models P158LE, P180LE, P222LE.

Specification for power unit engine

Technical specifications for Doosan power unit engines, including models PU158TI, PU180TI, PU222TI.

Engine power for generator

Detailed power output specifications for generator engines at different speeds and conditions.

Technical Information

Engine Model and Serial Number

Information on identifying engine models and serial numbers for warranty and parts ordering.

Engines Characteristic

Overview of the general characteristics and features of Doosan generator and power unit engines.

Engine lubrication

Explanation of the engine's force-feed lubrication system, including oil flow and components.

Engine cooling system

Overview of the liquid-cooling system, its components, and how it regulates engine temperature.

Troubleshooting

Engine Starting Impossible

Diagnostic flowchart for troubleshooting issues preventing engine starting, covering various systems.

Engine Overheated

Troubleshooting guide for engine overheating issues, identifying causes in cooling and fuel systems.

Output Insufficient

Diagnostic steps for addressing engine output deficiencies, covering fuel, air, and mechanical systems.

Oil pressure lowered

Troubleshooting flowchart for low oil pressure conditions, investigating oil level, quality, and relief valve.

Fuel Consumption Excessive

Guide to diagnosing excessive fuel consumption, relating it to operating conditions and system adjustments.

Oil Consumption Excessive

Troubleshooting steps for excessive oil consumption, identifying causes like leaks, worn parts, or incorrect levels.

Engine Knocking

Diagnostic approach for engine knocking, focusing on combustion issues, compression, and timing.

Battery Discharge

Troubleshooting chart for battery discharge issues, covering battery, wiring, and generator system checks.

Operation Tip

Periodic Inspection cycle

Schedule for routine engine inspections, detailing checks and replacements at specific hour intervals.

Disassembly and Reassembly of Major Components

Engine Disassembly

Procedures for disassembling major engine components, emphasizing cleanliness and organization.

Inspection

Engine Reassembly

Commissioning and Operation

Preparations

Pre-operation checks including fuel, coolant, and oil levels before starting the engine.

Starting

Step-by-step instructions for safely starting the engine, including precautions for cold engines.

Running In

Recommendations for new or overhauled engine break-in procedures to ensure proper seating and longevity.

During Operation

Guidelines for operating the engine safely, monitoring parameters, and responding to faults.

Shutting Down

Procedures for safely shutting down the engine, including idling before shutdown.

Maintenance and Care

Routine maintenance tasks and care procedures for the engine's systems and components.

Maintenance of Major Components

Fuel Injection System

Detailed information on the fuel injection system, including governor and speed control unit.

Governor system for generator engine

Explanation of the governor system for generator engines, comprising integral actuator and speed control.

Speed control unit for governor system

Description of the DWC-2000 speed control unit, its functions, features, and adjustments.

System troubleshooting

Troubleshooting guide for issues with the engine governing system, detailing tests and probable causes.

Injection pump calibration

Calibration data and rack diagrams for injection pumps used in P158LE, P180LE, PU158TI, PU180TI, P222LE, PU222TI engines.

Cooling System

Lubricating System

Diagnostics and troubleshooting

Troubleshooting guide for oil system issues like excessive consumption, low pressure, and oil deterioration.

Turbo Charger

Routine inspection and maintenance

Routine inspection and maintenance procedures for the turbocharger, covering intake, exhaust, fuel, and lubricating systems.

Periodic inspection and maintenance

Periodic inspection procedures for the turbocharger's rotor revolving state and end play.

Trouble cause diagnosis and remedy

Troubleshooting guide for common turbocharger issues like excessive exhaust gas, white smoke, and output loss.

Installation

Installing

Guidelines for engine and generator set installation, including bed rail, supporting brackets, and alignment.

Tightening Cylinder Head Bolts

Retightening cylinder head bolts on new engines

Procedure for retightening cylinder head bolts on new engines after initial break-in period.

Tightening cylinder head bolts after a repair

Method for tightening cylinder head bolts after engine repair, using angle-of-rotation.

Retightening cylinder head bolts after repairs by authorized specialist personnel (engine cold or warm)

Procedure for retightening cylinder head bolts after repairs, following specific torque and angle specifications.

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