950106-038007EN

Operation &
Maintenance Manual
MARINE ENGINE

V158TI, V180TI, V222TI,

AD158TI, AD180TI, AD222TI
 FOREWORD

This manual is designed to serve as a reference for the operation & Maintenance of V158TI/180TI/222TI
Marine engines and AD158TI/180TI/222TI marine generator engine united in one book.
The former is explained for operation and the latter is described for maintenance like parts disassembly,
maintenance & inspection and re-assembly etc in order to available understanding the maintenance procedure
more easily.
To maintain the engine in optimum condition and retain maximum performance for a long time, CORRECT
OPERATION and PROPER MAINTENANCE is essential.
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 content of this manual instruction may be changed without notice for some quality
improvement. Thank you.

2020. 06.
950106-038007EN
Doosan Infracore
* Items exempted from warranty coverage
● Malfunctions resulting from failing to comply with the proper handling instructions, regular inspections,
and machine storage techniques specified in the user manual
● Malfunctions resulting from failing to have the machine repaired at a designated dealer or center, or
resulting from the use of non-genuine parts
● Malfunctions resulting from unauthorized modifications, changes, or external hardware
● Malfunctions resulting from incorrect operation by the user, delayed repairs, accidents, and natural
disasters
* The contents of this operation and maintenance manual are the exclusive property of Doosan Infracore. Any
unauthorized reproduction, printing and distribution thereof are strictly prohibited.
 CONTENTS

1. SPECIFICATION ......................................................................................................................... 1
1.1. Engine Specification ........................................................................................................................... 1
1.2. Engine Aspects ................................................................................................................................... 5
1.3. Engine Performance Curve ................................................................................................................ 8
1.4. Engine Model & Serial Number .......................................................................................................... 9

2. SAFETY REGULATIONS.......................................................................................................... 11
2.1. General Notes .................................................................................................................................. 11
2.2. Regulations Designed to Prevent Accidents with Injury to Persons ................................................. 11
2.3. Regulations Designed to Prevent Damage to Engine and Premature Wear .................................... 13
2.4. Regulations Designed to Prevent Pollution ...................................................................................... 14
2.5. Notes on Safety in Handling Used Engine Oil .................................................................................. 14

3. COMMISSIONING AND OPERATION...................................................................................... 15

3.1. Inspections before Operation ........................................................................................................... 15
3.2. Starting ............................................................................................................................................. 22
3.3. Engine Break-in ................................................................................................................................ 23
3.4. Inspections after Starting .................................................................................................................. 25
3.5. Check after Initial 50 Hours Operation. ............................................................................................ 26
3.6. Operation In Winter .......................................................................................................................... 26
3.7. Tuning the Engine ............................................................................................................................ 27

4. GENERAL INFORMATION ....................................................................................................... 29

4.1. General Repair Instructions .............................................................................................................. 29
4.2. Periodical Inspection & Maintenance ............................................................................................... 30
4.3. Cooling System ................................................................................................................................ 31
4.4. Lubrication System ........................................................................................................................... 37
4.5. Intake & Exhaust System ................................................................................................................. 41
4.6. Fuel System ...................................................................................................................................... 43
4.7. Electric System ................................................................................................................................. 48
4.8. Valve Clearance ............................................................................................................................... 48
4.9. When the Engine is Sunk ................................................................................................................. 49

5. MAIN ACCESSORY PARTS..................................................................................................... 51

5.1. Reduction Gear ................................................................................................................................ 51
5.2. Front Power Take Off ....................................................................................................................... 53
5.3. Propeller Selection ........................................................................................................................... 60
5.4. Electric System ................................................................................................................................. 61

6. DISASSEMBLY AND ASSEMBLY OF MAJOR COMPONENTS ............................................ 64

6.1. Disassembly ..................................................................................................................................... 64
6.2. Inspection ......................................................................................................................................... 74
6.3. Engine Re-assembly ........................................................................................................................ 93
6.4. Trial Test after Maintenance ........................................................................................................... 112
7. MAIN PARTS MAINTENANCE ............................................................................................... 114
7.1. Lubricating System ......................................................................................................................... 114
7.2. Cooling System .............................................................................................................................. 115
7.3. Fuel System .................................................................................................................................... 115
7.4. Turbo-charger ................................................................................................................................. 139

8. TROUBLE SHOOTING ........................................................................................................... 166

 Appendix
1. SPECIFICATION

1.1. Engine Specification

1.1.1. V158TI

Marine Engine Specification

V158TI
Model Units
V158TIH V158TIM V158TIL
4 cycle, V-type, direct-injection, water cooled
Engine type
with wet-turbo charger & inter-cooler
Rating output (B.H.P) PS(kW)/rpm 480(353)/1,800 540(397)/2,100 680(500)/2,300
Displacement cc 14,618
Cylinder number - bore (Ø) x stroke mm 8 - Ø128 x 142
Valve clearance at cold In / Ex mm 0.25 ±0.05 / 0.35 ±0.05
Low idling rpm rpm 725 ±25
No load max. rpm rpm Below 2,070 Below 2,415 Below 2,645
Mean effective pressure kg/cm2 16.42 15.84 18.21
Mean piston speed m/sec. 8.52 9.94 10.89
Compression ratio 15.5 : 1
Firing order 1-5-7-2-6-3-4-8
Max. firing pressure of cylinder kg/cm2 130 128 150
Compression pressure at 200 rpm kg/cm2 24 (Initial condition)
Governor type of injection pump Mechanical variable speed (R.Q.V)
g/PS.h 155 163 185
Fuel consumption
liter/h 90 106 152
Injection timing (B.T.D.C) deg 15 ±1° 16 ±1° 18 ±1°
Fuel inj. nozzle opening pressure kg/cm2 286
Starting system Electric starting by starter motor
Starter motor capacity V - kW 24 - 6.6
Alternator capacity V-A 24 - 80
Battery V - Ah 24 - 200
Cooling system Indirect sea water cooling with heat exchanger
Cooling water capacity Max./Min. lit. 89 / 78
Fresh water pump type Centrifugal type, driven by V-belt pulley
Sea water pump type Bronze impeller type driven by V-belt pulley
Pan capacity lit. Max. : 31, Min. : 25 (Engine total : 35)
Lubricating oil (Engine)
Pressure kg/cm2 Full : 3.5, Idle : 1.2
Crankshaft Counter clockwise viewed from stern side
Direction of revolution
Propeller Clockwise viewed from stern side
Engine size Without M/G mm 1,337x1,222x1,074 1,337 x 1,222 x 1,074
(L x W x H) With M. gear mm 1,777x1,222x1,115 1,872 x 1,222 x 1,111
Without M/G kg 1,300 1,300
Engine dry weight
With M. gear kg 1,590 1,710

-1- Specification
1.1.2. V180TI

Marine Engine Specification

V180TI
Model Units
V180TIH V180TIM V180TIL
4 cycle, V-type, direct-injection, water cooled
Engine type
with wet-turbo charger & inter-cooler
Rating output (B.H.P) PS(kW)/rpm 600(441)/1,800 650(478)/2,100 820(603)/2,300
Displacement cc 18,273
Cylinder number - bore (Ø) x stroke mm 10 - Ø128 x 142
Valve clearance at cold In / Ex mm 0.25 ±0.05 / 0.35 ±0.05
Low idling rpm rpm 725 ±25
No load max. rpm rpm Below 2,070 Below 2,415 Below 2,645
Mean effective pressure kg/cm2 16.42 15.25 18.56
Mean piston speed m/sec. 8.52 9.94 10.89
Compression ratio 15.5 : 1
Firing order 1 - 6 - 5 - 10 - 2 - 7 - 3 - 8 - 4 - 9
Max. firing pressure of cylinder kg/cm2 130 128 150
Compression pressure at 200 rpm kg/cm2 24 (Initial condition)
Governor type of injection pump Mechanical variable speed (R.Q.V)
g/PS.h 153 156 185
Fuel consumption
liter/h 111 122 183
Injection timing (B.T.D.C) deg 16 ±1° 18 ±1° 18 ±1°
Fuel inj. nozzle opening pressure kg/cm2 286
Starting system Electric starting by starter motor
Starter motor capacity V - kW 24 - 6.6
Alternator capacity V-A 24 - 80
Battery V - Ah 24 - 200
Cooling system Indirect sea water cooling with heat exchanger
Cooling water capacity Max./Min. lit. 92 / 81
Fresh water pump type Centrifugal type, driven by V-belt pulley
Sea water pump type Bronze impeller type driven by V-belt pulley
Pan capacity lit. Max. : 35, Min. : 28 (Engine total : 38)
Lubricating oil (Engine)
Pressure kg/cm2 Full : 3.5, Idle : 1.2
Crankshaft Counter clockwise viewed from stern side
Direction of revolution
Propeller Clockwise viewed from stern side

Engine size Without M/G mm 1,495 x 1,222 x 1,169

(L x W x H) With M. gear mm 2,016 x 1,222 x 1,192
Without M/G kg 1,550
Engine dry weight
With M. gear kg 2,065

Specification -2-
1.1.3. V222TI

Marine Engine Specification

V222TI
Model Units
V222TIH V222TIM V222TIL
4 cycle, V-type, direct-injection, water cooled
Engine type
with wet-turbo charger & inter-cooler
Rating output (B.H.P) PS(kW)/rpm 720(530)/1,800 800(588)/2,100 1,000(736)/2,300
Displacement cc 21,927
Cylinder number - bore (Ø) x stroke mm 12 - Ø128 x 142
Valve clearance at cold In / Ex mm 0.25 ±0.05 / 0.35 ±0.05
Low idling rpm rpm 725 ±25
No load max. rpm rpm Below 2,070 Below 2,415 Below 2,645
Mean effective pressure kg/cm2 16.42 15.64 17.85
Mean piston speed m/sec. 8.52 9.94 10.89
Compression ratio 15.5 : 1
Firing order 1 - 12 - 5 - 8 - 3 - 10 - 6 - 7 - 2 - 11 - 4 - 9
Max. firing pressure of cylinder kg/cm2 130 126 150
Compression pressure at 200 rpm kg/cm2 24 (Initial condition)
Governor type of injection pump Mechanical variable speed (R.Q.V)
g/PS.h 152 160 190
Fuel consumption
liter/h 132 154 229
Injection timing (B.T.D.C) deg 17 ±1° 18 ±1° 19 ±1°
Fuel inj. nozzle opening pressure kg/cm2 286
Starting system Electric starting by starter motor
Starter motor capacity V - kW 24 - 6.6
Alternator capacity V-A 24 - 80
Battery V - Ah 24 - 200
Cooling system Indirect sea water cooling with heat exchanger
Cooling water capacity Max./Min. lit. 98 / 87
Fresh water pump type Centrifugal type, driven by V-belt pulley
Sea water pump type Bronze impeller type driven by V-belt pulley
Pan capacity lit. Max. : 40, Min. : 33 (Engine total : 43)
Lubricating oil (Engine)
Pressure kg/cm2 Full : 3.5, Idle : 1.2
Crankshaft Counter clockwise viewed from stern side
Direction of revolution
Propeller Clockwise viewed from stern side

Engine size Without M/G mm 1,653 x 1,222 x 1,199

(L x W x H) With M. gear mm 2,263 x 1,222 x 1,250
Without M/G kg 1,750
Engine dry weight
With M. gear kg 2,460

-3- Specification
1.1.4. AD158TI / AD180TI / AD222TI

Model DV Series
Units
Spec. AD158TI AD180TI AD222TI
4 cycle, V-type, direct-injection, water cooled
Engine type
with wet-turbo charger & inter-cooler
410(302)/1,500 485(357)/1,500 606(446)/1,500
50 Hz
Rating output PS(kW) (AD158TIF) (AD180TIF) (AD222TIF)
(B.H.P) / rpm 480(353)/1,800 600(441)/1,800 720(530)/1,800
60 Hz
(AD158TIS) (AD180TIS) (AD222TIS)
Displacement cc 14,618 18,273 21,927
Cyl. No - bore (Ø) x stroke mm 8 - Ø128 x 142 10 - Ø128 x 142 12 - Ø128 x 142
Valve clearance at cold mm 0.25 ±0.05 / 0.35 ±0.05
Low idling rpm rpm 800 ±50
Mechanical governor : 1,575 (52.5 Hz) / 1,890 (63 Hz)
No load max. rpm (50 Hz / 60 Hz) rpm
Electric governor : 1,500 (50 Hz) / 1,800 (60 Hz)
Mean effective press. (Initial) kg/cm2 16.83 / 16.42 15.93 / 16.42 16.58 / 16.42
Mean piston speed (50 Hz / 60 Hz) m/sec. 7.10 / 8.52
Compression ratio 14.9 : 1 15.5 : 1
Max. firing pressure of cylinder kg/cm2 130 130 130
Com. press. (at 200 rpm) kg/cm2 24 (Initial condition)
Governor type of inj. pump Electric governor
g/PS.h 148 / 153 152 / 153 151 / 150
Fuel consumption
liter/h 73 / 88 89 / 111 110 / 130
Injection timing
TIF/TIS deg 14 ±1° / 15 ±1° 16 ±1° / 18 ±1° 16 ±1° / 18 ±1°
(B.T.D.C)
Inj. nozzle opening press. kg/cm2 224
Starting system Electric starting by starter motor
Starter motor capacity V - kW 24V - 6.0
Alternator capacity V-A 24 - 80
Battery V - Ah 24V - 200
Cooling system Indirect cooling by sea water with heat exchanger
Cooling water capacity lit. Max. : 89, Min. : 78 Max. : 92, Min. : 81 Max. : 98, Min. : 87
Fresh water pump type Centrifugal type, driven by V-belt
Sea water pump type Rubber impeller type driven by gear
Max. : 31, Min. : 25 Max. : 35, Min. : 28 Max. : 40, Min. : 33
Pan capacity lit.
Lub. oil (Engine) (Engine total : 35) (Engine total : 38) (Engine total : 43)
Pressure kg/cm2 Full : 3.5, Idle : 1.2
Revolution of crankshaft Counter clockwise viewed from stern side
Engine size 1,037 x 1,222 x 1,195 x 1,222 x 1,353 x 1,222 x
mm
(L x W x H) 1,074 1,169 1,199
Engine dry weight (kg) 1,295 1,545 1,735

Specification -4-
1.2. Engine Aspects
Note : The images shown represent the standard model; they do not include all models.

1.2.1. Engine sectional view (Longitudinal → V222TI)

2 3 4

5
9

8 6

7
EB2M1001

1. Cylinder head 4. Tappet 7. Oil pump

2. Cylinder head cover 5. Camshaft 8. Crankshaft
3. Push rod 6. Flywheel 9. Thermostat

-5- Specification
1.2.2. Engine sectional view (Cross → V222TI)

1 2 3 4 1

14 5

6
6

9
7
13
8

12
9

10

7 11

EB2M1002

1. Intake manifold 6. Exhaust manifold 11. Oil cooler

2. Breather assembly 7. Piston 12. Oil level gauge
3. Injection pump 8. Connecting rod 13. Oil filter
4. Injection pipe 9. Cylinder liner 14. Push rod
5. Oil filler cap 10. Cylinder block

Specification -6-
1.2.3. Engine assembly (V222TI)

16 9 7 3 14
13
15 4

2
8 12
1 6 10 5 11

EDV2218083

1. Crank pulley 7. Fresh water filler cap 13. Exhaust manifold

2. Fuel filter 8. Sea water pump 14. Turbocharger (wet)
3. Intercooler 9. Heat exchange ass′y 15. Sea water inlet pipe
4. Oil drain pump 10. Starter 16. Sea water outlet pipe
5. Flywheel housing 11. Marine gear ass′y
6. Oil pan 12. Exhaust manifold

-7- Specification
1.3. Engine Performance Curve

1.3.1. V158TI

Heavy Duty Medium Duty Light Duty

500 500 500

400 400 400

d
a d oa
ll L
Output (PS)

Output (PS)

Output (PS)
500 ad 500 Lo 500
ll L
o ull Fu
F

ge
Fu

ge

an
400 400 400

an
e
ng

nR
nR
Ra

tio
tio
on

a
300 300 300

ra

er
ati

Op
Op
er
Op

200 200 200

Propulsion Curve Propulsion Curve Propulsion Curve
100 100 100

(g/PS.h)

(g/PS.h)

(g/PS.h)
Full Consumption 170 Full Consumption 170 Full Consumption 170
160 160 160
150 150 150
1000 1500 2000 1000 1500 2000 1000 1500 2000

Engine Speed (rpm) Engine Speed (rpm) Engine Speed (rpm)

EDV2218086

1.3.2. V180TI

Heavy Duty Medium Duty Light Duty

1000 1000 1000

d
oa
900 900 900

ll L
Fu
800 800 800
Output (PS)

Output (PS)

Output (PS)

nge
o ad
700 700 ll L 700

Ra
oa
d Fu

tion
nge

ll L
Fu

era
600 600 600
Ra
nge

Op
tion
Ra

era

500 500 500

tion

Op
era
Op

400 400 400

Propulsion Curve Propulsion Curve Propulsion Curve
300 300 300
Full Consumption
(g/PS.h)

(g/PS.h)

(g/PS.h)
Full Consumption 170 Full Consumption 170 170
160 160 160
150 150 150
1000 1500 2000 1000 1500 2000 1000 1500 2000
Engine Speed (rpm) Engine Speed (rpm) Engine Speed (rpm)
EDV2218087

1.3.3. V222TI

Heavy Duty Medium Duty Light Duty

800 800 800

d
oa
ll L

700 700 700

Fu

d
600 600 oa 600
oa
d ll L
ll L Fu
Output (PS)

Output (PS)

Output (PS)

Fu
ge

500 500 500

an
ge

nR
e

an
ng

nR

tio
Ra

400 400 400

era
tio
on

era
ati

Op
er

Op
Op

300 300 300

Propulsion Curve Propulsion Curve Propulsion Curve

200 200 200

100 100 100

Full Consumption Full Consumption Full Consumption
(g/PS.h)

(g/PS.h)

(g/PS.h)

170 170 170

160 160 160
150 150 150
1000 1500 2000 1000 1500 2000 1000 1500 2000
Engine Speed (rpm) Engine Speed (rpm) Engine Speed (rpm)
EDV2218088

Specification -8-
1.4. Engine Model & Serial Number
The engine serial number is inscribed on the
engine as illustrated. This number is required
when requesting warranty and ordering parts. It
is also referred to as engine model and serial
number because of their location.

Note :
The engine model name (V222TI) is
Name Plate
described in the name plate on the
cylinder block. EDV2218084

● Engine serial No. (Example : V222TI)

EBYKM200001

Serial No.
Production Year (2002)
Engine Model Suffix

-9- Specification
Specification - 10 -
2. SAFETY REGULATIONS

2.1. General Notes

Day-to-day use of power engines and the service products necessary for running them presents no problems
if the persons occupied with their operation, maintenance and care are given suitable training and think as
they work.
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.

2.2. Regulations Designed to Prevent Accidents with Injury to Persons

2.2.1. During commissioning, starting and operation

Before putting the engine into operation for the first time, read the operating instructions carefully and famil-
iarize yourself with the ″critical″ points, If you are unsure, ask your DOOSAN representative.
● 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.
● The engine must be started and operated only by authorized personnel. Ensure that the engine cannot be
started by unauthorized persons.
● When the engine is running, do not get too close to the rotating parts. Wear close-fitting clothing.
● Do not touch the engine with bare hands when it is warm from operation risk of burns.
● Exhaust gases are toxic. Comply with the installation instructions for the installation of DOOSAN marine
diesel engines which are to be operated in enclosed spaces. Ensure that there is adequate ventilation and
air extraction.
● Keep vicinity of engine, ladders and stairways free of oil and grease.
Accidents caused by slipping can have serious consequences.

- 11 - Safety regulations
2.2.2. During maintenance and care
● Always carry out maintenance work when the engine is switched off. If the engine has to be maintained
while it is running, e.g. changing the elements of change-over filters, remember that there is a risk of
scalding. Do not get too close to rotating parts.
● Change the oil when the engine is warm from operation.

Caution :
There is a risk of burns and scalding. Do not touch oil drain plug or oil filter with bare hands.

● Take into account the amount of oil in the sump. Use a vessel of sufficient size to ensure that the oil will
not overflow.
● Open the coolant circuit only when the engine has cooled down. If opening while the engine is still warm
unavoidable, comply with the instructions in the chapter entitled ″4.3. Cooling System″.
● Neither tighten up nor open pipes and hoses (lube oil circuit, coolant circuit and any additional hydraulic
oil circuit) during the operation. The fluid which flow out can cause injury.
● Fuel is inflammable. Do not smoke or use naked lights in its vicinity. The tank must be filled only when the
engine is switched off.
● When using compressed air, e.g. for cleaning the heat exchanger, wear goggles.
● Keep service products (anti-freeze) only in containers which can not be confused with drinks containers.
● Comply with the manufacturer′s instructions when handling batteries.

Caution :
Accumulator acid is toxic and caustic. Battery gases are explosive.

2.2.3. When carrying out checking, setting and repair work

● Checking, setting and repair work must be carried out by authorized personnel only.
● Use only tools which are in satisfactory condition. Slip caused by the worn open-end wrench could lead to
Injury.
● When the engine is hanging on a crane, no-one must be allowed to stand or pass under it. Keep lifting
gear in good condition.
● When checking injectors, do not put your hands under the jet of fuel.
Do not inhale at atomized fuel.
● When working on the electrical system disconnect the battery earth cable first.
After repair engine parts, connect it up again last in prevent short circuits.

- 12 - Safety regulations
2.3. Regulations Designed to Prevent Damage to Engine and Premature Wear
(1) Never demand more of the engine than it was designed to yield for its intended purpose. Detailed informa-
tion on this can be found in the sales literature. The injection pump must not be adjusted without prior writ-
ten permission of DOOSAN.
(2) If faults occur, find the cause immediately and have it eliminate in order to prevent more serious of dam-
age.
(3) Use only genuine DOOSAN spare parts. DOOSAN will accept no responsibility for damage resulting from
the installation of other parts which are supposedly ″just as good″.
(4) In addition to the above, note the following points.
● Never let the engine run when dry, i.e. without lube oil, fuel or coolant. Use only DOOSAN approved
service products. (engine oil, anti-freeze and anti-corrosion agent)
● Pay attention to cleanliness. The diesel fuel must be free of water. See ″4.6. Fuel System″.
● Have the engine maintained at the specified intervals.
● Do not switch off the engine immediately when it is warm, but let it run without load for about 5 minutes
so that temperature equalization can take place.
● Never put cold coolant into an overheated engine.
● Do not add so much engine oil that the oil level rises above the max. marking on the dipstick. Do not
exceed the maximum permissible tilt of the engine. Serious damage to the engine may result if these
instructions are not adhered to.
● Always ensure that the testing and monitoring equipment (for battery charge, oil pressure, and coolant
temperature) function satisfactorily.
● Do not let the sea water pump run dry. If there is a risk of frost, drain the water when the engine
switched off.

- 13 - Safety regulations
2.4. Regulations Designed to Prevent Pollution

2.4.1. Engine oil, filter element, fuel filter

● Take old oil only to an oil collection point. Take strict precautions to ensure that oil does not get into the
drains or into the ground and sea.
● The drinking water supply may be contaminated.
● Oil and fuel filter cartridges are classed as dangerous waste and must be treated as such.

2.4.2. Coolant
● Treat undiluted anti-corrosion agent and / or antifreeze as dangerous waste.
● When disposing of spent coolant comply with the regulations of the relevant local authorities.

2.5. Notes on Safety in Handling Used Engine Oil

Prolonged or repeated contact between the skin and any kind of engine oil decreases the skin. Drying, irrita-
tion or inflammation of the skin may therefore occur. Used engine oil also contains dangerous substances
which have caused skin cancer in animal experiments. If the basic rules of hygiene and health and safety at
work are observed, health risks are not to the expected as a result of handling used engine oil.

Health precautions

● Avoid prolonged or repeated skin contact with used engine oil.

● Protect your skin by means of suitable agents (creams etc.) or wear protective gloves.
● Clean skin which has been in contact with engine oil.
- Wash thoroughly with soap and water. A nailbrush is an effective aid.
- Certain products make it easier to clean your hands.
- Do not use petrol, diesel fuel, gas oil, thinners or solvents as washing agents.
● After washing apply a fatty skin cream to the skin.
● Change oil-soaked clothing and shoes.
● Do not put oily rags into your pockets.

Ensure that used engine oil is disposed of properly.

- Engine oil can endanger the water supply -

For this reason do not let engine oil get into the ground, waterways, the drains or the sewers.
Violations are punishable. Collect and dispose of used engine oil carefully.
For information on collection points please contact the seller, the supplier or the local authorities.

- 14 - Safety regulations
3. COMMISSIONING AND OPERATION

3.1. Inspections before Operation

3.1.1. Lubricating oil

a) The notches in dipstick must indicate the oil
level between max. and min. permissible.
b) The measurement of the oil level must be
done on a even water line and in 10 min-
utes after engine operating.
c) Examining the viscosity and the contamina-
tion of the oil smeared at the dipstick,
replace the engine oil if necessary.

EA4O4001

3.1.2. Cooling water

Checking the level of the cooling water in tank.

Caution :
If the installation angle of the engine exceeds 6 degrees, please remark the
maximum and minimum level of the oil dipstick by engraving on the lube oil
capacity of the engine. ( Refer to 4.4. ″Lubrication system″)

Check the opening pressure of the pressure

valve using cap tester. Replace the filler cap
assembly if the measured valve does not reach
the specified limit.
(Opening pressure of valve : 0.9 kg/cm2)

Note :
Because it is dangerous to open the
pressure cap quickly when coolant is
EDV15200001
hot, after covering the cap with a cloth
and then lower the inside pressure of
the tank by opening slowly at first,
open it up.

- 15 - Commissioning and operation

3.1.3. Sea water pump
Impeller of the sea water pump is a bronze
type, therefore you should install the sea water
strainer as right figure in order not to suck in
any hard pieces and sharp scales.
Install the sea water strainer in adequate size
for the engine between kingston valve and sea
water pump.
● Over-tightened belt or over loaded gear will
reduce the bearing life of the sea water EB2O3007
pump.
● If sea water is not sucked in sea water pump at starting, restart the engine after filling water in the sea
water pump housing and inlet hose.
● Make sure that all valves/cocks in the sea water line are opened before run.
● If there is a risk of freezing weather, drain the water by loosening bolts of end cover.
● Temperature range : 5°C (41°F) ~ 60°C (140°F)

3.1.4. Intake & exhaust Line

Make sure that intake & exhaust piping lines are properly designed and air filter element is fouled and worn
severely. If so, correct and clean or replace it.

3.1.5. Fuel line

Check the fuel line leaking on opening the valve.
The contamination of fuel may cause the nozzle clogging or the sticking of the injection pump components.
Therefore, cleanness of fuel system should be maintained at any time.

3.1.6. Bottom of the engine room

(1) Always keep the bottom clean.
Check the bilge for excessive water accumulation. Always keep the bilge clean and dry. Never allow the
water depth in the bilge to exceed the bottom of the engine.
If water accumulation is unavoidable, you have to install a bilge pump with an automatic control switch.

Caution :
The water level in the boat′s bilge will increase when the boat is operated at a high inclination before
rated speed is reached. Excessive water in the bilge can cause engine damage like corrosion,
malfunction of engine parts.

Commissioning and operation - 16 -

3.1.7. Gauge panel
Check the all gauges of the panel whether the function is in normal or not.
Before operation your engine familiarize yourself with the instruments supplied with your boat.

1) Analog gauge panel

● Deluxe panel

1 2 3 4 5

11

6 7 8 9 10
EDV2218013

1. Volt meter 5. Clutch oil press. gauge 9. Stop button

2. Water temp. gauge 6. Rotary switch 10. Key switch
3. Tachometer 7. Push button 11. Panel
4. Oil pressure gauge 8. Monitor warning lamp

● Dutch panel

1 2 3 4

5 6 7
EDV2218014

1. Water temp. gauge 4. Oil pressure gauge 7. Key switch

2. Hour meter 5. Stop button 8. Panel
3. Engine speed 6. Monitor warning lamp

- 17 - Commissioning and operation

 ● Single panel / Dual panel

1 2 3 4

10

5 6 7 8 9
EDV2218015

1. Tachometer 5. Monitor warning lamp 9. Key switch

2. Water temp. gauge 6. Push button 10. Panel
3. Oil pressure gauge 7. Rotary switch
4. Clutch oil press. gauge 8. Stop button

● Dual panel

1 2 3 4 5

12

6 7 8 9 10 11
EDV2218016

1. Pyrometer 5. Volt meter 9. Select switch

2. Tachometer 6. Select switch 10. Stop button
3. Water temp. gauge 7. Monitor warning lamp 11. Key switch
4. Oil pressure gauge 8. Push button 12. Panel

Commissioning and operation - 18 -

2) Digital gauge panel
● Circuit diagram

EDV2218035

- 19 - Commissioning and operation

 ● Front

2 2

3 4

EDX1218005

1. LCD 3. Key switch

2. Function Keys 4. Start / stop button

● Rear

1 3 4 5

2 7 8 9

EDX1218006

1. Power connector 6. Fuse

2. Signal connector 7. CCTV (Optional)
3. CAN 8. GPS (TBD)
4. Ext. buzzer 9. Built-in buzzer
5. USB

Commissioning and operation - 20 -

3.1.8. Engine stop & warning devices
V158TI/V180TI/V222TI gauge panel is equipped with an audible alarm to alert the operator to the following.
1) Engine stop device (Stop solenoid)
● When the engine oil pressure is less than 0.5 kg/cm2.
● When the engine over speed becomes more than 117% of the engine rated speed but, marine genera-
tor engine becomes more than 115%.

2) Engine warning lamps

Engine warning lamp is turned on with buzzer sound at the same time.
● When the engine oil pressure is less than 1 bar (1st stage) and 0.5 bar (2nd stage).
● When the engine water temperature is more than 93°C.
● When the battery is not charged.

If a warning lamp of the gauge panel on engine operation is turned on, you will find as follows.

The alarm horn will sound when the ignition is turned on and continue to sound until the key switch is shifted
into ″OFF″ position or minimum oil pressure is obtained. This provides a functional test of warning system.

If the engine oil pressure becomes to less than 0.5 kg/cm2, the alarm horn will sound and the
engine is stopped by stop solenoid at the same time automatically. Proceed as follows :

First, quickly observe the oil pressure gauge for the engine low pressure such as needle oscillation
indicating low oil. If oil temperature gauge indicates below 0.5 kg/cm2, put the control lever back to
the idle speed position IMMEDIATELY and shift the reduction gear control lever into the NETURAL
position. Do not restart engine until the cause for the alarm has been found and corrected. Refer to
″Performance Loss″ in Trouble Shooting Chart.
Check the oil lines or switch and sensor malfunction. If the cause for the alarm cannot be found,
contact your DOOSAN dealer.

- 21 - Commissioning and operation

3.2. Starting

3.2.1. Operation 1 (Analog panel)

After checking the warning lamps of the gauge panel and the NEUTRAL position of reduction gear control
lever, turn the key switch to the START position to crank the engine, at once.
Behavior - When the key switch is placed in the START position.
After the engine is cranked, convert the key switch to the ACC position quickly.
Behavior - As the engine is cranked, don’t fix the key switch too long (over 4 seconds) in the ″START″ posi-
tion. If you do, the starter may be malfunction.
If you fail the engine starting at first, restart the engine after waiting for 30 seconds at least to pre-
vent the circuit malfunction of the starter.

3.2.2. Operation 2 (Digital panel)

Digital panel system boot, shutdown and the engine stop function.
1) Insert the key into key switch on the product, please rotate 90 to the right (ON) (When the key is turned
″ON″, keeping the key jammed)
2) After key on, all the system boot in 17 secs.
3) When turn off the system rotate the key 90 to the left (OFF)
● When you rotate the key from the ignition state to the left (OFF) the 300 seconds alarm message pop-
up on the window then engine shutdown after 300 seconds with saving event.
● When a pop-up appears, if you rotate the key to the right (ON) pop-up disappears then the engine will
remain on.
Refer to ″User's Manual for Digital Panel″ for details.

Commissioning and operation - 22 -

3.3. Engine Break-in
During the first 20 hours of operation, you must follow the Engine Break-In procedure to ensure maximum per-
formance and long engine life.

Note :
Failure to follow the Engine Break-in procedure may result in serious engine damage.

3.3.1. New engine break-in 20 hours

All DOOSAN marine engines have been run for a short period of time as a final test at the factory. You must
follow the Engine Break-In procedure during the first 20 hours of operation to ensure maximum performance
and longest engine life.

Note :
To ensure proper lubrication during the break-in period, do not remove factory break-in oil until 20 hours
break-in is completed.

3.3.2. Initial two hours of break-in

For the first five to ten minutes of operation, operate engine at a fast idle (below 1,300 rpm) During the
remaining first two hours of operation, accelerate to bring boat onto plane quickly and bring throttle back to
maintain a planing attitude. During this period, vary the engine speed frequently by accelerating to approxi-
mately three-fourths throttle (1,500 ~ 1,600 rpm) for two to three minutes, then back to minimum planing
speed(700 ~ 800 rpm).
After the engine has reached operating temperature, momentarily reduce engine speed, then increase
engine speed, to assist the break-in of rings and bearings. Maintain planing boat attitude to avoid excessive
engine load.

Note :
Do not run engine at any constant rpm for prolonged periods of time for this initial two hours of break-in.

- 23 - Commissioning and operation

3.3.3. Next 8 hours
During the next 8 hours, continue to operate at approximately three-fourths throttle or less (minimum planing
speed). Occasionally reduce throttle to idle speed for a cooling period. During this 8 hours of operation it is
permissible to operate at full throttle for periods of less than two minutes only 2 times.

Note :
Do not run engine at a constant rpm for prolonged periods of time during the break-in
period.

3.3.4. Final 10 hours

During the final 10 hours of break-in, it is permissible to operate at full throttle for five to ten minutes at a time. After
warming engine to operating temperature, momentarily reduce then increase engine speed. Continue to operate
at approximately three-fourths throttle. Occasionally reduce engine speed to idle to provide cooling periods.

Note :
Do not run engine at a constant rpm for prolonged periods of time during the break-in
period.

During the break-in period, be particularly observe as follows :

● Check engine oil level frequently. Maintain oil level in the safe range, between the ″min.″ and ″max.″
marks on dipstick.
● Watch the oil pressure warning lamp. If the lamp blinks whenever the boat attitude (i.e. turning, climbing
on plane, etc.) is changed, it may be the oil pick-up screen is not covered with oil. Check oil dipstick. Add
oil to the oil pan, if required. Do not overfill.

Note :
Oil pressure will rise as RPM increases, and fall as the engine RPM decreases. In addition, cold oil
will generally show higher oil pressure for any specific RPM than hot oil. Both of these conditions
reflect normal engine operation.

● Watch the engine water temperature gauge and be sure there is proper water circulation. The water tem-
perature gauge needle may fluctuate if water level in expansion tank is too low.

Note :
Failure to follow the break-in procedure will avoid the engine warranty.

When the engine operation become to reach 50 hours in total including the break-in period 20 hours, replace
the engine oil and oil filter to new ones. Fill oil pan with recommended engine oil. Refer to ″4.4. Lubricating
System″.

Note :
When engine is overheated, do not stop the engine immediately.
Lower the engine load and run the engine and its cooling systems continuously.

Commissioning and operation - 24 -

3.3.5. Operating after break-in 20 hours
When starting a cold engine, always allow the engine to warm up gradually. Never run the engine at full throt-
tle until the engine is thoroughly warmed up.
And you′d better run the engine at three-fourths throttle (about 1,600 rpm) before initial 50 hours as possible.
Be sure to check the oil level frequently during the first 50 hours of operation since the oil consumption will be
high until the piston rings are properly seated.

3.4. Inspections after Starting

During operation the oil pressure in the engine lubrication system must be monitored. If the monitoring devices
register a drop in the lube oil pressure, switch off the engine immediately. And the charge warning lamp of the
alternator should go out when the engine is running.

● Do not disconnect the battery or pole terminals or the cables!

● If, during operation, the battery charge lamp suddenly lights up, stop the engine immediately and remedy
the fault in the electrical system!
● Engine should be stopped if the color, the noise or the odor of exhaust gas is not normal.
● Confirm the following things through warning lamps and gauge panel.

3.4.1. Pressure of lubricating oil

The normal pressure comes up to 1 bar at idling and 3 ~ 5 bar at rated speed. If the pressure fluctuates at
idling or does not reach up to the expected level at high speed, shut down the engine immediately and check
the oil level and the oil line leakage.

3.4.2. Temperature of cooling water

The cooling water temperature should be 71 ~ 85°C in normal operating conditions. Abnormally high cooling
water temperature could cause the overheating of engine and the sticking of cylinder components. And
excessively low cooling water temperature increases the fuel consumption, accelerates the wears of cylinder
liners and shortens the engine life-time.

- 25 - Commissioning and operation

3.5. Check after Initial 50 Hours Operation.
To insure your continued boating enjoyment, you should check as follows :

● Change engine oil and oil filter cartridge.

● Change fuel filter cartridge.
● Check coolant level.
● Check the tension of all drive belts.
● Check all engine mounts screws for tightness.
● Check for any deficiencies, malfunctions, signs of abuse, etc. Correction of any problems at this time will
prevent the worsening of a minor problem and help ensure a trouble free boating season.

Note :
This is an opportune time to discuss with your dealer any questions about your boat and stern drive
unit which may have arisen after the first 50 hours of operation and establish a routine preventive
maintenance schedule.

3.6. Operation In Winter

Pay special attention to the freezing of cooling water and the viscosity of lubricating oil.

3.6.1. Prevention against the freeze of cooling water

When not using anti-freeze, completely discharge the whole cooling water after engine running. The freeze
of cooling water causes the fatal damages of the engine. Because the antifreeze is used to prevent cooling
water from freeze and corrosion, it is always to be filled with the anti-freeze 35 ~ 40% of the whole coolant.

3.6.2. Prevention against excessive cooling

Drop of thermal efficiency caused by excessive cooling increases fuel consumption. Therefore should pre-
vent the engine from excessive cooling. If the temperature of coolant does not reach to normal condition (71
~ 85°C) after continuous operation, examine the thermostat or the other cooling lines.

3.6.3. Lubricating oil

As cold weather leads to the rise of oil viscosity, engine speed becomes unstable after starting. Therefore the
lubricating oil for winter (SAE 15W40 or 10W30) should be used to prevent this unstableness. Refer to ″4.4.
Lubricating system″.

Commissioning and operation - 26 -

3.7. Tuning the Engine
The purpose of an engine tune-up is to restore power and performance that′s been lost through wear, corro-
sion or deterioration of one or more parts or components. In the normal operation of an engine, these changes
can take place gradually at a number of points, so that it′s seldom advisable to attempt an improvement in per-
formance by correction of one or two items only. Time will be saved and more lasting results will be obtained
by following define and thorough procedure of analysis and correction of all items affecting power and perfor-
mance.
Economical, trouble-free operation can better be ensured if a complete tune-up is performed once every year,
preferably in the spring. Components that affect power and performance to be checked are:

● Components affecting fuel injection ;

Nozzle, delivery valve, fuel filter, fuel water separator, etc.
● Components affecting intake & exhaust ;
Air filter, inter-cooler, turbo-charger, silencer, good ventilation of engine room etc.
● Components affecting lubrication & cooling ;
Air & oil filter, anti- freeze, heat exchanger, rubber impeller, sea water filter, kingston valve, misalignment of
propeller, stableness of bed frame, bent propeller blade etc.

- 27 - Commissioning and operation

Commissioning and operation - 28 -
4. GENERAL INFORMATION

4.1. General Repair Instructions

1. Before performing service operation, disconnect the grounding cable from the battery for reducing the
chance of cable damage and burning due to short-circuiting.
2. Use covers to prevent the disassembled parts and components from damage or pollution.
3. Engine oil and anti-freeze solution must be handled with care. They can cause damage for painted parts.
4. The use of proper tools or specified special tools is important to perform the efficient and reliable mainte-
nance operation.
5. Use genuine DOOSAN parts necessarily.
6. Used cotter pins, gaskets, O-rings, oil seals, lock washer, self-lock nuts and rubber coated seal ring etc.
should be discarded. New ones should be used for re-assembled parts. If these are reused, normal perfor-
mance can not be maintained.
7. To facilitate reassembling, keep disassembled parts neatly in groups. Fixing bolts and nuts for reassembled
parts should be reused at the original position. They are varied in hardness or length because they are
designed depending on their application.
8. Clean the disassembled parts prior to inspection or re-assembly. By using compressed air, make oil ports
and etc. of them free from any foreign material.
9. Lubricate the surface of rotating and sliding parts with oil or grease before installation.
10. If necessary, use sealant onto gaskets to prevent leakage.
11. Carefully obey all specified torque to tighten bolts and nuts
12. When maintenance is completed, make a final check to be sure it has been done properly.

- 29 - General information
4.2. Periodical Inspection & Maintenance
In order to insure maximum, trouble-free engine performance at all times, regular inspection, adjustment
and maintenance are vital before occurring any problems.
● Daily inspections in below figure should be checked every day.
● The following maintenance details should be executed thoroughly at regular internals.

Every Every Every Every Every Every

Inspection Daily
50hrs 100hrs 250hrs 500hrs 600hrs 1,000 hrs
Coolant level check and refill 
Contamination of the coolant check and 1 year

the quantity of the anti-freeze change
Heat-exchanger and water cooling
1,200 hr
Cooling line cleaning
system 2,000 hrs
V-belt check and adjustment 
change
Thermostat check 2 years
2,000 hrs
Impeller of sea water pump check 
change
Oil level check 
Lubrication oil exchange  1st 
Oil filter cartridge replacement  1st 
Lubrication
system Marine gear oil exchange  1st 
Cylinder compression pressure check 

Rotor for bypass filter
change
In./Ex. valve clearance adjustment  1st 
 
Air filter element cleaning & change
Intake & clean change
exhaust
system
Inter-cooler cleaning 
Turbocharger cleaning 2,000 hr
Exhaust gas check 
Priming pump strainer cleaning 
Fuel tank check & cleaning 
Fuel Water separator cleaning 
system
Fuel filter exchange  1st 
Fuel Injection timing check 1 year
Fuel Injection nozzle check 1 year
Warning lamps check 
Engine
Battery charging check 
adjust
Wiring harness check 

General information - 30 -
4.3. Cooling System

4.3.1. Coolant level check and refill

● Replenish the deficient coolant in the expansion tank every day before running. The coolant must be
changed at intervals of 1,200 hours operation or six months whichever comes first. If the coolant is being
fouled greatly, it will lead engine overheat or coolant blow off from the expansion tank.
● The clean fresh water should be used for engine coolant.
● Additional agent (35 ~ 40% anti-freeze and 3 ~ 5% anti-corrosion agent) should be mixed with fresh water
for engine coolant to prevent the cooling system problem like freezing, corrosion and etc.

Caution :
Suitable mixture of anti-freeze and anti-corrosion agent can protect the engine corrosion from
deteriorating and raises a boiling point, but by using unsuitable mixture engine components like
water pump impeller and water jacket of cylinder block may be occurred a malfunction by any bad
corrosion damage or cavitation.

(1) Coolant replenishment

Let the plug in the highest level of the water lines or the upper plug of wet turbocharger open,
and fill the coolant about three forth of the expansion tank slowly until the air bubbles in water do
not come out through the plug hole. Then reassemble the plug.
After filling the coolant, run the engine at the idle rpm for around 5 minutes and you will find out
the engine coolant level becomes lower than before cause of escaping the air bubbles in water.
Then stop the engine and replenish additional coolant properly.

(2) Coolant change

● Open the pressure cap of expansion to remove the air pressure.

Caution :
When remove the pressure of the filler cap while the engine is still hot, cover the cap
with a cloth, then turn it counter-clockwise slowly to release internal steam pressure.
This will prevent a person from scalding by hot steam spouted out from the filler cap.

● V-type engines have 5 places of drain plug as follows

1) Lower part of right exhaust elbow
2) Front part of the left exhaust manifold cover
3) Lower part of the heat exchanger outlet pipe
4) Lower part of oil cooler
5) Cylinder block part of starter upper side.

● After water draining, re-assemble the drain plugs and then replenish the coolant as same as
″(1) Coolant replenishment″.

- 31 - General information
4.3.2. Contamination check of coolant and quantity of anti-freeze
● We recommend the engine coolant for DOOSAN marine engines should be mixture of fresh water and
additional agent (35 ~ 40% anti-freeze and 3 ~ 5% anti-corrosion agent).
Check the quantity of anti-freeze every 600 hours. From time to time, refill the anti-freeze as much as
required.
You can check the quantity of anti-freeze and anti-corrosion agent by using a FLEETGUARD test kit sim-
ply as follow. (FLEETGUARD CC2602M : DHI No. ; 60.99901-0038)

1) Contamination check

● How to use test kit (Striped pad)

(1) Collect half of a coolant sample cup from a drain plug at the lower side of the water pump inlet pipe
or cylinder block. Coolant must be between 10°C and 55°C when tested. Room temperature is pre-
ferred.

Do not collect the coolant from the expansion tank or overflow system.
The collected sample is less contaminated, so it can not be substituted for the quality of
whole coolant.

(2) Shake the bottle filled with sample coolant to mix well and take out one strip from bottle of the test
kit. Then dip the strip into coolant sample for 3 ~ 5 seconds, take it out and shake it briskly to
remove excess liquid.

Do not touch the pads on the end of the strip. Discard the kit if unused strips have
turned brown for the nitrite test pad.

(3) Wait for 45 seconds until color of the dipping stripe pad is turned into any colors and then compare
and record the results compared with the color figure as following order.

Caution
All three pad readings must be completed no later than 75 seconds after dipping strip.
Do not touch the stripe with fingers.

● How to judge the strip

Striped

c) b) a)

a) Compare FREEZEPOINT (end pad) to chart and record result.

b) Next compare MOLYDATE (middle pad) to chart and record result.
c) Finally compare NITRITE test to chart and record result.

General information - 32 -
 (1) Compare the end pad ″a)″ color of
% GLYCOL / FREEZEPOINT (䮎) (End Pad)
the strip with color blocks of a row at 25% 33% 40% 50% 60%
the upper part of the standard color
chart (below of the letter ″GLYCOL/ -12ଟ-15ଟ-18ଟ-21ଟ-23ଟ-29ଟ-34ଟ-43ଟ-51୅

FREEZE POINT″). Same color in the SCA Units per Litre

block of the row means the content
0.0 0.4 0.7 0.9 1.0 1.1 1.3 1.5
of anti-freeze in the coolant. (Normal Row 6
TEST

range is between 33% and 50%.) Row 5

0.0 0.4 0.6 0.7 0.9 0.9 1.1 1.3

(2) Compare the middle pad ″b)″ color of 0.0 0.4 0.5 0.5 0.6 0.7 1.0 1.2
Row 4
SERVICE
the strip with the color that the col-
0.0 0.3 0.4 0.4 0.6 0.7 0.9 1.1
umn block color of MOLYDATE at Row 3

the left side of the table intersects 0.0 0.2 0.3 0.4 0.5 0.6 0.8 1.0
Row 2

the row block color of NITRITE at the 0.0 0.2 0.2 0.2 0.4 0.5 0.7 0.9
bottom (pad ″c)″ color of the strip) on
Row 1
PRE CHARGE
0.0 0.1 0.2 0.2 0.3 0.4 0.6 0.9
the table ″SCA Units per Litre″. Row 0

(MIDDLE PAD)
(Normal range of ″SCA Units per

MOLYBDATE
A B C D E F G H
Litre″ is between 0.3 and 0.8 :
NITRITE
″green color area″) EA7O5013

During the comparison, if uncertain about color match, pick the lower numbered block.
(example: if the color of NITRITE pad is between standard color ″D″ and ″F″, then use
column E.)
(3) If the value of ″SCA Units per Litre″ is less than 0.3, refill the DCA4 liquid (anti-corrosion agent) a
little, But larger than 0.8, Drain some amount of engine coolant and replenish the fresh water
instead. The content of the anti-freeze and anti-corrosion agent can be regulated by this way.

Every year coolant must be replaced. It is essential the coolant should be mixture
of fresh water, proper anti-freeze and anti-corrosion agent.

4.3.3. Anti-freeze
The anti-freeze, 35 ~ 40% of the whole coolant, is always to be used to prevent the cooling system from the
corrosion. And in winter the amount of anti-freeze shown in the following table should be used in accordance
with the ambient temperature.
As the individual freezing points corresponding to the proportions of antifreeze in the table are subject to
change slightly according to the kind of antifreeze, you must follow the specifications provided by the anti-
freeze manufacturer.

- 33 - General information
 Ambient
Fresh water (%) Anti-freeze (%)
temperature (°C)
Over -10 85 15
-10 80 20
-15 73 27
-20 67 33
-25 60 40
-30 56 44
-40 50 50

Any coolant loss due to engine operation must be replenished. But adding fresh water for coolant tends to
lower the content of anti-freeze. Always replenish the coolant with a mixture of antifreeze and water, and
keep the proper content of antifreeze (35 ~ 40%).

4.3.4. Heat exchanger and cooling line cleaning

(1) Heat exchanger cleaning
If the heat exchanger tubes are clogged by
many small pieces or polluted by corro-
sion, the sea water quantity will be
reduced gradually also as a result of it
engine overheating may be occurred.

a) Remove the heat exchanger both left

and right side covers.
b) Remove the clogged small pieces and
EDV2218161
clean the heat-exchanger tubes.
When the heat-exchanger tubes do
cleaning, clean outside and inner side
of tubes with a small wire brush and
pressurized water.

(2) Fresh water line cleaning

If the cooling circuits are fouled with water scales or sludge particles, the cooling efficiency will be
dropped down.
The poor condition of the cooling system is normally due to use of unsuitable anti-freezing agents so
periodically clean the circuit interior with a cleaner

Cooling system cleaning interval : Every 1,200 hours

General information - 34 -
4.3.5. Check and adjust of V-belt Tension
(1) V - belt condition
Check the belt for cracks, oil, overheating and wear.
(2) V - belt Tension
By the finger-pressure the belt is pressed
Water pump pulley
by 10 ~ 15 mm between the water pump

mm
pulley and the alternator pulley in normal

10
condition. For the adjustment of the ten- Sea water
pump pulley
sion, loosen the adjusting bolts which sup-
10mm
port the alternator, adjust the tension and
tighten the bolts again. Idle pulley
(3) Change the V-belt Alt. pulley
Change the belt if necessary after every Crank pulley
EDV2218085
2,000 hours of operation.
If, in the case of a multiple belt drive, wear or differing tensions are found, always replace the complete
set of the belts.

Note :
Always apply to DOOSAN genuine parts every replacement.

4.3.6. Thermostat
The thermostat maintains a constant tempera- To heat exchanger
ture of coolant (71 ~ 85°C) and improves ther-
mal efficiency of the engine by preventing heat
loss.
Namely, when the temperature of coolant is
lower than 85°C, the thermostat valve is
closed to make the coolant bypass to directly
Bypass valve
From cooling
enter the water pump. When the coolant tem- water pump To bypass
tube
perature rises to open wide the thermostat
EAMC002I
valve, the bypass circuit is closed and the
water passage to the heat exchanger is
opened so that the coolant is forced to flow into
the heat exchanger.

Item Specifications
Type Wax-pallet type
Open at 71°C
Open wide at 85°C
Valve lift 8 mm or more

- 35 - General information
 ● Inspecting
(1) Check the wax pallet and spring for
damage.
(2) Put the thermostat in a container of Bar
Thermometer
water, then heat the water slowly and
check temperature with a thermometer.
If the valve lift is 0.1 mm (starting to
Wood plate
open) at temperature of 71°C and 8 mm
or more (opening wide) at temperature
of 85°C, the thermostat is normal.
EFM2055I

● Replacing thermostat and precautions for handling

(1) Precautions for handling
The wax pallet type thermostat does not react as quickly as bellows type one to a variation of tem-
perature of coolant. Such relatively slow reaction is mainly due to the large heat capacity of the wax
pellet type thermostat. Therefore, to avoid a sharp rise of coolant temperature, it is essential to idle the
engine sufficiently before running it. In cold weather, do not run the engine at overload or overspeed it
immediately after starting off.
(2) When draining out or replenishing coolant, do it slowly so that air is bled sufficiently from the entire
cooling system.
(3) Replacing thermostat

● If the thermostat is detected defective, replace with a new one.

● Change the thermostat every 2 years.

4.3.7. Sea water pump

As the sea water pump is a bronze impeller type driven by V-belt, should install the sea water strainer
between sea water pump and kingston valve to prevent malfunction of impeller due to clogging by any mat-
ters sucked.
Every the engine starts you should always check whether the kingston valve on the bottom of the boat is
opened. If sea water does not flowed out through outlet pipe of the boat outside, fill coolant in the sea water
pump inlet pipe and hose after loosening clamp.

General information - 36 -
4.4. Lubrication System

4.4.1. Oil level

● The notches in dipstick must indicate the oil
level between high and low permissible
when the vessel is in the water that is at
normal trim.
● The oil level should be checked at the hori-
zontal position of the boat after waiting
about 10 minutes since then the engine has MAX
been shut down. MIN
● Examining the viscosity and the contamina- EA6O5001
tion of the oil smeared at the dipstick
replace the engine oil if necessary.

Caution :
Do not add so much engine oil that
the oil level rises above the maximum
marking on the dipstick. Over filling
will result in damage to the engine like
a excessive blow-by gas.

EB0O7002

● How to re-mark the oil dipstick

Since the inclination angle of marine engine
may differ greatly among vessels, the high
and low oil levels on the dipstick should be
also changed for over 6 degree of the
engine inclination.
Dipstick should be re-marked by engraving
on the lube oil capacity of each engine. Be
sure to check and mark the oil levels
EB0O7003
between High and Low when the vessel is
commissioning at first. Please note that stamping or notching will weaken the dipstick and the tip of the
dipstick may break off in the oil pan.
The capacity of lube oil can be referred before ″1.1. Engine Specification″

- 37 - General information
4.4.2. Exchanging of lubrication oil
Engine oil and the oil filter is important factors affecting engine life. They affect ease of starting, fuel econ-
omy, combustion chamber deposits and engine wear. Change the engine oil at 50 hours of operation at first
and next exchange will be performed every 250 hours. At the end of the break in period (50 hours), change
the sump oil and replace the oil filter cartridge to new one.

1) Oil drainage
● While the oil is still hot, discharge the
sump oil or marine gear sump oil by
motion oil drain pump lever manually as
figure.

EB2M3001

● Refill new engine oil to the filler neck on

the head cover in accordance with the oil
capacity of the engine.
● Be careful about the mixing of dust or
contaminator during the supplement of
oil. Then confirm whether the oil level
gauge indicates the vicinity of its maxi-
mum level.
● For a few minutes, operate the engine at
idling in order to circulate oil through EB2M5001

lubrication system.
● Thereafter shut down the engine. After
waiting for about 10 minutes measure
the quantity of oil and refill the additional
oil if necessary.

Recommend of lubricating oil

Initial factory fill is high quality break-in oil for API Service CI-4 grade. During the break-in period,
frequently check the oil level. Somewhat higher oil consumption is normal until piston rings are seated.
The oil level should be maintained in the safe range between the Min. and Max. mark on the dipstick.
To obtain the best engine performance and engine life, Engine oil is specified by API service, lettered
designations and SAE viscosity numbers. If the specified engine oil is not available, use a reputable
brand of engine oil labeled for API Service CH or CI and SAE viscosity 10W40. Refer to oil
identification symbol on the container.

General information - 38 -
 Engine oil viscosity - ambient temperature

SAE 20, 20W SAE 40, 50

Single SAE 10W SAE 30

temp

Ambient -30 C -15 C -0 C 15 C 25 C 30 C

temp (-20 F) (-0 F) (-32 F) (60 F) (80 F) (90 F)

SAE 10W - 30

Multi
grade SAE 15W - 40

SAE 10W - 40, 20W - 40, 20W - 50

SAE 5W - 20

EDV2218163

4.4.3. Replacement of oil filter cartridge

At the same time of oil exchanges, replace the oil filter cartridges.
● Drain engine oil by loosening the drain plug on the filter head.

Caution :
Don′t forget tightening the drain plug after having drained engine oil.

● Loosen the oil filter by turning it counter-

clockwise with a filter wrench.
● With a rag wipe, clean the fitting face of the
filter body and the oil filter body so that new
oil filter cartridge can be seated properly.

Note :
It is strongly advisable to use
DOOSAN genuine oil filter cartridge
for replacement. EFM2010I

● Lightly oil the O-ring and turn the oil filter until sealing face is fitted against the O-ring. Turn 3/4 ~ 1 turns
further with the filter wrench.

During continuous operation the selector lever that both filter halves are in operation.
Observe positions of selector level.

- 39 - General information
 Right-hand filter cut out Continuous operation Left-hand filter cut out
(both filter halves in operation)

EDV2218091

Caution :
Do not leave selector lever in any intermediate position because this would be liable to interfere with
oil supply.

4.4.4. Oil centrifugal filter

● Oil centrifugal filter is an auxiliary filter
3
which has a special structure able to sepa- 2
rate some impurity from oil centrifugal by 4
means of oil pressure, and that can be used 5

semi-perpetually by maintaining without a

necessity of replacement.
● The oil centrifugal filter should be main-
tained at every time of oil replacement. 6

1 EDV2218089

4.4.5. Marine gear oil change

Always apply to API Service SAE #30 for reduction gear oil. Change the reduction gear oil at 100 hours of
operation at first and next exchange will be performed every 600 hours.

4.4.6. Cylinder compression pressure

● Stop the engine after warming up,
and take out nozzle holder assem-
bly.
● Install the special tool (compres-
sion gauge adapter) at the nozzle
holder hole, and connect the com-
pression pressure gauge there.

Standard value 20 ~ 24 kg/cm2

EB4O403I
Limit value 20 kg/cm2 or less
Difference between
Within ±10%
each cylinder
* Condition : Cooling water temperature 20°C, Engine rotation 200 rpm.(about 10 revolutions)

General information - 40 -
4.5. Intake & Exhaust System

4.5.1. Cleaning & change of the air filter element

The engine life and performance depends on
the intake air condition greatly.
A fouled air filter element result a decreased
intake air amount leading the engine output
decrease and finally may cause an engine
malfunction.
Further, a damaged air filer element results
wear on the cylinder component or the valve
mechanism etc. leading increased engine oil
consumption and decreased engine output,
finally leads to shorten the engine life.
The air filter element should clean periodically
as follow.

EA7O5006

Cleaning of the air filter element : Every 100 hours

Exchange of the air filter element : Every 400 hours
Replace the air cleaner if deformed, broken or cracked.

(1) Air filter element cleaning

● Wash the polluted element in warm water non-sudsy household detergent.

● Rinse the element with clean water.
● Dry it thoroughly with natural air or electric fan.
Don′t use a flame or compressed air for dry.
It makes damages to the element.

(2) Checking element

● Confirm inside of the element clean and dry.

● Replace the new element if tears, rips or damages are found.

- 41 - General information
4.5.2. Inter-cooler
Inter cooler depends on the intake air condition
greatly. The fouled air pollutes and clogs the
air fins of the inter cooler. As a result of this,
the engine output is decreased and the engine
malfunction may be occurred. Therefore
always check weather the intake air systems
like air filter element are worn or polluted.
The inter-cooler has to be removed from the
engine for cleaning.
EB2O3004

< Inter cooler cleaning >

In order to maintain the heat transfer efficiency of the inter-cooler, it is necessary to clean it at regular inter-
vals. For this purpose, dismantle the inter-cooler. In almost all cases, it will suffice to clean the individual
parts in a hot alkaline solution, e.g. a 3 to 5% P3-FD solution.
If hard and firmly adhering scale deposits continue to exist, a second treatment should be made with a des-
caling agent which will not corrode the cooler core. Use new gaskets when reassembling the inter-cooler.
Be sure to clean the sealing surfaces carefully before installing the gaskets.
Observe the specified pressure when making the hydraulic test.

Water side 400 kPa (4 bar)

Test gauge pressure
Charge air side 300 kPa (3 bar)

Observe the specified pressure when making the hydraulic test.

Cleaning of inter cooler : Every 1,000 hours.

4.5.3. Turbo-charger cleaning

● Turbo-charger should clean every 2,000 hours. The only points to be observed are the oil pipes which
should be checked at every oil change for leakage and restrictions and should check the condition of
turbo-charger like oil leaks, unusual turbo sounds periodically.
● Air cleaner element should be checked and cleaned periodically to prevent foreign matters from entering
the inside of the engine.
● Should check and measure the pressure of intake air and exhaust gas periodically. If there is an air leak-
age, should repair the problem at once to prevent from occurring the engine power loss and over heating.
● In case of operating in highly dust or oil-laden atmospheres, cleaning of the air compressor impeller may
be necessary from time to time. To this end, remove compressor casing (Caution : Do not skew it!) and
clean in a non-acid solvent, if necessary use a plastic scraper.

General information - 42 -
 If the air compressor should be badly fouled, it is recommended that the wheel be allowed to soak in a vessel
with solvent and to clean it then with a stiff non-steel brush. In doing so, take care to see that only the com-
pressor wheel is immersed and that the turbocharger is supported on the bearing casing and not on the
wheel.

4.5.4. Exhaust gas checking

Exhaust gas depends on much or less of it shows whether combustion condition of the engine is good or not.
If exhaust gas is any abnormal condition like excessive smoke, white smoke, black smoke, the engine should
be serviced maintenance from specialist.

4.6. Fuel System

As fuel injection pumps and injection nozzles consist of very complicated and precise components, the con-
tamination of fuel causes the clogging of the nozzle or the sticking of the components of injection pump.
Therefore, the cleanness of the fuel system should be maintained all the time.
If the engine is equipped with a fuel water separator, drain off any water that has accumulated. Water in fuel
can seriously affect engine performance and may cause engine damage.

4.6.1. Priming pump strainer cleaning

Clean the priming pump strainer every 100
hours operation. The strainer is incorporated in
the priming pump inlet side joint bolt. Clean the
strainer with the compressed air and rinse it in
the fuel oil.

Strainer

EDV15200002

4.6.2. Fuel tank cleaning & checking

Fill the tank with recommended fuel. Keeping tanks full reduces water condensation and helps keep fuel
cool, which is important to engine performance. Make sure fuel supply valves (if used) are opened. In marine
environment, the most likely fuel contaminants are water and microbial growth (black ″slime″). Generally, this
type of contamination is the result of poor fuel handling practices.
Black ″slime″ requires water in the fuel to form and grow, so the best prevention is to keep water content to a
minimum in storage tanks.
If diesel fuel which contains moisture is used, injection system and cylinder liners, pistons will be damaged.
Drain moisture and accumulated sediment from drainage device of storage tank regularly. You should
change the element of the water separator or fuel filter cartridge several times until fuel of the suction line is
cleaned.

- 43 - General information
 Notice :
A galvanized steel tank should never be used for fuel storage, because fuel oil reacts chemically
with the zinc coating to form powdery flakes which can quickly clog the fuel filters and damage the
fuel pump and injection nozzles.

● How to select fuel oil

Fuel quality is an important factor in obtaining satisfactory engine performance, long engine life, and
acceptable exhaust emission levels. DOOSAN engines are designed to operate on most diesel fuels mar-
keted today. In general, fuels meeting the properties of ASTM designation D975 (grades 1-D and 2-D)
have provided satisfactory performance.
The ASTM 975 specification, however, does not in itself adequately define the fuel characteristics needed
for assurance of fuel quality.
The properties listed in the fuel oil selection chart below have provided optimum engine performance.
Grade 2-D fuel is normally available for marine service. Grade 1-D fuel should not be used in pleasure
craft engines, except in an emergency.

General information - 44 -
 Fuel oil selection chart

General Fuel ASTM No. 1 No. 2

DIN 51601
Classification test ASTM 1-D ASTM 2-D
Gravity, (API #) D 287 40 ~ 44 33 ~ 37 0.815 ~ 0.855
Flash point
D 93 100 (38) 125 (52) 131 (55)
Min. °F (°C)
Viscosity, kinematic
D 445 1.3 ~ 2.4 1.9 ~ 4.1 1.8 ~ 10
CST 100 °F (40°C)
Cloud point °F #) D 2,500 See note 1) See note 1) See note 1)
Sulfur content
D 129 0.5 0.5 0.15
wt%, Max.
Carbon residue
D 524 0.15 0.35 0.1
on 10%, wt%, Max.
Accelerated stability
total insolubles D 2,274 1.5 1.5
mg/100 ml, Max. #)
Ash, wt%, Max. D 482 0.01 0.01
Cetane number, Min. +) D 613 45 45 > 45
Distillation
Temperature, °F (°C)
IMP, Typical #) 350(177) 375(191)
10% Typical #) D 86 385(196) 430(221)
50% Typical #) 45(218) 510(256) 680(360)
90% +) 500(260) Max. 625(329) Max.
End point #) 550(288) Max. 675(357) Max.
Water & Sediment
D 1796 0.05 0.05 0.05
%, Max.

#) Not specified In ASTM D 975

+) Differs from ASTM D 975

Note : 1. The cloud point should be 6°C (10°F) below the lowest expected fuel temperature to prevent clog-
ging of fuel fitters by crystals.

- 45 - General information
4.6.3. Water separator
DOOSAN recommends the fuel water separa- Bleed screw
tor to install between fuel tank and fuel injec-
tion pump strongly. out C D out
Condensation formed in a partially filled tank
Stage 5
promotes the growth of microbial organisms
that can clog fuel filters and restrict fuel flow Stage 4
and cause the engine power decrease before. in A B in
Water in the fuel will decrease the lubrication Stage 1
in the pump and possibly cause a failure of the
Stage 3
pump. Injection nozzles are also lubricated by
fuel and can also fail as a result of water in the Stage 2
fuel. Therefore, it is necessary to remove any
water from the fuel before it reaches the fuel
pump by using a fuel water separator. Drain valve
(push in and
Fuel water separators that are available from
turn yellow
DOOSAN are recommended. If another fuel knob)
water separator is to be used, it must be sized EDV15200003

for the engine′s fuel supply flow rate.

4.6.4. Fuel filter exchanging

a) Loosen the fuel filter by turning it counter-
clockwise with the filter wrench.
● Discard the used filter a designated
place.
b) Wipe the filter fitting face clean.
c) Apply a light coat of engine oil to the O-ring Lever

and supply fuel to the new filters.

d) Turn the new filter until the filter O-ring is fit-
ted against the sealing face.
EDV2218063
e) And then turn the filter cartridge about 3/4
~ 1 turn more with hands or filter wrench.

Right-hand filter cut out Continuous operation Left-hand filter cut out
(both filter halves in operation)

EDV2218091

Caution :
Do not leave selector lever in any intermediate position because this would be liable to interfere with oil supply.

General information - 46 -
 Bleeding of the fuel system

Whenever fuel filter is changed or the engine is stopped cause of the fuel lack, the air of fuel line
must be removed as follows.
Bleed the fuel by manually operating the priming pump with fuel filter outlet joint bolt and injection
pump bleeder screw loosened.

● Press the feed pump cap repeti-

tively until the fuel without bubbles
comes out from the bleeding plug
screw.
● After the whole air is pulled out, Strainer
close the plug screws of the filter
and the pump.
● Confirm the resistance of fuel deliv-
ery by repetition pressing of the
feed pump cap, Pressure and turn EB1M4003

the priming pump cap simultane-

ously to close it.

Note :
Removing the seal ring (copper seal ring/rubber coated seal ring) when bleeding of fuel
system replace it with a new one. Otherwise fuel leaks from the fuel filter joints, causing a
critical fault in engine performance.

4.6.5. Checking the fuel injection timing (by authorized specialist personnel)
Check the fuel injection timing every year. Refer to details ″6.3.15. Injection pump & injection timing″.

Caution :
● Check the fuel injection pump housing for cracks or breaks, and replace if damaged. Check
whether the lead seal for idling control arid speed control levers have been removed or not.
● No alterations must be made to the injection pump. If the lead seal is damaged the warranty on
the engine will become null and void.
● We strongly recommend that any faults developing in the injection pump should be taken care of
by authorized specialist personnel.

4.6.6. Injection nozzle maintenance (by authorized specialist personnel)

Check the fuel injection nozzle every year or increasing the smoke excessively.
Refer to details ″7.3.3. Fuel injection nozzle″

- 47 - General information
4.7. Electric System

4.7.1. Warning lamp check

Check the lamps of the gauge panel carefully whether the lamp is switch on or not while the engine is run-
ning. If the oil warning lamp is switched on below 0.5 bar of the oil pressure and the water temp warning lamp
is switched off over 95°C of water temperature, their function is normal.

4.7.2. Battery charging check

Always check whether battery capacity is sufficient or not before sailing far away from harbor.

4.7.3. Engine wiring check

Check the engine wiring is loosened, shorted or worn every 600 hours.

4.8. Valve Clearance

The valve clearances are to be adjusted at the times of the following situations.
● After initial 50 hours operation.
● When the engine is overhauled and the cylinder heads are disassembled.
● When severe noise comes from valve train.
● When the engine is not normally operated, even though there is no trouble in the fuel system.
The valve clearance of the cold engine are as follows ;
- Intake valves : 0.25 ±0.05 mm
- Exhaust valves : 0.35 ±0.05 mm

4.8.1. When the engine is not used long time

In case of the engine is not used long time, preserve the engine from corrosion, faulty matters in order to run
the engine operation easy and keep it long maintenance.
Especially the main external and internal components of the engine are likely to corrode as follows.
● Drain the coolant of the engine completely and refill the new flesh water in the engine and run it until the
water line is cleaned quite.
After draining the coolant refill the anti-freeze 35 ~ 40% with the fresh water again.
● Run the engine until engine coolant is up to normal temperature 71 ~ 85°C and then stop the engine.
● Change the oil and oil filter cartridge new one after running the engine for 10 ~ 15 minutes in order to
drain the faulty matters in the oil pan as clearly as possible.
● Close the valve or cock of the fuel tank and clean the fuel filter and water separator.
● Run the engine about 5 minutes in order to circulate the new fuel through the all lines fully.
● Clean the air filter element and If worn severely change it new one.

General information - 48 -
 ● Drain the reduction gear oil completely and clean the strainer inserted in the inner side of it and then refill
the specified oil (SAE #30) up to the maximum level of the oil dipsticks.
● Run the engine on idle rpm for 5 minutes and then shift the control lever of the reduction gear Neutral to
Forward, Neutral to Reverse position in turn to circulate the oil around the all lines of it.
● Put the engine throttle lever on idle position then reduction gear and FPTO lever on switch off position
(Neutral & OFF).
● Drain the engine coolant completely and remove the drain plugs.
● Close the kingston valve of the sea water line tightly, Specially likely to freeze, drain the water of the heat
exchanger, inter cooler, reduction gear oil cooler and keep the plugs opened. At last don′t forget to detach
the sea water pump impeller and preserve it a dark place.
● First of all detach the battery wire (-) and then the other wires and clean the wires. If the battery is refilled
with the distilled water, refill it but DOOSAN batteries need not. And apply the grease on the surface of the
wire terminals to protect corrosion.
● Loosen the V-belt to prevent its tension and push the paper sheet in the pulley homes under the V-belts.
● Run the engine on idle rpm or some more for 10 minutes once 10 days at least to lubricate all lubrication
system and charge the batteries of the engine.
● The engine not used for a long time should check the condition of it regularly. Specially apply the grease
on the engine parts likely to corrode.

4.9. When the Engine is Sunk

If the engine is sunk to water, remove the moisture of all engine parts as soon as possible and ask your DOO-
SAN dealer for service of the engine at once.
Repair man disassembles all parts of the engine and remove the salty moisture of each disassembled compo-
nent then apply oil to the parts at once.
At last check whether the components of the engine is dried and eroded away or damaged especially compo-
nents of the fuel system. This action must be finished quickly without delay time or maybe results engine fatal
damage from salty corrosion. Be sure to install the auto bilge pump in the bottom of the boat to keep the water
level below the flywheel housing and to prevent overflowing with water.

- 49 - General information
General information - 50 -
5. MAIN ACCESSORY PARTS

5.1. Reduction Gear

Refer to ″reduction gear manual″ provided with engine separately for detail operation and maintenance of
reduction & maintenance.

5.1.1. Construction and operation

The reduction gear is used for high-speed engine and consists of 4 major components such as input shaft,
gear shaft, output shaft, and housing.
The clutch for forward and reverse movements is composed of a hydraulic wet-type and multi-plate type, and
the construction and power line is as follows ;

1
2
3
4
5

11

6
7
8
9
10

EFM6006I

<Power line>
Neutral : 1-2-5-4-8
Forward : 1-2-5-3-7-10
Reverse : 1-2-5-4-8-9-6-7-10

1. Rubber block 6. Reverse pinion

2. Spider 7. Output shaft
3. Forward pinion 8. Reverse drive gear
4. Reverse drive gear 9. Gear shaft
5. Input shaft 10. Propeller shaft

- 51 - Main accessory parts

 The hydraulic-type clutch is composed of forward main body, reverse main body, output shaft, and selector
valve.
The selector valve assembly installed on the external part is a device designed to control forward, neutral,
and reverse movements and also it can be remote-controlled. The oil pumped up at the pump supplies
hydraulic pressure for the clutch assembly, lubricating portions on gear and bearings, and cooling system.
But when assembling this hydraulic type clutch, use care so that it is aligned with the engine correctly.

5.1.2. Operation
1) Before operation
● Check the tightening bolts and nuts on the components as a whole for looseness.
● Check the oil level with the oil level gauge.
(Run the engine at idle for a few minutes, then stop it before checking the oil level.)
● Place the control lever in the neutral position before starting the engine.

2) Starting
● Run the engine at idle for about 10 minutes.
● Check for oil leaks, unusual sound, temperature, etc. while idling the engine.
● While checking the clutch pressure, increase the engine rpm.

3) Driving and stopping

● Check to see that the specified pressure is obtained when engaging the clutch. The pressure may
drop slightly at low engine rpm, but it does not affect the operation of the engine.
● When attempting to change gears for forward or reverse movement, first put the engine rpm to idle.
● The temperature of oil at operation must be 60 ~ 90°C.
● When attempting to stop the engine, be sure to place the control lever in the neutral position.

4) Emergency bolt
The emergency bolt is designed to couple the clutch mechanically when the clutch indicates abnormal
condition or slip at clutch coupling operation. The reverse clutch pack has no emergency bolt. When using
the emergency bolt, first loosen the tightening bolts to remove the control block, tighten the 8 mm wrench
bolt on the forward disc pack using a 6 mm L-shaped wrench, then reassemble the control block in the
reverse order. Be sure to use this emergency bolt literally in case of emergency.

Snap Steel plate

ring Sintered plate
Emergency
bolt
Back Piston
plate

EA7O6011

Main accessory parts - 52 -

5.2. Front Power Take Off
Refer to Service and Operation manual of AP Power Take Off company for detail operation and maintenance.

5.2.1. PTO Description and operation

Below figure shows a section view of a typical multiple-plate PTO.
A driveshaft(1) is carried in a cast iron housing(2). The tapered roller bearing(4) locates in the flywheel(5)
(various types of bearing can be specified) to support the input end of the drive shaft. The body(6) is pressed
on the drive shaft and retained by a key(28). External (male) splines on the body are mated to internal
splines on the pressure plate(7). With double and triple plate PTO there are intermediate pressure plates(8)
which also slide on the body.
Between the body and pressure plates are the friction facings(9) which (as shown on the lower figure) are
molded with gear teeth along the outside diameter. The gear teeth on the facings engage with gear teeth on
the drive ring(10) which is in turn bolted to the engine flywheel.
Power flow is from the engine flywheel to the drive ring, through the drive ring gear teeth to the friction fac-
ings. With the PTO engaged, the facings are clamped between the pressure plates and transmit power
through the splines on the pressure plates to the body. Finally, power is transmitted to the drive shaft through
the key(28).

EDV2218092

- 53 - Main accessory parts

 Release levers(11) carried on the pressure plate are connected to a release sleeve(12) by control links(13).
The PTO is engaged by moving the lever(14) in the direction of the engine. The lever is attached to a cross-
shaft(15) in the PTO housing and a release bearing yoke(16). As the lever moves toward the engine, the
bearing yoke rotates with the cross shaft and moves the release bearing(17) and sleeve(12) to contact with
the adjusting ring assembly(18). As pressure is applied to the adjusting ring, the control links force the
release levers against the pressure plate. When sufficient pressure has been applied through the lever, the
release levers and control links snap ″over-center″ thus locking the pressure plates and friction facings
together in the engaged position.

Regular adjustment is required to maintain the over-center load as friction faces wear during
service.(see adjustment procedure).

5.2.2. How to use PTO

(1) PTO engagement procedure
Start the engine and run until sufficiently ″warmed up″ to maintain normal engine idle speed. With the
engine running at, or slightly above, idle speed but not in excess of 1,200 rpm, push handle firmly and
quickly, without stalling the engine, until the handle snaps into engaged position.

Do not slip the PTO excessively during engagement. Engagement of the PTO
at engine speeds above 1,200 rpm and/or excessive slipping of the PTO during
engagement or operation can cause clutch failure and will void the clutch warranty.

(2) Checking engagement load

Check PTO adjustment as follow :
● Using a torque wrench and 1-1/4″ (32 mm) socket on the hex fitting on the PTO operating handle,
check torque on cross shaft required to engage PTO.

Note :
If the PTO handle does not have a hex fitting, use special service tool on the cross shaft spline.
(Refer to the ″Service & Operation Manual of AP POWER TAKE OFF″)

● Readjust PTO with adjusting ring if necessary. (Refer to ″5.9.3. PTO engagement procedure″.)

<Engagement load at end of standard perating Lever 63.5 cm (25″)>

Over-center load at end of lever Equivalent torque at cross shaft

PTO Size
lbs. Kg lb.ft. Nm
10″ & 11.5″ 75 ~ 90 34 ~ 41 156 ~ 187 211 ~ 254
14″ 80 ~ 100 36 ~ 45 167 ~ 208 226 ~ 282

Main accessory parts - 54 -

 DOOSAN engines only apply to 11.5″ PTO size.
Do not adjust the PTO too tightly. Loads above the maximum quoted can cause PTO component
failure.

● Re-adjust PTO with adjusting ring if necessary.(Refer to PTO adjustment 5.2.2.)

● Recheck cross shaft torque.
● Repeat adjustment until correct torque is achieved at cross shaft.

Note :
After installation and during ″wear in″ frequent adjustment may be necessary to maintain correct
over center loads. Failure to do this adjustment will result in excessive wear and/or burn out which in
not warrantable.

Do not adjust the PTO too tightly. Loads above the maximum quoted can cause PTO component
failure.

(3) PTO adjustment

● Do not attempt to adjust PTO with the engine running.

<Removing PTO from engine> <Shaft bearing adjustment>

EB2O5003

● To adjust the PTO remove the inspection cover and release either the adjuster lock or socket head
screw in the red adjuster ring from the splines in the clutch body. Once the lock or socket screws are
disengaged turn the adjuster ring by hand, or by tapping it with a soft metal drift and a hammer until
the approriate over center load or cross shaft torque is obtained.
(See table bow or inspection cover).

- 55 - Main accessory parts

 <Adjusting rings>

EB2O5002

● Relocate lock or socket screw, turning adjuster ring clockwise if required, to ensure engagement of the
screw or lock in the nearest spline space. The socket screw should be tightened with a torque of 10-
13 Ibs.ft.(14 ~ 18 Nm)
● Remove all foreign objects (tools etc.) from the PTO housing and replace the inspection cover.

(4) Facing check

● If facings are worn, heat affected, or contaminated with lubricant they must be replaced. Severe discol-
oration of facings often indicates the PTO has been operating in a slipping condition, possibly due to
faulty adjustment.
● In cases of severe lubricant contamination, the source of the lubrication must be found and rectified.
Examine the teeth for wear or cracks, replace as required.
● New PTO assemblies and those serviced with new friction facings will require frequent adjustment
until the facings are fully bedded in.

Do not use the PTO friction factions on over slip and over wear.
It may be resulted in any early failure.

Main accessory parts - 56 -

(5) Lubrication point
● The release bearing is lubricated through a grease nipple on the PTO housing which is connected to
the bearing by a flexible hose. The drive shaft output bearings are lubricated through a grease nipple
located on the PTO housing just above the bearings. Internal drillings in the housing carry the grease
to the bearings.
● Do not over grease. Excess lubrication at any of the points can result in contamination of the friction
facings which will cause immediate PTO failure.

ᐰ PIVOT PINS
ᐭ RELEASE
BEARING

ᐱ PILOT BEARING
(GREASABLE TYPE

ᐯ CROSS SHAFT
(2 Fittings) ᐮ MAIN BEARING ᐰ YOKE ENDS
EDV2218064

Note :
Refer to the ″Service & Operation Manual of AP POWER TAKE OFF″ attached with AP Co.
clutch itself for all detail contents.

- 57 - Main accessory parts

5.2.3. Exploded view of typical 11-1/2″ ~ 14″ twin clutch

PIVOT PIN
PLAIN WASHERS
& SPLIT PINS
OR CIRCLIPS
SPLIT
PINS

EB4O5002

Main accessory parts - 58 -

5.2.4. Front power take-off (F.P.T.O)
1) For medium power
For front power take-off in line with crank-
shaft, it is a standard procedure to support
drive shaft and V-pulley by two pillow blocks
by using flexile coupling for connection to
engine.
When the front PTO is installed, be sure to
take deflection reading. Radial run-out
should be no more than 0.02 mm.
Be sure to limit the front PTO output within EA4O7001
the maximum allowable horsepower as
specified for each model in figure below.
(Torque represents when there is no pro-
peller load)

Model Load(kW) rpm Model Load(kW) rpm

V158TIE 162 1,500 V180TI 220 1,500
V158TI 176 1,500 V222TI 265 1,500

2) For small power

The right figure is applicable to the drive
arrangement in which the distance between Crank V-pulley, PTO
pulley
the end face of the engine pulley and the MAX. 170mm
Engine
centerline through pulley groove is not (6.7 in) dia.

greater than 60 mm. The distance is indi-

cated
as ″L″ in right figure.

L
EA4O7002

Model L mm Belt driven side load(kW) rpm

V158TIE 91
V158TI 95
60 1,500
V180TI 115
V222TI 125

- 59 - Main accessory parts

5.3. Propeller Selection
Your dealer has chosen a propeller designed to

OUTPUT
POWER
deliver top performance and economy under 100% C D
most conditions. To obtain the maximum per- 90%
80%
centage of available horsepower (A), the engine
70%
RPM at Full Throttle should be in the specified A
60%
Full Throttle Operating Rage (B). 50%
B
40%
Refer to Specifications in Performance Curve. 30%

RPM
EA4O7003

If the engine′s full throttle RPM on normal

load is below the specified on the low side of the range, use a propeller with less pitch to increase the RPM.
Should the engine′s full throttle RPM want to exceed the specified range (B), the engine RPM is limited by the
governor. Use a propeller of higher pitch to stop the limiting by the governor.

Note : Engine damage can result from incorrect propeller selection which :
●(C) Prevents engine RPM from attaining the specified ″Full Throttle Operating Range″.
Engine is laboring, install lower pitch propeller.
●(D) Allows engine RPM above the specified. ″Full Throttle Operating Range″. Engine RPM is
livited by the governor, install a higher pitch propeller.

Main accessory parts - 60 -

5.4. Electric System

5.4.1. Alternator

24V x 80A
Terminal R

Terminal B Terminal L

EDV2218021

Battery +

0.5 MFD

Regulator

Relay Terminal

Trio Diode Lamp Terminal

EDV2218022

The alternator is fitted with integral silicon rectifiers. A transistorized regulator mounted on the alternator con-
trols the alternator voltage evenly. The alternator should be operated with the regulator and battery con-
nected in circuit to avoid the damage of the rectifier and regulator.
The alternator is maintenance free, but it must be protected against dust and above all against moisture
therefore it must be mounted a cover for protector properly.

- 61 - Main accessory parts

5.4.2. Precautions in use
● Pay attention to dropping the battery voltage capacity when they are left for long time even without use.
● As starting may not be done well sometime in cold winter season, do not try it to be continuous immedi-
ately but try to start again after waiting about 30 seconds.
● Prior to operating the gauge panel, make sure the polarity of battery once again (In majority of polarities,
red side is ″+″ and black one is ″-″)
● On disassembling the gauge panel may be accompanied a risk of electrical shock, always work after pull-
ing off the connector at rear side of it without fail.
● If the silver paper etc is used for connecting the cut-off fuse, because the excessive current might flow into
the parts to damage, when fuse is cut off, after resolving the problem locating the cause, replace it with
new fuse.
● Since battery has a danger of explosion by a heat, it must not be placed at the spot where generates a lot
of heat.
● When engine is in stop, pull out the key always. Thus, a hazard of fire or wound due to wrong operation
may not happen.
● In case of scrapping the batteries, observe the followings.

Note : Do not throw it in the fire to scrap.

It should not be thrown away into the places where are liable to cause the environmental pollution
such as stream, river and mountain. Pack them as far as possible and dispose it as rubbish that is
unable to use again.

● DOOSAN will not be responsible to the problems that might be raised by the disassembling and structural
change of this product without consultation.

Main accessory parts - 62 -

5.4.3. Starter motor
The starter motor is installed on the flywheel
Circuit diagram
housing. 50 30
When the starting key switch is turned on, the
starter motor pinion flies out and engages the
ring gear of the flywheel. Then the main con-
tact is closed, current flows, and the engine is
started.
M
After the engine starts, the pinion automatically
returns to its initial position when the starting 31
EB2M6002
key switch is released. Once the engine starts,
the starting key switch should be released
immediately.
Otherwise, the starter motor may be damaged
or burned out. In case of repairing the engine,
dip the pinion of the starter and ring gear into
the fuel and remove the corrosion with brush.
After that apply the grease on them to protect
the corrosion.
Whenever you clean the starter, always pay
attention not to occur the electric short due to
entering the water etc.
EB2M6001

Starter motor always should be prevented from humid.

Precaution
Before working the electric system of the engine be sure to detach the battery wire (-) to
prevent from electric short.

- 63 - Main accessory parts

Main accessory parts - 64 -
6. DISASSEMBLY AND ASSEMBLY OF MAJOR COMPONENTS

6.1. Disassembly

6.1.1. General precautions

● Maintenance operation should be carried out in a bright and clean place.
● Before disassembly, provide racks for arrangement of various tools and disassembled parts.
● Arrange the disassembled parts in the disassembly sequence and use care to prevent any damage to
them.

6.1.2. Cooling water

● Open the pressure cap of heat exchanger tank to remove the air pressure.
● Loosen the drain plugs as follows and then drain out the cooling water into a container.
1) Below the right wet turbocharger elbow
2) Below the left exhaust manifold cover
3) Below the heat exchanger inlet pipe.
4) Below the oil cooler housing
5) Cylinder block face upper the starter.

6.1.3. Engine oil

Remove the oil after opening the oil drain cock
of engine or reduction gear side, and let engine
oil discharge into the prepared vessel.

EB2M3001

6.1.4. Sea water pump

● Remove sea water pipes connected to the
inlet and outlet pipes.
● Remove the sea water pumps.

EFM2001I

- 65 - Disassembly and assembly of major components

6.1.5. V-belt.
Loosen the belt tension adjusting bolts, and
remove the V-belt.

EFM2002I

6.1.6. Alternator
Remove the supporting guide piece for install-
ing the alternator and the bracket bolts.
Disassemble the alternator.

EFM2003I

6.1.7. Vibration damper

Remove the fixing bolts for crankshaft pulley in
reverse order of assembly and disassemble
the crankshaft pulley and vibration damper.

EFM2004I

6.1.8. Oil filter assembly

This filter is change-over type, that is the ser-
vicing procedure is for the filter side requiring
to be shut off while the engine is running.
During continuous operation, the selector lever
should be placed in a position where both filter
halves are in operation.
● Disassemble the oil filter cartridge using a
filter wrench.
EFM2010I

Disassembly and assembly of major components - 66 -

 ● Do not use again the cartridge removed
after use.
● Remove the oil filter head fixing bolts and
disassemble the filter head.

EFM2006I

6.1.9. Cooling water pump

● Loosen the various hose clamps for the
connections.
● Remove the cooling water discharging pipe
and disassemble the thermostat.
● Loosen the water pump fixing bolts and
detach the cooling water pump.

EFM2007I

6.1.10. Starting motor

Loosen the starting motor fixing nuts and dis-
mantle the starting motor.

EFM2008I

6.1.11. Fuel filter

This filter is change-over type, that is the ser-
vicing procedure is for the filter side requiring
to be shut off while the engine is running.
During continuous operation, the selector
lever should be placed in a position where
both filter halves are in operation.

EB2M2001

- 67 - Disassembly and assembly of major components

 ● Disassemble the rubber hoses of the fuel
supply and discharge.
● Remove the fuel filter fixing bolts and dis-
assemble the filter.

6.1.12. Injection pipe

● Disassemble the injection pipe from the
nozzle holder and fuel injection pump.
● Disassemble various fuel pipe and hose.

EB2M3003

6.1.13. Oil cooler assembly

● By removing the plug screw of cooling
water discharge port, the cooling water is
discharged.
● By removing the cooler housing fixing bolts
and detach the oil cooler housing from the
cylinder block.

EFM2012I

● Remove the oil cooler cover fixing bolts

and disassemble the oil cooler.

EFM2012I

Disassembly and assembly of major components - 68 -

6.1.14. Turbocharger
● Loosen the hose clamp for connecting the
intake stake and tear down the air intake
stake.
● Loosen the clamp for connecting the air
intake manifold.
● Remove the hollow screw of the turbo-
charger inlet & outlet pipe for lubricating,
and tear the pipes down.
● Loosen the turbocharger fixing nuts and
EDV2218090
detach the turbocharger from the exhaust
manifold elbow.

6.1.15. Inter-cooler
● Tear down the various hoses and pipes
from the inter cooler.
● Remove the inter-cooler fixing bolts and
detach it.

EFM2014I

6.1.16. Exhaust manifold

● Loosen the exhaust manifold fixing bolts
and dismantle the manifold from the cylin-
der head.

EFM2015I

- 69 - Disassembly and assembly of major components

6.1.17. Intake manifold
● Remove the manifold fixing bolts and
detach the intake manifold from the cylin-
der head.

EFM2016I

6.1.18 Heat exchanger

● Remove the hoses and the pipes.
● Remove the cover bolts
● Remove the 4 fixing bolts from the lower
plate.
● Pull out the heat exchanger tube bundle.
● Clean the tubes.

EFM2017I

6.1.19. Flywheel housing cover

● Detach the side cover.
● Disassemble the flywheel housing cover.

EFM2018I

6.1.20. Fuel injection pump

● Remove the oil hoses for lubrication and
the fuel hoses.
● Loosen the fixing bolts of fuel injection
pump and detach the fuel Injection pump.

EFM2019S

Disassembly and assembly of major components - 70 -

6.1.21. Cylinder head cover
Remove the fixing bolts and tear the cylinder
head cover down.

EFM2020I

6.1.22. Nozzle holder

● By means of a special tool, loosen the noz-
zle holder assembly and take it out.

EFM2021I

6.1.23. Rocker arm

● Remove the rocker arm bracket fixing bolts
and take the rocker arm assembly out.
● Pull out the push rod.

EFM2022I

6.1.24. Cylinder head

● Loosen the cylinder head fixing bolts in the
reverse order of assembling, and remove
them all and then take the cylinder head
out.
● Remove the cylinder head gasket and
scrap it.
● Eliminate the residue from the cylinder
head face and cylinder block face.
EFM2023I

- 71 - Disassembly and assembly of major components

 Note :
Be careful not to damage the cylinder head face where its gasket contacts.

6.1.25. Oil pan

● Remove the fixing bolts and detach the oil
pan.
● Remove the oil pan gasket and scrap it.

EFM2024I

6.1.26. Oil pump

● Remove the oil suction pipe fixing bolts and
tear them down.
● Remove the oil relief valve fixing bolts and
take them out.
● Remove the oil pump fixing bolts and
detach the oil pump.

EFM2025I

6.1.27. Piston
● Remove the connecting rod cap bolts in the
reverse order of assembling and follow the
similar method as in the cylinder head bolt
removal.
● Tapping the upper and lower connecting
rod caps lightly with a non steel hammer,
detach them and take the bearings out.
● By pushing the piston assembly with a
wooden bar toward the cylinder head′s
EFM2026I
direction, remove the piston.

Note :
Be careful of the removed pistons not to collide each other or with the other parts.
At the storage of pistons, maintain them in the order of cylinder number. (In order for
connecting rod caps not to mix one another, temporarily assemble them to the
corresponding connecting rods.)

Disassembly and assembly of major components - 72 -

6.1.28. Front oil seal holder
● Remove the oil seal holder fixing bolts and
tear it down.
● Remove the oil seal and gasket from the oil
seal holder and scrap them.

EFM2027I

6.1.29. Flywheel
● Remove the flywheel fixing bolts in the
order of disassembling and detach the fly-
wheel.

EFM2028I

● Remove the flywheel ring gear.

- Heat the ring gear evenly with a gas
burner (up to 200°C) to invite volumetric
expansion.
- Tapping around the edges of the ring gear
with a hammer and brass bar to remove
it.

Caution : EA0M4028
Do not damage the flywheel.

6.1.30. Flywheel housing

● Loosen the housing fixing bolts and detach
the flywheel housing.
● Remove the oil seal from the flywheel
housing.

EA6M2010

- 73 - Disassembly and assembly of major components

6.1.31. Crankshaft
● Loosen the bolts from bearing caps.
● Dissemble the main bearing cap fixing
bolts in order of assembling.
● Remove them in the same way of the cylin-
der head bolts.
● Maintain the removed bearing caps in the
order of cylinder number.
● Temporarily install the bolts at the both side
of crankshaft, and lift the shaft with a rope. EFM2029I

Note :
Do not mingle with the metal bearings and bearing caps randomly. To prevent mixing, temporarily
assemble the metal bearings to the corresponding bearing caps in turn.

6.1.32. Camshaft and tappet

● Pull out the tappets from the cylinder block.
● Remove the camshaft being careful not to damage the camshaft and its bearings.
6.1.33. Oil spray nozzle
● Remove the spray nozzle fixing bolts and
tear down the oil spray nozzles.

6.1.34. Cylinder liner

● By means of a special tool (Extractor), pull
out the liner from the cylinder block.

EFM2030I

Disassembly and assembly of major components - 74 -

6.2. Inspection

6.2.1. Cylinder block

1) Clean the cylinder block thoroughly and check a visual inspection for cracks or damage.
2) Replace if cracked or severely damaged, and correct if slightly damaged.
3) Check the oil and water passing lines for restriction or corrosion.
4) Inspect the cylinder block′s camshaft bush to any damage and the alignment of oil supply holes and if
abnormal or severe wears, replace it.
5) Make a hydraulic test to check for any cracks or air leaks.

Hydraulic test :
Stop up each outlet port of water and oil passages in the cylinder block, apply air pressure of about 5 kg/cm2
against the inlet ports, then immerse the cylinder block in water for about 1 minute to check any leaks. (Water
temperature: 70°C)

6.2.2. Cylinder liner measurement

● Assemble the cylinder liner at the cylinder
block and measure inner diameter at upper,
middle, lower that is, 3 steps by 45° interval
and calculate the average values after elim-
inating the maximum and minimum values.
● If the measured values are very close to the
limit value or beyond, replace it.

Standard Limit
Liner
ø127.990 ~ EFM2032I
inner dia. ø128.16 mm
ø128.010 mm

6.2.3. Cylinder head

● Carefully remove carbon from the lower face of the cylinder head using nonmetallic material to prevent
scratching of the valve seat faces.
● Check the entire cylinder head for very fine cracks or damage invisible to ordinary sight using a hydraulic
tester or a magnetic flaw detector.

- 75 - Disassembly and assembly of major components

 (1) Cylinder head disassembly

Note :
Be careful for the cylinder head gasket
contact face of the cylinder head not to be
damaged.

● Remove the cotter pin pressing the

Valve spring
valve spring by means of a special tool. compressor

EA0M4007

● Take out the valve stem seal.

● Pull out the intake and exhaust valves.
● Remove the valve guides from the com-
bustion room side of cylinder head by
means of a special tool.

EFM2034I

(2) Inspection and measurement of cylinder head

Inspection of cracks and damage

● Eliminate the carbon residue and gasket piece from the cylinder head lower face thoroughly. Then be
careful for the valve seat not to be damaged.
● For cracks or damages to search difficult may be inspected by a hydraulic test or a magnetic powder
test. (Hydraulic test is same as for cylinder block.)

Distortion of cylinder head bottom face

1) Distortion at the lower face
● Measure the amount of distortion
(t)
using a straight edge and a feeler
gauge at six positions as shown in
B
the right figure. A
● If the measured value exceeds the C
D
standard value, retrace the head with
grinding paper of fine grain size to
correct such defects. E
F
EA3M2031

Disassembly and assembly of major components - 76 -

 ● If the measured value exceeds the
maximum allowable limit, replace the
cylinder head.

<Lower face warp and height>

Standard Limit
War page 0.05 mm
0.2 mm
or less
EA6M2002
Thickness : t 113.9 ~
112.9 mm
(reference) 114.0 mm

(3) Inspection and measurement of valve and valve guide

a) Valve
● After cleaning the valves with clean
diesel oil, measure the valve as fol-
low.
Measure the valve stem’s outside
diameter at upper, middle, and lower
to determine the wears and when the Stem tip
wear limit is more than limit, replace
the valves.

Valve Standard Limit EFM2036I

ø11.969 ~
Intake ø11.949 mm
ø11.980 mm
ø11.944 ~
Exhaust ø11.914 mm
ø11.955 mm

● inspect the scratch and wear of valve

stem seal contacting face, and if nec-
essary correct with the grinding
paper but if severe replace it.
● If valve head thickness becomes less
than limit, replace the valve. A

Valve Standard Limit

Intake 4.6 ~ 5.0 mm 4.1 mm
EE1OM066
4.33 ~
Exhaust 3.83 mm
4.83 mm

- 77 - Disassembly and assembly of major components

 b) Check of valve guide
● Insert the valve into valve guide and
measure the clearance
between valve and valve guide by
the shaking degree of valve. If the
clearance is bigger, measure the
valve and then replace the more
worn valve guide.
● If the valve guide has already been
replaced, measure the center with
EA0M4052
valve seat if it deviates or not and if
abnormal it must be corrected.

Note :
Simultaneously be processed when in
guide reamer process.

Valve Standard Limit

Intake 0.020 ~ 0.049 mm 0.10 mm
Exhaust 0.045 ~ 0.074 mm 0.15 mm

c) Valve seat
● Visual inspection
Check if the exterior of the valve spring is damaged with the naked eye. Replace it with a new one
if required.
● Valve seat thickness and angle
Assemble the valves at the cylinder head and using the measuring instrument from the lower face,
measure the projection amount of valve. If the measured wear is excessive, replace the valve seat.

<Valve projecting amount>

Items Standard
Intake (A) 0.65 ~ 0.95 mm Valves
Exhaust (B) 0.65 ~ 0.95 mm
Valve seat

<Valve seat angle>

A
Items Standard
Intake (A) 60° B
EE1OM068
Exhaust (B) 45°

Disassembly and assembly of major components - 78 -

 ● The disassembly of valve seat cam
be pulled out by means of a special
Valve seat
tool with the arc welding done at two insert
points of valve seat rotating tool or
valve seat.
Cylinder head
● Regarding the valve seat assem-
bling, shrink the valve seat by putting
it in the dry ices for about 1 hour or
so, and then press it into the cylinder Welding bead
EA3M2032
head by means of a special tool.
● After coating the grinding powder
paste on valve head contacting face
of valve seat, and after executing a
sufficient lapping operation with the
rotating and grinding motion of valve,
wipe off the grinding agent thor-
oughly.

d) Valve spring
● Visual inspection
Check if the exterior of the valve
spring is damaged with the naked
eye. Replace it with a new one if
required.
● By means of spring tester, measure
the tension and free length.
● Measure the perpendicularity of
valve spring. EA3M2033
● In case that the measured value
exceeds the limit value, replace it.

<Dual spring perpendicularity regular>

Items Free length

Inside 65.5 mm
Spring
Outside 64 mm

- 79 - Disassembly and assembly of major components

 <Single spring perpendicularity regular - marine>
Items Free length
Intake/ Inside 72.43 mm
Exhaust Outside 67.17 mm

<Single spring perpendicularity regular - marine generator>

Items Free length
Intake/
Outside 61.9 mm
Exhaust

<Valve spring tension standard - marine>

Spring
Length Limit
tension
Items P1/P2 P1/P2
P1/P2
(mm) (kg)
(kg)
In 46.3/ 16.0/ ±1.0/
Intake/ side 32.3 29.5 ±2.5
Exhaust Out 46.8/ 39.0/ ±2.0/
side 32.8 71.5 ±5.0 Spring tester

EA0M4056

<Valve spring tension standard - marine generator>

Spring
Length Limit
tension
Items P1/P2 P1/P2
P1/P2
(mm) (kg)
(kg)
Intake/ Out 46.8/ 47.0/ ±2.5/
Exhaust side 32.8 90.5 ±4.5

● Squareness of valve spring: Measure

the sequareness of the valve spring
Inclination
with the surface plate and the right-
angle square. If the reading exceeds
the tolerance limit, replace the valve
Free length

spring.
<Marine>
Items Standard Limit
Square
Intake/ Inside/
1.8 mm 2.0 mm EJM2050I
Exhaust Outside

<Marine - marine generator>

Items Standard Limit
Intake/ Inside/
1.2 mm 2.0 mm
Exhaust Outside

Disassembly and assembly of major components - 80 -

e) Assembling cylinder head
● Clean the cylinder head thoroughly.
● Coat the valve stems and valve guides with engine oil and assemble the valves.
● Replace the valve stem seals with new ones and insert the stem seals to the valve guides of cylin-
der head with a special tool. (Be careful for the valve stem seals not to be damaged)
● Install the valve spring washer to valve guide.
● Put in the valve spring and then attach the valve spring plate on the springs.

Note :
Install the valve spring seat with Painted portion
″TOP″ (Painted in Dual spring - (Assemble spring
to the upper side)
Yellow / Single spring - red) side up.

EE1OM070

● Pressing the spring down with a spe-

cial tool, assemble by inserting the
valve cotter.
● After the valve is assembled, inspect
the valve tapping it lightly with an ure-
thane hammer if accurate assem-
bling was done.

EFM2040I

- 81 - Disassembly and assembly of major components

6.2.4. Rocker arm
1) Cylinder head disassembly
● Remove the snap rings in both ends of
rocker arm with a pair of pliers.
● Tear down washer, rocker arm.
● Disassemble the rocker arm bush by
means of a press.

EFM2091I

2) Inspection and measurement

a) Rocker arm bracket
(Single unit type with a shaft)
● Measure the outer diameter of rocker
arm bracket with outside micrometer
at the position that the rocker arm is
installed, and in case that it exceeds
the limit value, replace.

Standard Limit
Bush Inner ø25.005 ~ ø25.083 Diameter
Dia. ø25.035 mm mm
EA6M2003
Shaft ø24.967 ~ ø24.930
outer Dia. ø24.990 mm mm
0.015 ~
Exhaust 0.14 mm
0.068 mm

b) Rocker arm
● Inspect the rocker arm surface that
contacts with the valve stem for any
scratch, step wear and correct the
minor degree of wear with an oil
stone or the fine grinding paper and
replace if they are severe.

Disassembly and assembly of major components - 82 -

 c) Tappet and push rod
● By means of outside micrometer,
measure the outer diameter of tappet
and replace the severe ones.

Items Standard Limit (1)

(1) Unevenness
Unevenness (2)
(2) Crank
Crank (3)
(3) Normal
Normal
Tappet 0.035
0.15 mm
clearance ~ 0.077 mm

(4)
(4) Abnormal
Abnormal EA0M4070
EA0M4070

● By inspecting the tappet surface that

contacts with the camshaft′s cam for
any crack and scratch etc., and if the
degree is small, correct them with an
oil stone or the grinding paper but if
severe replace them.
● Place the push rod on the surface
plate and rolling it, Inspect the curv-
ing degree with a clearance gauge Feeler gauge
EA0M4073
and if abnormal, replace it.

<Run-out>

Limit 0.3 mm or less

d) Rocker arm reassembling

Inspect the oil passages of rocker arm and rocker arm bracket for any clogs and reassemble them
in the reverse order of disassembling after thorough cleaning.

6.2.5. Camshaft
(1) Axial end play
● Push the camshaft toward the pulley
side.
● Place a dial gauge onto the camshaft
gear.

EPM2016S

- 83 - Disassembly and assembly of major components

 ● Measure the camshaft's axial end play,
moving the camshaft gear by means of
a driver.

Items Standard Limit

End 0.24 ~
0.9 mm
play 0.86 mm

● If excessive end play, assemble it by EPM2017S

means of other thrust washer.

(2) Inspection and measurement

● Visual check
With inspecting the cam surface for any damage with naked eyes and correct any minor scratches by
means of an oil stone grinding and if severe, replace it.

● Cam lobe height

Use a micrometer to measure the cam
lobe height and journal diameter. If the
measured number is less than the spec-
ified limit, the camshaft must replaced.

Items Standard Limit

I II I II

Cam 56.032 A

Intake 56.370 mm
mm
C B B
lobe D A

height 56.091 EA0M4062

(C) Exhaust 56.430 mm mm
Cam Journal ø69.91 ~ ø69.560
Diameter (A, B) ø69.94 mm mm

● Cam bearing diameter

Measure the camshaft bush inside Camshaft bearing
diameter with a cylinder gauge and by
comparing the inside and outside diam-
eters, replace if abnormal

Items Standard Limit

ø70.070 ~
Thust ø69.464 mm
ø70.090 mm
EA0M4063
ø70.000 ~
Middle ø69.192 mm
ø70.030 mm

Disassembly and assembly of major components - 84 -

● Clearance
Between camshaft journal and body.

Items Standard Limit

0.060 ~
Thust 0.240 mm
0.120 mm
0.130 ~
Middle 0.240 mm
0.180 mm

● Camshaft bearing replacement

Replace the camshaft bearing with a
special tool.

Disassembly
& assembly tool
EF8OM058

● Camshaft run-out
With placing the camshaft on the 2 ea of
V-blocks, and inspect the run out of the
camshaft, adjust or replace the severe
one

Standard Limit
0.05 mm 0.15 mm

EF8OM059

● Cam lobe height

Use a micrometer to measure the cam lobe height and journal diameter.
If the measured number is less than the specified limit, the camshaft must replaced.

- 85 - Disassembly and assembly of major components

6.2.6. Crankshaft
(1) Inspection and measurement
● Inspect for any scratch or damage with
naked eyes, and grind to the undersize A
according to the damaged degree and
use the undersized bearing. B B
● Inspect for any crack by means of mag-
netic powder and color check, and A
replace the cracked ones.

EA3M2050

a) Journal and pin diameter

● With outside micrometer, measure
the outside diameter of crank journal
and crank pin at the direction and
position of the figure shown and take
the wear.

<Crankshaft journal outside diameter>

Standard ø103.98 ~ ø104.00 mm

<Crankshaft pin outside diameter>

Standard ø98.98 ~ ø90.00 mm 1 3 4

● In case that the lopsided wear is 2 2

more than the limit value, grind to the
3 4
undersize, and use the undersized 1
bearing.

EA0M4017
<kinds of bearings for undersize>
(a) Standard
(b) 0.10 (Inside diameter 0.10 mm less than standard)
(c) 0.25 (Inside diameter 0.25 mm less than standard)
(d) 0.50 (Inside diameter 0.50 mm less than standard)
(e) 0.75 (Inside diameter 0.75 mm less than standard)
(f) 1.00 (Inside diameter 1.00 mm less than standard)

Disassembly and assembly of major components - 86 -

 ● There are kinds as above, and the
crankshaft also can be used by "R"
regrinding as above.

"R"
<“R part” standard value>
1 Crank pin ′R′ : 4.0-0.5
0

"R" "R" "R"

2 Crank journal ′R′ : 4.0-0.5
0

Correct Incorrect Incorrect

EFM2048I

Note :
In case of crankshaft regrinding, the
″R part″ at the end of bearing must
accurately be ground without fail and
should avoid any processed jaw or
coarse surface

b) Run out of crankshaft

● Place the crankshaft on the V-block.
● Place the dial gauge on the surface
plate and measure the run out of
crankshaft rotating the crankshaft

Standard Limit
0.06 mm 0.4 mm

(2) Inspection on crankshaft bearing and

connecting rod bearing inspection
● Inspect the crankshaft bearing and con-
necting rod bearing for any damages
such as lopsided wear, scratch etc. and
if abnormal, replace it.
● Inspect the oil clearance between the
crankshaft and bearing.

- 87 - Disassembly and assembly of major components

 a) How to utilize the cylinder gauge
1 Assemble the main bearing at the
cylinder block and after tightening
the bearing cap at the specified
torque, measure the inside diame-
ter.

Journal bearing ø104.066 ~

standard diameter ø104.115 mm

Bearing cap Initial 30 kg.m +

bolt torque angle 90°

2 Assemble the bearing at the bigger

Section
end of connecting rod, and after A 10 A-B
tightening the bearing cap at the 10
specified torque, measure the
2 8
inside diameter. 1 3
8

Journal bearing ø90.056 ~

standard diameter ø90.098 mm
B
EFM2049I
Connecting rod Initial 30 kg.m +
bolt torque angle 90°

3 Assemble the bearing at the bigger end of connecting rod, and after tightening the bearing cap
at the specified torque, measure the inside diameter.

Standard Limit
0.056 ~ 0.118 mm 0.143 mm

b) How to utilize plastic gauge

1 Install the crankshaft in the cylinder block and place the plastic gauge on the crankshaft journal
and pin at axial direction and then after tightening the bearing cap at the specified torque and
again after tearing apart the bearing cap, measure the flatten plastic gauge thickness by pick it
up. This is the oil clearance.
2 With the same points, the oil clearance of connecting rod also can be measured.

Disassembly and assembly of major components - 88 -

 End play
● Assemble the crankshaft in the cylinder
block.
● Install the dial gauge, and measure the
end play of crankshaft by pushing the
crankshaft to axial direction.

Standard Limit
0.140 ~ 0.361 mm 0.4 mm
EFM2050I

6.2.7. Piston
(1) Piston disassembling
● Pull out the snap ring for piston pin and
with a pair of snap ring pliers.
● With a round bar, the piston pin.

EA3M2029

● With a pair of pliers, remove the piston

rings.
● Clean the piston thoroughly.

EFM2051I

(2) Inspection & measurement of the piston

● With naked eyes, inspect the piston for any wear, crack and scratch and particularly inspect carefully
at the ring grooves for any wear.

- 89 - Disassembly and assembly of major components

 ● With the outside micrometer, measure
the piston′s outside diameter the mea-
suring position is 71.5 mm from the pis-
ton lower end, and the direction of
measurement must be perpendicular to
the piston pin direction.

Standard ø127.739 ~ ø127.757 mm 71.5 mm

EA3M2045
● By comparing the measured value of the
piston outside diameter with the cylinder
liner inside diameter, the bigger clear-
ance is replaced.
● Measurement of cylinder bore
Assemble the cylinder liner at the cylin-
der block and measure inner diameter at
upper, middle, lower that is, 3 steps by 2

45° interval and calculate the average

values after eliminating the maximum
and minimum values.

Standard ø127.990 ~ ø128.010 mm

EAMD067I
● Measure the clearance between the cyl-
inder liner bore and the piston outer
diameter, if it is more than the use limit
value, replace either one that is more
severe.

Standard 0.233 ~ 0.271 mm

(3) Piston ring & ring groove

Inspection
In case of piston ring′s wear, damage or engine overhaul, replace piston rings.

Gap clearance
Measure the piston ring cut part.
● Insert the piston ring at the cylinder
liner′s upper part perpendicularly.
Filler gauge
● With a feeler gauge, measure the gap
clearance of piston ring.
● If the measured value exceeds the
limit value, replace it.

EA0M4033

Disassembly and assembly of major components - 90 -

 <Piston ring gap>

Division Standard Limit

Top ring 0.30 ~ 0.50 mm 1.5 mm
2nd ring 1.10 ~ 1.30 mm 1.5 mm
Oil ring 0.25 ~ 0.55 mm 1.5 mm

Piston ring groove clearance.

● Assemble the piston ring at the piston.
● Measure the each ring′s groove clear-
ance and if the measured value Feeler gauge
exceeds the limit value, replace rings
or piston.
<Piston side clearance>

Limit
Division Specified value
value
EA0M4032
Top ring 0.105 ~ 0.150 mm 1.5 mm
2nd ring 0.050 ~ 0.082 mm 0.15 mm
Oil ring 0.030 ~ 0.062 mm 0.15 mm

(4) Piston pin

Outside diameter
With the outside micrometer, measure the
piston pin′s outside diameter and if the
value is same as the use limit value or less,
replace it.

Standard Limit
ø45.994 ~ ø46.0 mm ø45.979 mm

EA0M4031
Piston pin & connecting rod bush clear-
ance
Inspect the clearance between the piston
pin and the connecting rod bush, if it is
more than the use limit value, replace either
one that is more severe.

Limit 0.055 ~ 0.071 mm

EA3M2047

- 91 - Disassembly and assembly of major components

 (5) Connecting rod
Distortion and parallel
Install the measurement tester as figure.
Measure the distortion of the bigger and
smaller end bearing holes after that do as
regard parallel of both holes and if abnor-
mal, replace the connecting rod.

Standard Limit
0.02 mm 0.2 mm
Feeler gauge
EA0M4034
Amounts of wear
● After assembling the connecting rod in the crankshaft measure the clearance between connecting
rod bigger hole and crank pin diameter using filler gauge.
● Assemble the connecting rod in the piston and then measure the clearance of these parts.
● If it is more than the use limit value, replace the connecting rod.

Standard Limit
0.02 mm 0.2 mm

(6) Piston reassembling

● After heating the piston at the piston
heater for about 5 min (120 ~ 150°C), by
aligning the piston pin hole with the pin
hole of connecting rod′s smaller end,
insert the oil coated piston pin.

Note :
Confirm the direction of connecting
rod and assemble.
EA3M2058

● With the snap ring plier, insert the snap rings of the piston pin.
● With confirming the upper side indication of piston ring, after assembling the ring in the piston ring
groove, inspect if the movement of ring is smooth.
● Arrange the assembled piston in order as the cylinder number.

Disassembly and assembly of major components - 92 -

6.2.8. Injection nozzle
● Set the nozzle assembly between the vise
holder and disassemble it.
● Remove the nozzle nuts and disassemble
the inner parts.
1 Nozzle holder body
● Inspect the disassembled parts if there is
any damage, replace it.
2 Cap nut
3 Adjusting shim
● Assembling can be done in the reverse
4 Compression spring
order of disassembling.
● After assembling the nozzle, set it in the 5 Spindle

injection pressure measuring tester.

6 Spacer
7 Nozzle nut

8 Nozzle
EFM2054I

● By manipulating the tester handle, inspect

the injection pressure and atomizing state.

<Operating pressure>

New nozzle holder 300 +8 kg/cm2

Used nozzle holder 285 +8 kg/cm2

EFM2056I

● In case of low or high injection pressure,

adjust by adding or reducing the spring ten-
sion adjusting shims.
● In case that atomizing state is not good, it
should be replaced.

Normal Abnormal Abnormal

EFM2057I

- 93 - Disassembly and assembly of major components

6.3. Engine Re-assembly

6.3.1. General preparation

● Clean all the disassembled parts, particularly oil and water ports, using compressed air, then check that
they are free from restrictions.
● Arrange the general and special tools in order for engine assembly operation.
● To wet each sliding part, prepare the clean engine oil.
● Prepare service materials such as sealant, gaskets, etc.
● Discard used gaskets, seal rings, and consumable parts, and replace with new ones.
● Apply only the specified torque for bolts in the specified tightening order and avoid over-tightening.
● Be sure to check that all the engine parts operate smoothly after being reassembled.
● Check the bolts for looseness after preliminary re-assembly.
● After completing the engine re-assembly operation, check if there is missing parts or shortage of parts.
● Keep your hands clean during the working.

6.3.2. Cylinder block

Cover the floor of the workshop with wood plate or thick paper to prevent damage to the cylinder
head and place the head face of the cylinder block towards downward.

6.3.3. Cylinder liner

● Replace the used O-rings with new ones
and insert the O-ring in the cylinder liner
upper side, but the other one in the cylinder
block lower side separately.
● Coat the joint parts where O-ring contacts
with oil.
● After slipping the cylinder liner smoothly
into the cylinder block, press it in being
careful for O-ring not to damage.
EA6M2008
● After completion of assembling the cylinder liner, confirm no leaks with 4 kg/cm2 hydraulic test.

Disassembly and assembly of major components - 94 -

6.3.4. Oil spray nozzle
● Assemble the oil spray nozzle.
● Tighten the fixing bolts.

6.3.5. Tappet
Coat the tappet wholly with clean oil and push
in the tappet hole of the cylinder block.

EAMD072S

6.3.6. Crankshaft
● Put the wear ring into the heater to heat it
up to 150 ~ 200°C level, push it over the
crankshaft by means of a jig.

Wear ring
EA6M2009

● Assemble the main bearing to the cylinder

block and coat it with engine oil. Then
assemble the bearing that has a hole to the
cylinder block side and one that has no hole
to the bearing cap and be careful not to
change.

EFM2060I

- 95 - Disassembly and assembly of major components

 ● Assemble temporarily one bolt each at both
bolt holes and by connecting the wire to the
bolts, lift it with crane or chain block and put
down on the cylinder block carefully.
7 5 3 1 2 4 6
● Coat the crankshaft journal and pin parts
with engine oil, and after fitting the main
bearing into the bearing cap and assemble
it to the cylinder block making sure of the
number in order not to change the bearing
EFM2061
cap.

● According to the tightening order,

tighten the bearing cap bolts with 30 kg.m and with rotating angle method (90° +10°) and tight-
ening order are as follows.

< Bearing cap bolt's tightening order >

(1) First step : screw down 1 ~ 2 threads.
(2) Second step : tighten with a bout
15 kg.m by wrench.
(3) Third step : tighten with a bout 25 kg.m
by torque wrench.
(4) Fourth step : tighten with 30 kg.m by
torque wrench.
(5) Fifth step : tighten with final rotating
angle method 90° +10°.
However, according to above tighten-
EFM2062I
ing order, tighten step by step.

● Inspect if the crank shaft's rotation is smooth.

● Assemble the crankshaft gear on the crankshaft and coat a white paint mark on ″1″ part in order to
find easily.

6.3.7. Camshaft
● Coat the cam bush of cylinder block and
camshaft with engine oil.
● Assemble the cam bush and camshaft for
them not to be damaged.
● Assemble the crankshaft gear and the cam-
shaft gear making sure that the gear marks
1
on both gears are aligned together. 1 1

EFM2063I

Disassembly and assembly of major components - 96 -

6.3.8. Flywheel housing
● Coat the thrust washer fixing bolt with an
adhesive and tighten it with specified
torque.

Torque 3.1 kg.m

EFM2065I

● Coat the oil seal with lubricating oil and

assemble it carefully not to be deviated or
damaged by means of special tool. (Man-
drel for assembling).
● Attach the gasket on the surface of cylinder
block where the flywheel housing is to be
installed. (In order to prevent the gasket slip
down, coat a grease on the cylinder block
surface.)
EA6M2010
● Temporarily assemble 2ea of guide bolts for
installing the flywheel housing to the cylin-
der block.
● After fitting the flywheel housing holes to the guide pins and engage temporarily 2 ~ 3 threads of fixing
bolts, and according to the tightening order (zigzag method) tighten them in the specified torque.

Torque 7.5 kg.m

6.3.9. Tacho sensor

● Loosen the lock nut to hexagonal side of
sensor.
● Rotate (CW) the tacho-sensor on fly wheel
housing, until the end of it reach on fly
wheel ring gear as figure.
● Rotate (CCW) the tacho-sensor for 270°
(gap: about 1.0 mm) and fix the lock nut.
● Tolerance limit is 27° (gap ±0.1 mm)

- 97 - Disassembly and assembly of major components

6.3.10. Flywheel
● Installation of flywheel ring gear With a gas
burner, heat the ring gear evenly until heat
expansion takes place, then install it using
a hammer.
Do not allow the temperature of the
ring gear to exceed 200°C (390°F).

EA0M4029

● By means of mandrel, press in the wear

ring at the backward face.
● Install two guide bolts for installing the fly-
wheel to the crankshaft.

Wear ring Ring gear

EA6M2004

● After letting the guide pin insert through the

flywheel holes and engaging the fixing
bolts by 2 ~ 3 threads temporarily, tighten
them to the specified torque according to
lightening order. (Zigzag order) 9
4 7
5
2 1
6 10
8 3
Torque 26 kg.m

Lubricate with engine oil

EA6M2005

6.3.11. Oil cooler

● Attach a gasket on the surface in the oil
cooler housing where the oil cooler is
installed.
● Tighten the oil cooler with fixing bolts.
● Install the oil cooler assembly by tightening
the fixing bolts in the zigzag order.

M8 3.1 kg.m
Torque
M10 5.5 kg.m
EFM2067I

Disassembly and assembly of major components - 98 -

6.3.12. Heat exchanger
● Assemble 4ea of fixing bolts.
● Assemble the heat exchange tube.
2-baffle side of the heat exchange
tube should be installed upward.

● Assemble the cover bolts.

Be careful to install O-ring and gasket

properly.
EFM2017I
● Assemble the connecting hoses and pipes.

6.3.13. Starting motor

● Install stud bolts at the bolt holes on the fly-
wheel housing for installing the starter.
● Insert the starter into the flywheel housing
and tighten the fixing bolts.

EFM2008I

6.3.14. Piston
● Coat the pistons and connecting rod bear-
ings sufficiently with clean engine oil. 120 O

● By means of a special tool, insert the piston 2nd ring gap Top ring gap
rings and adjust the angles between the Piston pin
ring gaps at 120° as right figure.
● Push in the piston with hands or wooden
bar into cylinder. (Be careful for piston and 120 O
120O

rings not to be damaged.) Piston

Oil ring gap
EFM2069I

- 99 - Disassembly and assembly of major components

 ● Pushing the piston down, rotate the crank-
shaft about 180° and fit the bearing cap to Top ring
the connecting rod.
● After engaging 2 - 3 threads of bolts primar- 2nd ring

ily rind then tighten them.

Oil ring

EA6M2006

<Connecting rod bolt tightening order>

(1) First step : Engage 2 - 3 threads by hands.
(2) Second step : Tighten to about 7 kg.m with wrench.
(3) Third step : By means of torque wrench tighten to 10 kg.m.
(4) Fourth step : Finally assemble by means of rotation angle method 90°+10°.
However, according to above tightening order, tighten them step by step.

* Standard length of bolt and use limit:

(from head seat to bolt tip)

Standard length Use limit

67.5 -0.3 mm 69 mm

● By moving the connecting rod bearing cap

by hands, make sure if there is any play in
left and right.
● With same ways as above, assemble in
each cylinder rotating the crankshaft.

EFM2070I

6.3.15. Front oil seal holder

● After placing the oil seal in the oil holder
hole properly, press it in with a mandrel. (Be
careful for oil seal not be damaged.)
● Attach the gasket at oil seal holder.
● Align the dowel pin with the oil seal holder
dowel hole and assemble them by tapping
lightly the dowel pin part with an urethane
hammer.
EFM2073I

Disassembly and assembly of major components - 100 -

 When in assembling, take care not to hurt the oil seal by the crankshaft.

Note :
Without coating the oil seal with oil or lubricant, assemble it in the dry state.

● Tighten the fixing bolts in the zigzag method.

6.3.16. Vibration damper

● Assemble the vibration damper tightening
firstly by the crankshaft pulley and the fix-
ing bolts.
● Insert the crankshaft pulley assembly to the
crankshaft and tighten the fixing bolts in the
method of zigzag to the specified torque.

Torque 21 kg.m

EFM2092I

6.3.17. Oil pump

● Put the oil pump at the place to be installed
on the cylinder block.
● Attach the gasket at the surface of oil pump
where the pressure regulating valve is to
be installed and place the regulating valve
on the gasket.
● Assemble the oil pump by tightening the
fixing bolts.
● Attach the gasket at the surface of the oil EFM2074I
pump where the oil suction pipe is to be
installed, and install the oil suction pipe by
tightening the fixing bolts.
● Assemble the pipe bracket on the cylinder block side with bolts.

6.3.18. Oil pan

● Clean thoroughly the gasket that is project-
ing at the junction parts of front oil seal
holder and flywheel housing of cylinder
block′s lower face with a scraper. In the
process of gasket removal, be careful for
the gasket pieces not to get into the engine
inside.
● Attach the gasket to the cylinder block.
EFM2075I

- 101 - Disassembly and assembly of major components

 ● Install the oil pan and tighten the fixing bolts. T h e n take care not to squeeze out the gasket.
● Install the guide tube and insert the oil level gauge.

6.3.19. Cylinder head

● Blow the cylinder head bolt holes with com-
pressed air to remove the foreign material
cleanly.
● Wipe off cleanly the junction part of cylinder
block's head gasket.
● After confirming whether there is foreign
material or not necessarily, if there is,
remove it.
● Assemble a gasket fitting with the fixing pin EFM2076I
of cylinder block.
● Fit the cylinder head assembly on the cylin-
der block aligning with its dowel pin. (Take
care not to damage the head gasket.)
● Tighten the cylinder head bolts to the specified torque according to step by step.
However, prior to tightening the bolts, with a long steel rule, the parallel between the cylinder heads must
be adjusted.
< Cylinder head bolts tightening order >
(1) First step: Tighten temporarily 1 - 2
Intake side(Spark plug)
threads by hands.
1

(2) Second step: Tighten to a bout 8 kg.m

with wrench. 6 3

(3) Third step: Tighten to 15 kg.m with a

torque wrench.
(4) Fourth step: Rotate 90° by rotation
4 5
angle method .
2
(5) Fifth step: Finally tighten additionally
Exhaust side EFM2077I
rotating 90°.

* Standard length of bolt and use limit:

from the head seat face to tip

Bolt No. Standard length Use limit

3, 6 168 mm 171 mm
2, 4, 5 144 mm 147 mm
1 109 mm 112 mm

Take care for the foreign material not to get into the cylinder head suction passages.

Disassembly and assembly of major components - 102 -

6.3.20. Nozzle
Put the new seal ring in nozzle hole of the cyl-
inder head and after inserting the nozzle
assembly, tighten it to assemble However,
coat the nozzle outer part with the stuck pre-
venting agents and assemble it.

EFM2090I

6.3.21. Rocker arm

● Coat the push rod with engine oil and put it
into the push rod hole.
● Make a position the rocker arm assembly
on the cylinder head and tighten the fixing
bolts to the specified tightening torque.

Torque 6.2 kg.m

● Adjust the valve clearance.

EFM2091I
Regarding the adjustment, refer to the reg-
ular maintenance part.

- 103 - Disassembly and assembly of major components

6.3.22. Valve clearance adjust procedure
Method 1
1) Rotate the crankshaft so that #1. cylinder may be positioned at the compression TDC (Top Dead Cen-
ter).

Note :
#1. Cylinder is located at the side where cooling water pump was installed.
In case of 8/12 cylinder engine, #6. cylinder is positioned at the valve overlap when #1. cylinder is
positioned at the compression TDC (Top dead center).
In case of 10 cylinder engine, #7. cylinder is positioned at the valve overlap when #1. cylinder is
positioned at the compression TDC (Top dead center).

Cooling fan
7
1
6 8
1 2
5 7 9 12
1 2 11 3
10
6 8 10 10 9

8
2 9 3 8
7
4
7 8
7 6
9
7
6 11 6
5
5
4
3 5 4 4 5
3 4 3
8 2
10
3 12 2
1 4 2
1 5 1 6

Flywheel
8 Cylinder engine 10 Cylinder engine 12 Cylinder engine

EA6O6008

2) Loosen the lock nut of the #1. cylinder

rocker arm.
3) Push the feeler gauge between a rocker
arm and a valve stem.
4) Adjust the clearance screw respectively
and then tighten with the lock nut.

2 3
1 EDV2218007

5) As for the valve clearance, adjust it when in cold, as follows.

Specified Value Measurement Tolerance

In. Valve Ex. Valve In. Valve Ex. Valve
0.25 mm 0.35 mm ±0.05 mm

6) Rotate the crankshaft. When a cylinder reaches the compression TDC (Top Dead Center), adjust the
valve clearance of the cylinder

Disassembly and assembly of major components - 104 -

 7) When a cylinder valve overlap, adjust the valve clearance cylinder of the compression TDC (Top Dead
Center), as follow.
* 8 cylinder engine (V158TI/AD158TI)

Valve overlap cylinder No.

1 5 7 2 6 3 4 8
6 3 4 8 1 5 7 2
Adjusting Valve Cylinder No. (In./Ex. Valve)

* 10 cylinder engine (V180TI/AD180TI)

Valve overlap cylinder No.

1 6 5 10 2 7 3 8 4 9
7 3 8 4 9 1 6 5 10 2
Adjusting valve cylinder No. (In./Ex. Valve)

* 12 cylinder engine (V222TI/AD222TI)

Valve overlap cylinder No.

1 12 5 8 3 10 6 7 2 11 4 9
6 7 2 11 4 9 1 12 5 8 3 10
Adjusting valve cylinder No. (In./Ex. Valve)

6.3.23. Cylinder head cover

● Attach the new gasket on the surface of
cylinder head where the cover is to be
installed.
● Assemble the cylinder head cover by tight-
ening the fixing bolts.
● Insert the oil filler cap.

EFM2020I

- 105 - Disassembly and assembly of major components

6.3.24. Fuel injection pump
● Turn the crankshaft so as to let the cylinder
No. 6 for V158TI, AD158TI, V222TI,
AD222TI engines and the cylinder No. 7 for
V180TI, AD180TI come to the overlap TDC
(Top Dead Center).
● Rotate the crankshaft to reverse about 30°
(in order to remove a backlash) and then
rotate it to engine rotating direction to set
the fuel injection timing angle.
EFM2071I
● Coat the O-ring with grease and insert it at
the lower part of fuel injection pump.
(Be careful O-ring not to be removed)
● Prior to install the fuel pump drive gear, fit the rubber gasket first.
● Tighten temporarily the fuel injection pump drive gear with aligning the pointer on drive gear with injection
pump pointer.

● Fit the injection pump in the appropriate

position using a special tool.(Special tool
No. : EF120-189)

EB2O3008

● After fixing the jig hole on the limit cap of

the injection pump rotate the jig counter-
clockwise and align the jig pin to the
machined corner of the cylinder block, then
assemble the injection pump.
● After completing the preparation for injec-
tion pump assembling, install the injection
pump and tighten the bolts in the zigzag
method.
EFM2071I
● After assembling the injection pump,
find out whether the injection pump pointer and drive gear′s pointer is aligned, and if aligned, tighten the
fixing bolts that were temporarily tightened. However, if not aligned, loosen the fixing bolts and turn the
fuel pump so as to align the pointers then tighten the fixing bolts.
In case of exchange the injection pump, should fill the engine oil in the governor of the injection
pump before the engine running.

Disassembly and assembly of major components - 106 -

 <Oil quantity of the injection pump>

V158TIE/V158TI V180TI V222TI

0.95 liter 1.1 liter 1.3 liter

6.3.25. Injection timing

<How to check the injection timing>
● Check the current injection timing of the
engine as follows before adjusting it but if
the injection timing is wrong should do it.

1) Remove the plug screw assembled in

case cover on the injection pump drive
gear.(Some cases are needed to
remove cover assembly)
And turn the crank pulley so that the
mark on pointer provided on injection
pump coincides with matching mark
FB
(FB) on the flange surface of the drive
gear. Flange
EBO4012I Pointer

2) Check the injection timing degree

whether the V-type edge of the flywheel
housing sight hole coincides with the
engine injection timing degree marked
on the flywheel corresponding to fuel
delivery position.
15

EBO4014I

- 107 - Disassembly and assembly of major components

 <How to adjust injection timing>
● If upper pre-checked injection timing
degree is wrong, follow as below.
1) Loosen the fixing bolts(M8) of the injec-
tion pump driving gear in order to adjust
the injection timing slightly.
2) Turn the crank pulley clockwise until V-
groove of the flywheel housing sight hole
is aligned with the injection timing
degree of the engine EBO4016I

3) Coincide the mark on pointer provided in injection pump with the matching mark (FB) on the flange
surface of the drive gear by turning the flange in the oblong holes of the drive gear.
4) Tighten the bolt (M8) to specified torque. (2.2 kg.m) not to move the drive gear
5) After confirmation that fastening bolts are completely tightened check the start point (injection timing
degree) of fuel delivery setting once more if not right repeat it again as same as upper way.

<Fuel injection timing degree>

V158TI V158TI V180TI V222TI

26° 24° 24° 24°

6.3.26. Flywheel housing cover

● Attach the gasket to the flywheel housing
cover.
● Install the flywheel housing cover and
tighten the fixing bolts by zigzag method.

EFM2072I

6.3.27. Oil filter

● Install the oil filter cartridge.

EFM2079I

Disassembly and assembly of major components - 108 -

6.3.28. Oil centrifugal filter
● Assembling is done in the reverse order of
disassembling and take care at the state of
O-ring installation.
● At the engine operation, make sure the
smooth operation and no oil leaks from all
the engine connections.
● Tighten the housing lock nut to specified
torque.

Torque 1.5 kg.m EFM2080I

6.3.29. Fresh water pump

● Attach the gasket of the fresh water pump.
(at cylinder block side)
● Assemble the fresh water pump by tighten-
ing the fixing bolts. (zigzag method)
● Insert the thermostat of fresh water pump.
● Insert the O-ring to the thermostat and
assemble the cooling water pipes by tight-
ening the fixing bolts.
EFM2081I

6.3.30. Intake manifold

● Attach the new gasket to the cylinder head
side.
● Assemble the intake manifold by tightening
the fixing bolts.
● Attach the gasket to the inlet flange and
assemble by tightening the fixing bolts.
● Assemble both sides by the above method.
● Attach the gasket to the equalizing pipe
that connects the intake manifolds of both EFM2082I
sides and assemble both manifolds by
tightening the fixing bolts.

- 109 - Disassembly and assembly of major components

6.3.31. Exhaust manifold
● Prior to assembling the exhaust manifold,
attach the gasket firstly to the cover and
elbow exhaust pipe and assemble them to
the engine block tightening the bolts evenly
as the right figure.

EFM2084I

● Attach new gaskets to the exhaust mani-

fold and then assemble the exhaust mani-
fold with the fixing bolts.
● Attach the gasket to the exhaust elbow that
is connected to the exhaust manifold, and
assemble the elbow by tighten the nuts for
connection.

Be careful not to drop the manifold

EFM2083I
because it is very heavy.

6.3.32. Inter-cooler
● After assembling the inter-cooler fixing
bracket on the engine cylinder block,
assemble the inter-cooler with the fixing
bolts.
● Assemble the various hoses and pipes.

EFM2014I

6.3.33. Turbocharger
● Attach the gasket to the exhaust elbow and
assemble the turbocharger with fixing bolts.
● Attach the gasket on the oil supply and the
discharge pipe and then assemble the
pipes with fixing bolts.
● At the same way as above, other side can
be assembled.

EB2M3004

Disassembly and assembly of major components - 110 -

6.3.34. Fuel injection pipe
● Connect the fuel injection pipes to the fuel
injection pump and the nozzle respectively
and then assemble them by tightening
nuts.
● Assemble the fuel return pipes by tighten-
ing fixing nuts.

EFM2087I

6.3.35. Fuel filter

● After installing the fuel filter in the bracket
and assemble the fuel inlet and outlet
hoses.
● Check the fuel adjusting cock whether its
position is placed as figure in order to use
both filters all the time.

EB2M2001

6.3.36. Alternator
● Assemble the alternator bracket to the
lower part of cylinder block by tightening
the fixing bolts.
● Install the alternator supporting plate.
● Connect the crankshaft and the alternator
and water pump pulleys with V-belts by
inserting them into the respective pulleys.
● Adjust the alternator support nut until the
belt tension can be 10 mm ~ 15 mm by
EFM2002I
pushing with thumb.

- 111 - Disassembly and assembly of major components

6.3.37. Idle pulley
● Install the idle pulley.
● Connect the water pump, the crank and the
idle pulleys with driving V-belts.
● Tighten eye bolt and nut. (10 mm ~ 15 mm
or so pushing with a thumb).

EFM2089I

6.3.38. Sea water pump

● Assemble the sea water pump.
● Assemble the sea water filter on the inlet
flange of sea water pump.
● Adjust the V-belt tension.

EFM2001I

6.3.39. Heat Exchanger

● Assemble the heat exchanger bracket in
the cylinder block.
● Install the heat exchanger on the bracket.
● Connect the inlet & outlet pipe of the heat
exchanger.

EDV2218161

Disassembly and assembly of major components - 112 -

6.4. Trial Test after Maintenance
Because the sliding surfaces of a maintenance engine are not lapped enough, the oil film can be destroyed
easily by overload or over-speed and the engine life-time may be shortened. Therefore the following things
must be obeyed by all means. (Refer to 3.3)

Up to the first 50 hours

● Engine should be run at fast idling (1,000 ~ 1,200 rpm) until the temperature of the engine becomes nor-
mal operating condition.
● Overload or continuous high speed operation should be avoided.
● High speed operation with no load should be prevented.
● Abrupt start and stop of the engine should be avoided.
● Engine speed must be under 70% of its maximum speed.
● Maintenance and inspection must be accomplished thoroughly.

- 113 - Disassembly and assembly of major components

Disassembly and assembly of major components - 114 -
7. MAIN PARTS MAINTENANCE

7.1. Lubricating System

Lubricating oil pumped by the gear oil pump in the oil pan is filtrated in the oil filter.
This filtrated oil passed on the oil cooler and next the main oil gallery of the cylinder block where is distributed
to lubricate the various sliding parts, fuel injection pump, and turbo-charger etc also in order to ensure normal
engine performance.

7.1.1. Specifications

Item Specifications Item Specifications

Forced pressure Adjusting valve for spray
Lubricating system 1.5 ~ 1.8 kg/cm2
circulation nozzle opening pressure

Oil pump type Gear type Oil filter type Full flow

Relief valve opening pressure 10 - 1.0 kg/cm2 Bypass for filter element Cartridge type

Bypass for oil cooler opening

5 ±0.5 kg/cm2
pressure

7.1.2.Oil pump

7
5

0.5

1
4

EB4O7001

1. Oil Pump Housing 4. Oil Pump Gear

2. Cover 5. Oil Pump Drive Gear
3. Oil Pump Gear 6, 7. Bolts

- 115 - Main parts maintenance

7.2. Cooling System

7.2.1. Fresh water pump assembly

Impeller

Cover

þ137
Spline shaft

Mechanical seal
Hub
Oppression
Rubber seal

Pump housing

EDV2218164

7.3. Fuel System

7.3.1. Injection pump

The components relating to the injection pump should be serviced at regular intervals as the plunger and
delivery valve may be worn after a given length of time for use and cause the deterioration of the engine.

Make sure that servicing should be performed at the professional maintenance

shop as authorized by Bosch or Zexel Company.

For adjustment of fuel injection volume, refer to the ′Specifications of fuel injection pump′ described as fol-
lows.

Main parts maintenance - 116 -

1) V158TIH
(1) Main data and specifications

Model : PE8P120A520LV
Injection pump : 65.11101-7680
Governor : RQV 300/900
Plunger : 2 418 455 188
Delivery valve : 2 418 552 039
Pre-stroke : 4.50 ±0.05 mm
Injection timing : BTDC 15 ±1°
Injection order : 1-5-7-2-6-3-4-8
Fuel feed pump : 0 440 008 152 (FP/KD22P78-2)
Rotating direction : C.C.W. at driving gear side

(2) Calibration data

Nozzle & Holder ass′y 1 688 901 019 Opening pressure : 208.5 bar
(A) Test condition
Injection pipe (OD, ID, L) 1 680 750 075 ø8.0 x ø3.0 - 1,000 mm
for injection pump
Test oil ISO4113 Temperature : 40 ±2°C
65.10101-7053 Nozzle (5 × ø0.418)
Nozzle & Holder Ass′y
(B) Engine standard parts 0 432 131 669 Spec. : 280 bar
Injection pipe (OD, ID, L) ø6 x ø2.0 - 750 mm
Rack diagram and setting valve at each point
Pump Injection Q′ty on RIG (mm3 /1,000st)
Check Rack position Press.
speed (A) Test condition
point (mm) Remarks (mmHg)
(rpm) for inj. pump
V1 11.20 ±0.05 900 235.4 ±3.0 Max. power 1,500
Refer to
V2 11.20 ±0.10 700 230.4 ±3.0 - 1,500
(3) rack diagram
VS 8.96 ±0.20 500 159.8 ±1.0 - 0
LQ 6.15 ±0.20 350 53.7 ±15.0 Only 2/3/4/8 0
A3 7.10 ±0.50 1,010 109.4 ±15.0 Only 2/3/4/8 0
ST with Cap 100 127.5 ±10.0 Only 2/3/4/8 0
Boost pressure dependent full -load stop (boost compensator spring operation point)
Pump Injection Q′ty on RIG (mm3 /1,000st)
Check Rack position Press.
speed (A) Test condition (B) Engine
point (mm) (mmHg)
(rpm) for inj. pump standard parts
Refer to
P1 11.20 ±0.05 500 - - 1,500
(4) boost pressure
P2 8.96 ±0.05 500 - - 0
P3 9.25 ±0.10 500 275
P4 10.38 ±0.05 500 - - 450
Weight Weight =630g Lever ratio (min/max) Not fixed
Idle spring k=14.03N/mm Plunger ø12
Middle spring k=57.14N/mm Delivery valve retraction volume 90 mm3/st
Inner spring None Delivery valve opening pressure -
LDA spring k=30.50N/mm Delivery valve spring k = 7.2N/mm
Feed spring Double action Timer None

- 117 - Main parts maintenance

(3) Rack diagram

12 V2 V1

10 VS
RACK POSITION (mm)

LQ
6
A3
4

0
0 200 400 600 800 1000 1200
ENGINE SPEED (rpm)
EB2M5001

(4) Boost compensator pressure

12
P1

10 P4
RACK POSITION (mm)

P2
P3

4
0 200 400 600 800 1000 1200

EB2M5002

Main parts maintenance - 118 -

2) V158TIM
(1) Main data and specifications

Model : PE8P120A520LV
Injection pump : 65.11101-7680
Governor : RQV 300/900
Plunger : 2 418 455 188
Delivery valve : 2 418 552 039
Pre-stroke : 4.50 ±0.05 mm
Injection timing : BTDC 16 ±1°
Injection order : 1-5-7-2-6-3-4-8
Fuel feed pump : 0 440 008 152 (FP/KD22P78-2)
Rotating direction : C.C.W. at driving gear side

(2) Calibration data

Nozzle & Holder ass′y 1 688 901 019 Opening pressure : 212.6 bar
(A) Test condition
Injection pipe (OD, ID, L) 1 680 750 075 ø8.0 x ø3.0 - 1,000 mm
for injection pump
Test oil ISO4113 Temperature : 40 ±2°C
65.10101-7053 Nozzle (5 × ø0.418)
Nozzle & Holder ass′y
(B) Engine standard parts 0 432 131 669 Spec. : 285.5 bar
Injection pipe (OD, ID, L) ø6 x ø2 - 750 mm
Rack diagram and setting valve at each point
Pump Injection Q′ty on RIG (mm3 /1,000st)
Check Rack position Press.
speed (A) Test condition
point (mm) Remarks (mmHg)
(rpm) for inj. pump
V1 12.00 ±0.05 1,050 266.0 ±3.0 Max. power 1,500
Refer to
V2 12.00 ±0.10 800 266.0 ±3.0 - 1,500
(3) rack diagram
VS 8.96 ±0.20 500 159.8 ±1.0 - 0
LQ 6.15 ±0.20 350 53.7 ±15.0 Only 2/3/4/8 0
A3 7.10 ±0.50 1,150 109.4 ±15.0 Only 2/3/4/8 0
ST with Cap 100 127.5 ±10.0 Only 2/3/4/8 0
Boost pressure dependent full -load stop (boost compensator spring operation point)
Pump Injection Q′ty on RIG (mm3 /1,000st)
Check Rack position Press.
speed (A) Test condition (B) Engine
point (mm) (mmHg)
(rpm) for inj. pump standard parts
Refer to
P1 12.00 ±0.05 500 - - 1,500
(4) boost pressure
P2 8.96 ±0.05 500 - - 0
P3 9.25 ±0.10 500 275
P4 11.20 ±0.05 500 - - 600
Weight Weight =630g Lever ratio (min/max) Not fixed
Idle spring k=14.03N/mm Plunger ø12
Middle spring k=57.14N/mm Delivery valve retraction volume 90 mm3/st
Inner spring k=21.98N/mm Delivery valve opening pressure -
LDA spring k=30.50N/mm Delivery valve spring k = 7.2N/mm
Feed spring Double action Timer None

- 119 - Main parts maintenance

(3) Rack diagram

X[
}Y }X
XY

XW }z
RACK POSITION (mm)

_
sx hZ
]

W
W YWW [WW ]WW _WW XWWW XYWW X[WW
ENGINE SPEED (rpm)
EB2M5003

(4) Boost compensator pressure

14
P1
12
RACK POSITION (mm)

P4
10 P2
P3

0
0 200 400 600 800 1000 1200 1400

EB2M5004

Main parts maintenance - 120 -

3) V158TIL
(1) Main data and specifications

Model : PE8P120A520LV
Injection pump : 65.11101-7680
Governor : RQV 300/900
Plunger : 2 418 455 188
Delivery valve : 2 418 552 039
Pre-stroke : 4.50 ±0.05 mm
Injection timing : BTDC 18 ±1°
Injection order : 1-5-7-2-6-3-4-8
Fuel feed pump : 0 440 008 152 (FP/KD22P78-2)
Rotating direction : C.C.W. at driving gear side

(2) Calibration data

Nozzle & Holder ass′y 1 688 901 019 Opening pressure : 212.6 bar
(A) Test condition
Injection Pipe (OD, ID, L) 1 680 750 075 ø8.0 x ø3.0 x 1,000 mm
for injection pump
Test oil FUSUS Temperature : 40 ±5°C
65.10101-7053 Nozzle (5 × ø0.418)
Nozzle & Holder ass′y
65.10102-6070 Spec. : 285.5 bar
(B) Engine standard parts
65.10301-6053A
Injection pipe (OD, ID, L) ø2.0 x ø6.35 x 750 mm
65.10301-6054A
Rack diagram and setting valve at each point
Pump Injection Q′ty on RIG (mm3 /1,000st)
Check Rack position Press.
speed (A) Test condition
point (mm) Remarks (mmHg)
(rpm) for inj. pump
RP 14.02 1,150 362.3 - 1,500
Refer to
ABT 14.06 500 447.5 - 1,500
(3) rack diagram
ZBT 8,39 500 204.4 - -
HS 4,76 1,320 91.5 - -
LS 4,00 350 50.0 - -
ST W/CAP 100 180.0 - -
Boost pressure dependent full -load stop (boost compensator spring operation point)
Pump Injection Q′ty on RIG (mm3 /1,000st)
Check Rack position Press.
speed (A) Test condition (B) Engine
point (mm) (mmHg)
(rpm) for inj. pump standard parts
Refer to
P1 8.39 500 0
(4) boost pressure
P2 8.39 - 300
P3 14.06 - 1,150
P4 14.06 - 1,500
Weight Weight =630g Lever ratio (min/max) Not fixed
Idle spring k=14.03N/mm Plunger ø12
Middle spring k=57.14N/mm Delivery valve retraction volume 90 mm3/st
Inner spring k=21.98N/mm Delivery valve opening pressure -
LDA spring k=30.50N/mm Delivery valve spring k = 7.2N/mm
Feed spring Double action Timer None

- 121 - Main parts maintenance

(3) Rack diagram

16

14 ABT RP

12

10
ZBT
8

6
HS
4 LS

0
0 500 1000 1500

EDV2218074

(4) Boost compensator pressure

16

15
P3 P4
14

13

12

11

10

9
P1
8 P2
7

6
0 500 1000 1500 2000 2500

EDV2218075

Main parts maintenance - 122 -

4) V180TIH
(1) Main data and specifications

Model : PE10P120A520LV
Injection pump : 65.11101-7681
Governor : RQV 300/900
Plunger : 2 418 455 188
Delivery valve : 2 418 552 039
Pre-stroke : 4.50 ±0.05 mm
Injection timing : BTDC 16 ±1°
Injection order : 1-6-5-10-2-7-3-8-4-9
Fuel feed pump : 0 440 008 152, 0 440 008 090 (FP/KD22P78-2, KP/KD22P80-1)
Rotating direction : C.C.W. at driving gear side

(2) Calibration data

Nozzle & Holder ass′y 1 688 901 019 Opening pressure : 208.5 bar
(A) Test condition
Injection pipe (OD, ID, L) 1 680 750 075 ø8.0 x ø3.0 - 1,000 mm
for injection pump
Test oil ISO4113 Temperature : 40 ±2°C
65.10101-7053 Nozzle (5 × ø0.418)
Nozzle & Holder ass′y
(B) Engine standard parts 0 432 131 669 Spec. : 280 bar
Injection pipe (OD, ID, L) ø6 x ø2.0 - 750 mm
Rack diagram and setting valve at each point
Pump Injection Q′ty on RIG (mm3 /1,000st)
Check Rack position Press.
speed (A) Test condition
point (mm) Remarks (mmHg)
(rpm) for inj. pump
V1 11.55 ±0.05 900 244 ±3.0 Max. power 1,500
Refer to
V2 11.55 ±0.10 700 242 ±3.0 - 1,500
(3) rack diagram
VS 9.20 ±0.20 500 162 ±1.0 - 0
LQ 6.10 ±0.20 350 48 ±15.0 Only 4/5/6/8/10 0
A3 7.30 ±0.50 1,020 112 ±15.0 Only 4/5/6/8/10 0
ST with Cap 100 115 ±10.0 Only 4/5/6/8/10 0
Boost pressure dependent full -load stop (boost compensator spring operation point)
Pump Injection Q′ty on RIG (mm3 /1,000st)
Check Rack position Press.
speed (A) Test condition (B) Engine
point (mm) (mmHg)
(rpm) for inj. pump standard parts
Refer to
P1 11.55 ±0.05 500 - - 1,500
(4) boost pressure
P2 9.20 ±0.05 500 - - 0
P3 9.90 ±0.10 500 300
P4 10.90 ±0.05 500 - - 450
Weight Weight =630g Lever ratio (min/max) Not fixed
Idle spring k=14.03N/mm Plunger ø12
Middle spring k=57.14N/mm Delivery valve retraction volume 90 mm3/st
Inner spring None Delivery valve opening pressure -
LDA spring k=30.50N/mm Delivery valve spring k = 7.2N/mm
Feed spring Double action×2 Timer None

- 123 - Main parts maintenance

(3) Rack diagram

12 V2 V1

10 VS
RACK POSITION (mm)

LQ
6
A3

0
0 200 400 600 800 1000 1200
ENGINE SPEED (rpm)
EDV2218058

(4) Boost compensator pressure

12
P1

10 P4
RACK POSITION (mm)

P2
P3

4
0 200 400 600 800 1000 1200

EDV2218071

Main parts maintenance - 124 -

5) V180TIM
(1) Main data and specifications

Model : PE8P120A520LV
Injection pump : 65.11101-7681
Governor : RQV 300/900
Plunger : 2 418 455 188
Delivery valve : 2 418 552 039
Pre-stroke : 4.50 ±0.05 mm
Injection timing : BTDC 18 ±1°
Injection order : 1-5-7-2-6-3-4-8
Fuel feed pump : 0 440 008 152 (FP/KD22P78-2)
Rotating direction : C.C.W. at driving gear side

(2) Calibration data

Nozzle & Holder ass′y 1 688 901 019 Opening pressure : 212.6 bar
(A) Test condition
Injection pipe (OD, ID, L) 1 680 750 075 ø8.0 x ø3.0 - 1,000 mm
for injection pump
Test oil ISO4113 Temperature : 40 ±2°C
65.10101-7053 Nozzle (5 × ø0.418)
Nozzle & Holder ass′y
(B) Engine standard parts 0 432 131 669 Spec. : 285.5 bar
Injection pipe (OD, ID, L) ø6 x ø2.0 - 750 mm
Rack diagram and setting valve at each point
Pump Injection Q′ty on RIG (mm3 /1,000st)
Check Rack position Press.
speed (A) Test condition
point (mm) Remarks (mmHg)
(rpm) for inj. pump
V1 11.55 ±0.05 1,050 243.0 ±3.0 Max. power 1,500
Refer to
V2 11.55 ±0.10 800 240.4 ±3.0 - 1,500
(3) rack diagram
VS 8.96 ±0.20 500 159.8 ±1.0 - 0
LQ 6.15 ±0.20 350 53.7 ±15.0 Only 2/3/4/8 0
A3 7.10 ±0.50 1,150 109.4 ±15.0 Only 2/3/4/8 0
ST with Cap 100 127.5 ±10.0 Only 2/3/4/8 0
Boost pressure dependent full -load stop (boost compensator spring operation point)
Pump Injection Q′ty on RIG (mm3 /1,000st)
Check Rack position Press.
speed (A) Test condition (B) Engine
point (mm) (mmHg)
(rpm) for inj. pump standard parts
Refer to
P1 11.55 ±0.05 500 - - 1,500
(4) boost pressure
P2 8.96 ±0.05 500 - - 0
P3 9.9 ±0.10 500 275
P4 10.90 ±0.05 500 - - 450
Weight Weight =630g Lever ratio (min/max) Not fixed
Idle spring k=14.03N/mm Plunger ø12
Middle spring k=57.14N/mm Delivery valve retraction volume 90 mm3/st
Inner spring k=21.98N/mm Delivery valve opening pressure -
LDA spring k=30.50N/mm Delivery valve spring k = 7.2N/mm
Feed spring Double action Timer None

- 125 - Main parts maintenance

(3) Rack diagram

12
V2 V1

10 VS
RACK POSITION (mm)

LQ
A3
6

0
0 200 400 600 800 1000 1200 1400
ENGINE SPEED (rpm)
EDV2218077

(4) Boost compensator pressure

12
P1

10 P4
RACK POSITION (mm)

P2
P3

4
0 200 400 600 800 1000 1200

EDV2218071

Main parts maintenance - 126 -

6) V180TIL
(1) Main data and specifications

Model : PE8P120A520LV
Injection pump : 65.11101-7681
Governor : RQV 300/900
Plunger : 2 418 455 188
Delivery valve : 2 418 552 039
Pre-stroke : 4.50 ±0.05 mm
Injection timing : BTDC 18 ±1°
Injection order : 1-6-5-10-2-7-3-8-4-9
Fuel feed pump : 0 440 008 152 (FP/KD22P78-2)
Rotating direction : C.C.W. at driving gear side

(2) Calibration data

Nozzle & Holder ass′y 1 688 901 019 Opening pressure : 212.6 bar
(A) Test condition
Injection pipe (OD, ID, L) 1 680 750 075 ø3.0 x ø8.0 x 1,000 mm
for injection pump
Test oil FUSUS Temperature : 40 ±5°C
65.10101-7053 Nozzle (5 × ø0.418)
Nozzle & Holder ass′y
65.10102-6070 Spec. : 285.5 bar
(B) Engine standard parts
65.10301-6055B
Injection pipe (OD, ID, L) ø2.0 x ø6.35 x 750 mm
65.10301-6056B
Rack diagram and setting valve at each point
Pump Injection Q′ty on RIG (mm3 /1,000st)
Check Rack position Press.
speed (A) Test condition
point (mm) Remarks (mmHg)
(rpm) for inj. pump
RP 13.33 1,150 297.3 - 1,000
Refer to
ABT 13.37 500 306.7 - 1,000
(3) rack diagram
ZBT 8,52 500 143.2 - -
HS 6,12 1,320 85.5 - -
LS 5,43 350 36.1 - -
ST W/CAP 100 187.5 - -
Boost pressure dependent full -load stop (boost compensator spring operation point)
Pump Injection Q′ty on RIG (mm3 /1,000st)
Check Rack position Press.
speed (A) Test condition (B) Engine
point (mm) (mmHg)
(rpm) for inj. pump standard parts
Refer to
P1 8.52 500 0
(4) boost pressure
P2 8.52 - 300
P3 13.37 - 1,000
P4 13.37 - 1,500
Weight Weight =630g Lever ratio (min/max) Not fixed
Idle spring k=14.03N/mm Plunger ø12
Middle spring k=57.14N/mm Delivery valve retraction volume 90 mm3/st
Inner spring k=21.98N/mm Delivery valve opening pressure -
LDA spring k=30.50N/mm Delivery valve spring k = 7.2N/mm
Feed spring Double action Timer None

- 127 - Main parts maintenance

(3) Rack diagram

16

14 ABT RP

12

10
ZBT
8

6 HS
LS
4

0
0 500 1000 1500

EDV2218078

(4) Boost compensator pressure

16

15

14 P3 P4
13

12

11

10

9 P1

8 P2

6
0 500 1000 1500 2000 2500

EDV2218079

Main parts maintenance - 128 -

7) V222TIH
(1) Main data and specifications

Model : PE12P120A500LV
Injection pump : 65.11101-7682
Governor : RQV 300/900
Plunger : 2 418 455 188
Delivery valve : 2 418 552 039
Pre-stroke : 4.50 ±0.05 mm
Injection timing : BTDC 17 ±1°
Injection order : 1-12-10-7-8-11-5-2-3-6-4-9
Fuel feed pump : 0 440 008 152, 0 440 008 090 (FP/KD22P78-2, KP/KD22P80-1)
Rotating direction : C.C.W. at driving gear side

(2) Calibration data

Nozzle & Holder ass′y 1 688 901 019 Opening pressure : 208.5 bar
(A) Test condition
Injection pipe (OD, ID, L) 1 680 750 075 ø8.0 x ø3.0 - 1,000 mm
for injection pump
Test oil ISO4113 Temperature : 40 ±2°C
65.10101-7053 Nozzle (5 × ø0.418)
Nozzle & Holder ass′y
(B) Engine standard parts 0 432 131 669 Spec. : 280 bar
Injection pipe (OD, ID, L) ø6 x ø2.0 - 750 mm
Rack diagram and setting valve at each point
Pump Injection Q′ty on RIG (mm3 /1,000st)
Check Rack position Press.
speed (A) Test condition
point (mm) Remarks (mmHg)
(rpm) for inj. pump
V1 11.55 ±0.05 900 244 ±3.0 Max. power 1,500
Refer to
V2 11.55 ±0.10 700 242 ±3.0 - 1,500
(3) rack diagram
VS 9.20 ±0.20 500 162 ±1.0 - 0
LQ 6.10 ±0.20 350 48 ±15.0 Only 4/5/6/8/10/12 0
A3 7.30 ±0.50 1,020 112 ±15.0 Only 4/5/6/8/10/12 0
ST with Cap 100 115 ±10.0 Only 4/5/6/8/10/12 0
Boost pressure dependent full -load stop (boost compensator spring operation point)
Pump Injection Q′ty on RIG (mm3 /1,000st)
Check Rack position Press.
speed (A) Test condition (B) Engine
point (mm) (mmHg)
(rpm) for inj. pump standard parts
Refer to
P1 11.55 ±0.05 500 - - 1,500
(4) boost pressure
P2 8.96 ±0.05 500 - - 0
P3 9.90 ±0.10 500 300
P4 10.90 ±0.05 500 - - 450
Weight Weight =630g Lever ratio (min/max) Not fixed
Idle spring k=14.03N/mm Plunger ø12
Middle spring k=57.14N/mm Delivery valve retraction volume 90 mm3/st
Inner spring None Delivery valve opening pressure -
LDA spring k=30.50N/mm Delivery valve spring k = 7.2N/mm
Feed spring Double action×2 Timer None

- 129 - Main parts maintenance

(3) Rack diagram

12 V2 V1

10 VS
RACK POSITION (mm)

LQ
6
A3

0
0 200 400 600 800 1000 1200
ENGINE SPEED (rpm)
EDV2218076

(4) Boost compensator pressure

12
P1

10 P4
RACK POSITION (mm)

P2
P3

4
0 200 400 600 800 1000 1200

EDV2218071

Main parts maintenance - 130 -

8) V222TIM
(1) Main data and specifications

Model : PE12P120A500LV
Injection pump : 65.11101-7682
Governor : RQV 300/900
Plunger : 2 418 455 188
Delivery valve : 2 418 552 039
Pre-stroke : 4.50 ±0.05 mm
Injection timing : BTDC 18 ±1°
Injection order : 1-12-10-7-8-11-5-2-3-6-4-9
Fuel feed pump : 0 440 008 152, 0 440 008 090 (FP/KD22P78-2, KP/KD22P80-1)
Rotating direction : C.C.W. at driving gear side

(2) Calibration data

Nozzle & Holder ass′y 1 688 901 019 Opening pressure : 212.6 bar
(A) Test condition
Injection pipe (OD, ID, L) 1 680 750 075 ø8.0 x ø3.0 - 1,000 mm
for injection pump
Test oil ISO4113 Temperature : 40 ±2°C
65.10101-7053 Nozzle (5 × ø0.418)
Nozzle & Holder ass′y
(B) Engine standard parts 0 432 131 669 Spec. : 285.5 bar
Injection pipe (OD, ID, L) ø6 x ø2.0 - 750 mm
Rack diagram and setting valve at each point
Pump Injection Q′ty on RIG (mm3 /1,000st)
Check Rack position Press.
speed (A) Test condition
point (mm) Remarks (mmHg)
(rpm) for inj. pump
V1 12.00 ±0.05 1,050 266.0 ±3.0 Max. power 1,500
Refer to
V2 12.00 ±0.10 800 266.0 ±3.0 - 1,500
(3) rack diagram
VS 8.96 ±0.20 500 159.8 ±1.0 - 0
LQ 6.15 ±0.20 350 53.7 ±15.0 Only 2/3/4/8 0
A3 7.10 ±0.50 1,150 109.4 ±15.0 Only 2/3/4/8 0
ST with Cap 100 127.5 ±10.0 Only 2/3/4/8 0
Boost pressure dependent full -load stop (boost compensator spring operation point)
Pump Injection Q′ty on RIG (mm3 /1,000st)
Check Rack position Press.
speed (A) Test condition (B) Engine
point (mm) (mmHg)
(rpm) for inj. pump standard parts
Refer to
P1 12.00 ±0.05 500 - - 1,500
(4) boost pressure
P2 8.96 ±0.05 500 - - 0
P3 9.25 ±0.10 500 275
P4 11.20 ±0.05 500 - - 600
Weight Weight =630g Lever ratio (min/max) Not fixed
Idle spring k=14.03N/mm Plunger ø12
Middle spring k=57.14N/mm Delivery valve retraction volume 90 mm3/st
Inner spring k=21.98N/mm Delivery valve opening pressure -
LDA spring k=30.50N/mm Delivery valve spring k = 7.2N/mm
Feed spring Double action Timer None

- 131 - Main parts maintenance

(3) Rack diagram

X[
}Y }X
XY

XW }z
RACK POSITION (mm)

_
sx hZ
]

W
W YWW [WW ]WW _WW XWWW XYWW X[WW
ENGINE SPEED (rpm)
EDV2218072

(4) Boost compensator pressure

14
P1
12
RACK POSITION (mm)

P4
10 P2
P3

0
0 200 400 600 800 1000 1200 1400

EDV2218073

Main parts maintenance - 132 -

9) V222TIL
(1) Main data and specifications

Model : PE12P120A500LV
Injection pump : 65.11101-7682
Governor : RQV 300/900
Plunger : 2 418 455 188
Delivery valve : 2 418 552 039
Pre-stroke : 4.50 ±0.05 mm
Injection timing : BTDC 19 ±1°
Injection order : 1-12-10-7-8-11-5-2-3-6-4-9
Fuel feed pump : 0 440 008 152, 0 440 008 090 (FP/KD22P78-2, KP/KD22P80-1)
Rotating direction : C.C.W. at driving gear side

(2) Calibration data

Nozzle & Holder ass′y 1 688 901 019 Opening pressure : 212.6 bar
(A) Test condition
Injection pipe (OD, ID, L) 1 680 750 075 ø3.0 x ø8.0 x 1,000 mm
for injection pump
Test oil FUSUS Temperature : 40 ±5°C
65.10101-7053 Nozzle (5 × ø0.418)
Nozzle & Holder ass′y
65.10102-6070 Spec. : 285.5 bar
(B) Engine standard parts
65.10301-6113
Injection pipe (OD, ID, L) ø2.0 x ø6.35 x 850 mm
65.10301-6114A
Rack diagram and setting valve at each point
Pump Injection Q′ty on RIG (mm3 /1,000st)
Check Rack position Press.
speed (A) Test condition
point (mm) Remarks (mmHg)
(rpm) for inj. pump
RP 13.19 1,150 423.8 - 1,500
Refer to
ABT 13.22 500 384.4 - 1,500
(3) rack diagram
ZBT 8,56 500 161.6 - -
HS 5,00 1,320 80.6 - -
LS 4,00 350 50.0 - -
ST W/CAP 100 180.0 - -
Boost pressure dependent full -load stop (boost compensator spring operation point)
Pump Injection Q′ty on RIG (mm3 /1,000st)
Check Rack position Press.
speed (A) Test condition (B) Engine
point (mm) (mmHg)
(rpm) for inj. pump standard parts
Refer to
P1 8.56 500 0
(4) boost pressure
P2 8.56 - 440
P3 13.22 - 1,170
P4 13.22 - 1,500
Weight Weight =630g Lever ratio (min/max) Not fixed
Idle spring k=14.03N/mm Plunger ø12
Middle spring k=57.14N/mm Delivery valve retraction volume 90 mm3/st
Inner spring k=21.98N/mm Delivery valve opening pressure -
LDA spring k=30.50N/mm Delivery valve spring k = 7.2N/mm
Feed spring Double action Timer None

- 133 - Main parts maintenance

(3) Rack diagram

16

14 ABT RP

12

10
ZBT
8

6
HS
4 LS

0
0 500 1000 1500

EDV2218074

(4) Boost compensator pressure

16

15

14
P3 P4
13

12

11

10

8 P1 P2

6
0 500 1000 1500 2000 2500

EDV2218081

Main parts maintenance - 134 -

7.3.2. Fuel feed pump
1) General descriptions and construction
The P-type injection pump is mounted with
Priming
K-ADS or KP type feed pump. These pump
Priming
pumps have the same basic construction pump

and operation, and the general descriptions Check Check valve

Check valve
of the KP type pump are given below : valve
Check valve
Discharge
Outlet
The figures show its construction (right fig- Inlet
Suction
side side
ure) and operation (below figure). The pis-
ton in the fuel feed pump is driven by the Piston Tappet
Tappet
Piston
Camshaft
push rod and tappet via the camshaft of Camshaft EQM4019I
EDV2218165
injection pump and performs reciprocating
operation to control the suction and delivery
of fuel.
When the cam reaches the Bottom Dead Center as shown in the figure, the fuel is drawn in through the
check valve on the inlet side. The fuel pressurized as the cam rotates on flows through the check valve on
the outlet side as shown in (B). If feeding pressure increases abnormally, the spring is compressed,
resulting in interrupting further delivery of fuel as shown in (C).

(A) (B) (C)

Inlet side Outlet side Interruption
EQM4020I

This feed pump is mounted with a priming pump designed to permit manual feeding of fuel from the fuel
tank with the injection pump mounted in the engine. During the manual feeding operation, air must be bled
from the fuel lines. When using the priming pump, fix it securely to prevent the possible entry of moisture
or other foreign substances in the inside of the feed pump.

- 135 - Main parts maintenance

 In addition, a strainer is fitted into joint bolt
on the inlet side of the fuel feed pump to fil-
trate any foreign substances possibly mixed
in fuel.
Strainer

EB1M4003

2) Disassembly

● EQM4021S

● Clamp the feed pump with a vise and disassemble the plugs (30, 32), strainer (31) and gaskets (35,
36).
● Take off the priming pump (25), plug (16), both gaskets (18), spring (15), and check valve (14).
● Take off the plug (7), gasket (8), spring (6), and piston (5) on the piston side.
● Pull out the snap ring (20) holding the tappet (10).
● Disassemble the snap ring, then take off the tappet (10) and push rod (1).

3) Inspection
● If the check valve is damaged or scored on its seat face, replace it with a new one.
● Inspect the piston and tappet for damage.
● Replace the push rod if excessively worn, and replace together with the pump housing if required. The
inspection for wear should be performed in the same procedure as for suction pressure test described
below.

Main parts maintenance - 136 -

4) Re-assembly
● Re-assembly operation is performed in reverse order of disassembly. All the gaskets must be replaced
with new ones at re-assembly.

5) Testing
● Suction capacity test
Connect one end of a hose to the inlet
Outlet hose
side of the feed pump and immerse the
other end of it into the fuel tank as illus- Feed pump
trated.
Hold the feed pump in position about 1
m above the fuel level of the fuel tank.
Operate the tappet at the rate of Inlet hose
100 rpm and check to see if fuel is drawn
in and delivered for 40 seconds or so.

Fuel tank

EQM4022I

● Delivery test
Make a test with the feed pump mounted
on a pump tester as illustrated. Operate
the pump at the rate of 1,000 rpm and
check to see if the pump delivery is more
than 405 cc/15 seconds.

EAMC016I

● Sealing test
Plug up the delivery port on the feed Mass cylinder
Compressed air
pump and apply compressed air of 2 kg/ 2kg/cm 2
cm2 into the inlet side. Submerge the
feed pump in a container of diesel fuel
and check for air leak.

Feed pump

EQM4023I

- 137 - Main parts maintenance

7.3.3. Injection nozzle
The injection nozzle assembly consists of the nozzle body and needle valve assembly. Pressurized fuel
delivered from the fuel injection pump is sprayed into the combustion chamber past the injection nozzle at
proper spray pressure and spray angle, then burnt completely to achieve effective engine performance.
The fuel injected should necessarily be ignited immediately and combusted in a short period of time as too
long a combustion period will prevent the high speedy operation of the engine and can cause serious engine
knocking.

(1) At valve closed (2) At valve opened

EQM4024I

1) Structure
A copper seal fitted to the injector ensures
3
gas-tight seating and good heat dissipation.
The opening pressure of the nozzle is
adjusted by means of shims at the com-
SHIM
pression spring.
COIL SPRING

1.Nozzle holder assembly 1

GUIDE BUSH

2.Nozzle tip INTERMEDIATE

WASHER
3.Nozzle locking nut 2
4.Seal ring
UNION NUT

4
EDV2218082

2) Maintenance
● After removing carbon deposit, submerge the nozzle in diesel oil and clean it.
● Replace all the gaskets with new ones.
● Assemble the parts and tighten them to specified torque.

Main parts maintenance - 138 -

3) Inspection and adjustment
● Assemble the nozzle in the nozzle tester and operate the nozzle tester 2 or 3 times to bleed air. After
pressurizing it measure the nozzle pressure.

New nozzle 300 +8 kg/cm2

Used nozzle 285 +8 kg/cm2

● Re-check the injection pressure and see if the spray pattern is normal.
● Adjust the injection pressure to the standard pressure using shims if the injection pressure is poor.
● Nozzle opening pressure is adjusted by thickness of shims installed on the compress spring. There-
fore in case of low or high injection pressure, adjust by adding or reducing the spring tension adjusting
shims.
● In case that atomizing state is not good it should be replaced.
● After adjusting the injection pressure tighten the cap nut to specified torque.

Normal Abnormal Abnormal

EFM1006I

Caution
As the fuel injection line is operated by high pressure, should pay particular attention to treat.

● Fix the nozzle holder securely when assemble it.

● Do not bend the injection pipe so much it as deformed severely.
● Do not use the abnormal bending pipe preventing from cracking.
● Do not bend the end portion of injection pipe over 2 or 3 degree to assemble it easily.

- 139 - Main parts maintenance

7.4. Turbo-charger

7.4.1. Specification

Model V158TIH V180TIH V222TIH

Engine output (PS / rpm) 480 / 1,800 600 / 1,800 720 / 1,800

Turbo-charger model HX35M HX40M HX50M

Maximum allowable exhaust

700
gas temperature (Turbine inlet)

Lubricating system Forced oil supply

Model V158TIM V180TIM V222TIM

Engine output (PS / rpm) 540 / 2,100 650 / 2,100 800 / 2,100

Turbo-charger model HX35M HX40M HX50M

Maximum allowable exhaust

700
gas temperature (Turbine inlet)

Lubricating system Forced oil supply

Model V158TIL V180TIL V222TIL

Engine output (PS / rpm) 680 / 2,300 820 / 2,300 1,000 / 2,300

Turbo-charger model HX40M HX50M HX50M

Maximum allowable exhaust

700
gas temperature (Turbine inlet)

Lubricating system Forced oil supply

Main parts maintenance - 140 -

7.4.2. Construction of the turbo-charger

17

23 22 21
24

19
3
25 20
26
27
5 4

8 7
12 11 10 9

13
18

14
15
16 2 28

EAMC055S
EDV2218017

1. Turbine housing 11. Bearing 21. Nut

2. V-vent 12. Thrust collar 22. Bolt
3. Wheel 13. Screw 23. Clamp
4. Piston ring 14. Thrust bearing 24. Compressor housing
5. Wheel shroud 15. Thrust spacer 25. Elbow
6. Center housing 16. Pistion ring 26. Clamp
7. Retaining ring 17. Seal ring 27. Hose
8. Bearing 18. Seal ring 28. Bolt
9. Retaining ring 19. Rear plate
10. Retaining ring 20. Bolt

- 141 - Main parts maintenance

7.4.3. Inspection
As the condition of turbocharger depends greatly on how well the engine is serviced, it is very important to
maintain the engine in accordance with the specified maintenance procedure and pay particular attention to
checking oil & air leaks, unusual sound on running.

1) Checking of the rotor for rotating condition

The inspection of the rotor assembly for rotating condition should be performed by the degree of unusual
sound on running. If a sound detecting bar is used, install its tip on the turbocharger housing and increase
the engine revolutions slowly. If a high-pitch sound is heard every 2 ~ 3 seconds or continuously, it means
that the rotor assembly is not normal. In this case, as the metal bearing and rotor are likely to be in abnor-
mal conditions, the turbocharger should be replaced or repaired.

2) Checking of the rotor end play

The radial and axial clearances of the rotor should check after every 2,000 hours operation. This precau-
tion will enable measuring for any wear of axial clearance bearings to be detected in good time before
serious damage is caused to the rotor and bearings. Disassemble the turbocharger from the engine, then
check the rotor axial play and radial play.

(1) When disassembling the turbocharger, be sure to plug the oil inlet and outlet ports
(2) If the measured axial and radial plays are beyond the limit of wear, replace or repair the turbocharger.

● Measuring rotor axial clearance

Axial clearance 0.12 mm Turbine wheel chamber

Magnetic vise

● Measuring radial clearance

Radial clearance 0.58 mm

Move the turbine
shaft to axial
direction
Dial gauge

Wear limit : 0.12mm EA7O5011

Dial gauge
Magnetic vise

Radial play Move the turbine shaft

Limit of wear : 0.58mm in both directions
simultaneously

Oil inlet
EA7O5012

Main parts maintenance - 142 -

 3) Precautions for reassembling the turbocharger onto the engine
For re-assembly of the turbocharger or handling it after re-assembly operation, be sure to observe the fol-
lowing precautions:
Especially, pay attention to prevent foreign matters from entering the inside of the turbocharger.

(1) Lubricating system

● Before reassembling the turbocharger onto the engine, inject new oil in the oil inlet port and lubri-
cate the journal and thrust bearings by rotating them with hand.
● Clean not only the pipes installed between the engine and oil inlet port but also the oil outlet pipe
and check them for damage or foreign matters.
● Assemble each joint on oil pipes securely to prevent oil leaks.

(2) Intake system

● Check the inside of the intake system for foreign matters.
● Assemble each joint on the intake duct and air cleaner securely to prevent air leaks.

(3) Exhaust system

● Check the inside of the exhaust system for foreign matters.
● Be sure to use heat resisting steel bolts and nuts. Do not interchange them with ordinary steel
bolts and nuts when performing re-assembly operation. Apply anti-seizure coating to the bolts and
nuts.
● Assemble each joint on the exhaust pipes securely to prevent gas leaks.

7.4.4. Component Identification

1) Turbo charge identification
A date plate is fitted to the compressor
housing (8). The information on this date
plate must be quoted for service and parts
support.

<HX 35> EDV2218093

EDV2218094
<HX 50>

- 143 - Main parts maintenance

 2) Center housing rotating assembly

EA7M4005

3) Watercooled bearing housing (4)

Optionally this can have additional water
feed and drain plug fittings.

EA7M4063

4) New compressor wheel lock nut (61)

Holset have introduced a new compressor
Old New
wheel lock nut which is to be all new WH1C/
E turbochargers. If you turbo is fitted with
the new nut, it indicated that this turbo-
charger may have been built using the core
balance process at point of manufacture
rather than the traditional rotor balance pro-
cess The new nut will also require a differ-
ent torque process when rebuilding the EDV2218095
turbo after service.

Caution :
Always use specified torque. Failure
to do so may result in turbocharger/
engine failure.

Torque value Nm Ib Ins

New lock nut 17 150
Old lock nut 16 160

Main parts maintenance - 144 -

 Caution :
Always make sure the turbinewheel
shaft end and the compressor wheel
have alignment marks before
disassembly of the CHRA.
If no marks exist, scribe the shaft
and compressor wheel (as shown)
before removing the compressor
wheel lock nut.
Always check balance the rotor
EDV2218096
before rebuild.

7.4.5. Disassembly
● Before disassembling the turbocharger,
scribe the parts listed below to help in align-
ment during assembly.
- Compressor housing (8)
- Turbine housing (5)
- Bearing housing (4)

EDV2218097

● Secure the turbine housing (5) in a vice.

HX35 : Remove the compressor cover
circlip (91) using circlip pliers.

EDV2218098

- 145 - Main parts maintenance

 HX50 : Loosen and remove the 8 bolts
(59) lock washers (54) clamp
plates (51).
HX55 : Loosen and remove the compres-
sor side V-band lock nut (62).

EDV2218053

● Gently remove the compressor cover (8),

and if fitted, remove the O-ring seal (41).

Caution :
The compressor wheel blades can be
easily damaged when the compressor
housing is removed.

EDV2218052

● Loosen and remove the 6 bolts (57) and

clamp plates (88).
Or remove v-band lock nut and v-band if fit-
ted.

EDV2218099

● Remove the CHRA from the turbine hous-

ing.

Caution :
The turbine blades can be easily
damaged when the turbine housing is
removed.

EDV2218100

Main parts maintenance - 146 -

● Locate the Center Housing Rotating
Assembly (CHRA) onto a 19 mm socket
clamped in the jaws of a vice or a suitable
fixture.

Caution :
Always make sure the turbine wheel
shaft and the compressor wheel have
alignment marks before disassembly
EDV2218054
of the CHRA.
If no marks exist, scribe the shaft and compressor wheel (as shown) before removing the
compressor wheel lock nut. (refer to 4.3.4.)

● Remove the compressor wheel lock nut

(61).

Note :
Left hand thread.

EDV2218101

● Remove the compressor wheel (7).

EDV2218102

● Remove the remaining CHRA from the

socket and gently slide the shaft and wheel
(6) from the bearing housing (4).

EDV2218103

- 147 - Main parts maintenance

 ● Carefully remove and discard the piston
ring seal(s) (13).

- HX35(V158TI) : 1EA
- HX50(V180TI/V222TI) : 2EA

Caution :
Care should be taken not to score the
assembly turbine wheel shaft. EDV2218104

● Remove the heat shield (38).

EDV2218105

● Place the bearing housing on a flat surface

and using circlip pliers, remove the insert
retaining ring (66).

EDV2218106

● Gently remove the oil seal plate (43) as fo

lows.

- HX35 : Using two flat nose pliers

EDV2218107

Main parts maintenance - 148 -

 - HX50 : Using two flat screwdrivers.

EDV2218108

● Remove the oil slinger (31).

- HX35

EDV2218055

- HX50

EDV2218109

● Remove and discard the piston ring seal

(16).

EDV2218110

- 149 - Main parts maintenance

 <HX35>
● Remove and discard the oil baffle (33).

EDV2218111

● Remove and discard the O-ring seal (32).

EDV2218112

● Remove the thrust bearing (12).

EDV2218113

<HX50>
● Remove and discard the O-ring seal (32).

EDV2218114

Main parts maintenance - 150 -

● Remove and discard the oil baffle (33).

EDV2218115

● Remove the thrust bearing (12).

EDV2218116

● Remove the thrust collar (36).

EDV2218117

● Using circlip pliers, remove and discard the

two circlips (64) and the journal bearing (11)
from the compressor end.

EDV2218118

- 151 - Main parts maintenance

 ● Turn the bearing housing over and repair
the process.

EDV2218057

7.4.6. Cleaning
With the turbocharger completely dismantled for overhaul, soak all the components in a non-caustic metal
cleaner to loosen deposits. Bead blast the turbine housing if chemicals do not clean sufficiently.
On aluminium parts a bristle brush can be used. Never use a wire brush or metal scraper on any turbo-
charger component. Ensure that all the palls are finally cleaned with an air jet, especially drilled passages
and machined apertures. Turbine Wheel: In the event of carbon build-up, it may be necessary so carefully
blast the Piston Ring Groove area of the turbine wheel using low grade shot medium.

Caution :
Shot blasting specific areas for long periods of time may effect component balance.

The surface adjacent to the turbine and compressor wheels on the stationary housings must be clean,
smooth and free from deposits.

7.4.7. Inspection

Caution :
Do not attempt to straighten the turbine shaft.

a) Place the shaft on a V-block, using a dial

gauge rotate the turbine wheel and check
for movement on the dial gauge. Replace
the assembly turbine wheel if it is bent.
Max shaft bend allowed 0.025 mm
(0.001 ins).

Shaft bend mm in.

(Max.) 0.025 0.001
EDV2218119

Main parts maintenance - 152 -

<Major components>
● Assembly turbine wheel (6)
b) Inspect the piston ring groove walls for
wear.

- HX35 (V158TI)

Turbine wheel mm in.

piston ring groove
(Min.) 1.664 0.0665

- HX50 (V180TI/ V222TI) EDV2218120

Turbine wheel
mm in.
piston ring groove
Single ring (Min.) 1.664 0.0665
Twin ring (Min.) 3.538 0.1393

c) Inspect the bearing journals for excessive scratches and wear. Minor light scratches may be tolerated.

- HX35 (V158TI)

Assembly turbine mm in.

wheel jounals
(Min.) 10.972 0.432

- HX50 (V180TI/ V222TI)

Assembly turbine mm in.

wheel jounals
(Min.) 3.538 0.1393

d) Inspect for cracked, bent or damaged blades but DO NOT ATTEMPT TO STRAIGHTEN BLADES.

● Turbine housing (5)

Inspect the profile for damage caused by
possible contact with the rotor. Check all
threads for damage. Inspect the outer and
internal walls for cracks or flaking caused
by overheating also check mounting flanges
for signs of distortion.
Replace with new if any of the above are
visible.
EDV2218121

- 153 - Main parts maintenance

 ● Compressor housing (8)
Inspect the profile for damage due to possi-
ble contact with the rotor. Check the V-band
groove.
Replace with new if any of the above are
visible.

EDV2218122

● Bearing housing (4)

Inspect the bore for wear or score mark on
both the bearing and piston ring area. Also
check all tapped holes are clean and free
from dirt.
Replace with new if any damage is found.

- HX35 (V158TI)

Bearing Housing mm in.

EDV2218123
Bore (Min.) 15.885 0.6254

● Compressor wheel (7)

Inspect carefully for cracked, bent or dam-
aged blades but DO NOT ATTEMPT TO
STRAIGHTEN BLADES.
Replace with new if any damage is found.

EDV2218124

<Minor components>
● Oil slinger (31)
Inspect and replace if the piston ring seal
groove walls are scored or damaged. Also
check for signs of rubbing on the flat sur-
faces.

Groove Width mm in.

(Max.) 1.664 0.0665

EDV2218125

Main parts maintenance - 154 -

 ● Oil seal plate (43)
Inspect the seal bore, replace if
scored or damaged.

EDV2218126

● Heat shield (38)

Check and replace if the heat shield id dis-
torted or if signs of rubbing or cracking are
visible.

EDV2218127

7.4.8. Assembly
● Make sure that the circlips are always fitted
with the bevelled edge facing the journal
bearing.

Caution :
Circlips (64). Premature failure will result if
the circlips are fitted incorrectly.

EDV2218128

● Rotor balance
Before assembly, always make sure that
both compressor wheel and assembly tur-
bine wheel are individually balanced. (refer
to 4.3.4.)
Then check balance of the rotor assembly
to ensure it is within the required limits.

EDV2218129

- 155 - Main parts maintenance

 Mark up each individual item to help ensure
correct alignment during assembly.

- HX35 (V158TI)

Rotor balance
g.mm oz. ins.
limits (Max.)
Turbine end 1.5 0.002
Compressor end 1.5 0.002

- HX50 (V188TI, V222TI)

Rotor balance
g.mm oz. ins.
limits (Max.)
Turbine end 2.2 0.003
Compressor end 4.4 0.006

● Place the bearing housing (4) on a bench

with the turbine end facing uppermost.
Fit the inner circlip (64) with the bevelled
edge facing upwards.

EDV2218130

● Lubricate the journal bearing (11) and

install into position.
Fit the outer circlip (64) with the bevelled
edge facing the bearing.
Turn the bearing housing over and repeat
the process.

EDV2218131

Main parts maintenance - 156 -

● Install the heat shield (38).

EDV2218132

● Install the two new piston ring seals (13) to

the assembly turbine wheel (6).

EDV2218133

● Lubricate the shaft using clean engine oil.

Caution :
Align the piston ring seals (16) so the
gaps are positioned 180° from the oil
drain hole. Gently press down on the
turbine wheel - a slight rotation of the
wheel will assist in properly locating
the piston ring seals.
EDV2218134

● Support the assembly turbine wheel (6) and

bearing housing in a suitable fixture.

EDV2218135

- 157 - Main parts maintenance

 ● Install the thrust collar (36).

Caution :
Align the balance mark on the thrust
collar with that on the shaft.

EDV2218136

● Using clean engine oil, lubricate the thrust bearing (12).

Install the thrust bearing.

- HX35

EDV2218137

- HX50

EDV2218138

● Fit the new piston ring seal (13) to the oil

slinger (31).

EDV2218139

Main parts maintenance - 158 -

<HX35>
● Using clean engine oil, lubricate the oil
slinger (31) and install into the oil seal plate
(43).

EDV2218140

● Install the oil baffle (33) into the oil seal

plate (43).

EDV2218141

● Apply a small amount of engine oil to the oil

seal plate (43) and place the O-ring seal
(32) into position.

EDV2218142

<HX50>
● Apply a small amount of engine oil to the O-
ring seal (32), and place into position.

EDV2218143

- 159 - Main parts maintenance

 ● Install the oil baffle (33) into the oil seal
plate (43).

EDV2218144

● Using clean engine oil, lubricate the oil

slinger (31) and install into the oil seal plate
(43).

EDV2218145

● Install the oil seal plate (43) into the bearing

housing (4).

Caution :
Align the balance marks on the oil
slinger (31) with that on the shaft end.

EDV2218146

● Gently tap the oil seal plate (43) with a soft

hammer to seat in position.

EDV2218147

Main parts maintenance - 160 -

● Using circlip plier, install the retaining ring
(66).

EDV2218148

● Align the balance marks and install the

compressor wheel (7).

EDV2218149

● Install the compressor wheel lock nut(61)

and tighten to the torque value.

Note :
Left hand thread.

Nm in-lbs
Torque value
17 150

EDV2218150
Caution :
Ensure that the balance marks are aligned on the compressor wheel and the shaft.

<HX35>
● Carefully slide the retainer ring (91) over the
assembly turbine wheel (6). Locate the
C.H.R.A. into the turbine housing (5).
Install the 2 clamp plates (88) and tighten
the 6 bolts (57) to the torque

Torque value Nm in-lbs

bolts (57) 14 120

EDV2218151

- 161 - Main parts maintenance

 <HX50>
● Locate the C.H.R.A. into the turbine hous-
ing (5).
Install the 3 clamp plates (88) and tighten
the 6 bolts (57) to the torque value.

Torque value Nm in-lbs

Bolts (57) 20 180

If fitted, install v-band clamp (28) and

tighten the v-band lock nut.

Torque value Nm in-lbs

bolts (57) 8 75

Caution :
Make sure the scribe marks are aligned.

EDV2218152

● Secure the turbine housing and check the

trust clearance using a dial gauge.

- HX50 (V180TI/ V222TI)

Trust clearance mm In
Minimum 0.038 0.0015
Maximum 0.093 0.0037

EDV2218153

● Secure the turbine housing and check the

trust clearance using a dial gauge.

- HX50 (V180TI/ V222TI)

Radial clearance mm In
Minimum 0.394 0.0155
Maximum 0.635 0.0250

EDV2218154

Main parts maintenance - 162 -

 ● Loosely fit the V-band clamp.
Lubricate and install the O-ring seal (41) if
fitted.
Install the compressor cover (8).

Caution :
The compressor wheel blades can be easily
damaged when the compressor housing is
installed. EDV2218155

● HX50
HX50 HX55
Install the 2 clamp plates (51), eight lock
washers (54) and tighten the 8 bolts (59) to
the torque value.

● HX55
Install the V-band clamp (29) and tighten
the lock nut (62) to the torque value.
EDV2218156
- HX50/HX55 (V180TI/ V222TI)

Trust clearance Nm In-lbs

Lock nut (62) 8.5 75
Bolts (57) 20.3 18

Caution :
Make sure the scribe marks are aligned.

7.4.3. Inspection
As the condition of turbocharger depends greatly on how well the engine is serviced, it is very important to
maintain the engine in accordance with the specified maintenance procedure and pay particular attention to
checking oil & air leaks, unusual sound on running.

1) Checking of the rotor for rotating condition

The inspection of the rotor assembly for rotating condition should be performed by the degree of unusual
sound on running. If a sound detecting bar is used, install its tip on the turbocharger housing and increase
the engine revolutions slowly. If a high-pitch sound is heard every 2 ~ 3 seconds or continue, it means that
the rotor assembly is not normal. In this case, as the metal bearing and rotor are likely to be in abnormal
conditions, the turbocharger should be replaced or repaired.

- 163 - Main parts maintenance

 2) Checking of the rotor end play
The radial and axial clearances of the rotor should check after every 2,000 hours operation. This precau-
tion will enable measuring for any wear of axial clearance bearings to be detected in good time before
serious damage is caused to the rotor and bearings.
Disassemble the turbocharger from the engine, then check the rotor axial play and radial play.

(1) When disassembling the turbocharger, be sure to plug the oil inlet and outlet ports
(2) If the measured axial and radial plays are beyond the limit of wear, replace or repair the turbocharger.

● Measuring rotor axial clearance

Turbine wheel chamber
Magnetic vise
Axial clearance 0.12 mm

● Measuring radial clearance

Move the turbine
Radial clearance 0.58 mm shaft to axial
direction
Dial gauge

Wear limit : 0.12mm EA7O5011

Dial gauge
Magnetic vise

Radial play Move the turbine shaft

Limit of wear : 0.58mm in both directions
simultaneously

Oil inlet
EA7O5012

Main parts maintenance - 164 -

3) Precautions for reassembling the turbocharger onto the engine
For re-assembly of the turbocharger or handling it after re-assembly operation, be sure to observe the fol-
lowing precautions :
Especially, pay attention to prevent foreign matters from entering the inside of the turbocharger.

(1) Lubricating system

● Before reassembling the turbocharger onto the engine, inject new oil in the oil inlet port and lubri-
cate the journal and thrust bearings by rotating them with hand.
● Clean not only the pipes installed between the engine and oil inlet port but also the oil outlet pipe
and check them for damage or foreign matters.
● Assemble each joint on oil pipes securely to prevent oil leaks.

(2) Intake system

● Check the inside of the intake system for foreign matters.
● Assemble each joint on the intake duct and air cleaner securely to prevent air leaks.

(3) Exhaust system

● Check the inside of the exhaust system for foreign matters.
● Be sure to use heat resisting steel bolts and nuts. Do not interchange them with ordinary steel bolts
and nuts when performing re-assembly operation. Apply anti-seizure coating to the bolts and nuts.
● Assemble each joint on the exhaust pipes securely to prevent gas leaks.

- 165 - Main parts maintenance

Main parts maintenance - 166 -
8. TROUBLE SHOOTING
The following description summarizes the probable cause of and remedy for general failure by item. Immedi-
ate countermeasures should be taken before a failure is inflamed if any symptom is detected.

Hard to start the engine

Fuel system admits air Bleed air (check feed pump)

Clogged fuel supply piping or clogged air Detect the cause and remove clogs or
vent pipe in tank. obstacles.

Clogged fuel filter Replace filter element with a new one.

Fuel feed pump failure Check for function. Service fuel pump or
replace with a new one if less discharge
volume is found.

Insufficient compression Check according to “Insufficient output”

Improperly adjust valve stick or clearance in Adjust clearance of intake/exhaust valves.

intake/exhaust valves. Cheek valve guide, spring, and rocker arm
mechanism for damage.

Improper injection timing or valve timing. Check for injection timing and valve timing.

Totally check exhaust system (for dented

Clogged exhaust pipe (too high back pressure) or twisted pipes and clogged silencer, etc.)

Fuel injection valve failure or errors in Check for part type No.
selection types. Service or replace fuel injection valves.

Fuel injection pump failure Check, service or adjust.

Does starting-aid in cold weather function Check whether a proper voltage continuously
normally? occurs in low temperature starting-aid
circuit while switch is turned ON.

When glow plugs are used, key switch is

turned “HEAT” position of key switch.
If glow plug is reheated, engine starts. If
not, glow plugs fail or circuit is defective.

If fire once occurs, and goes out if starter

motor is switched ON, voltage is insufficient
or circuit is defective (such as erroneous
selection of starter switch)

- 167 - Trouble shooting

 Insufficient output

Driven machine normal? Hydraulic pressure source Change or reduce the propeller pitch

Excess intake air resistance Clogged air cleaner Clogged intake air pipe
Clean Clean

Excess exhaust Clogged Clogged exhaust Clogged cylinder

resistance muffler pipe head exhaust outlet
Clean or replace Clean

Fuel system Air intrusion into Clogged Clogged

failure fuel system fuel filter fuel pipe
Air bleeding Clean or replace Clean

Clogged air vent in fuel tank

Insufficient fuel volume from feed pump

Governor Improper Fuel injec- Clogged fuel Fuel injec-

adjustment tion pres- injection valve tion valve
sure nozzle seizure
Adjust Clean or replace Clean

Lever link Improper Fuel pump Faulty Worn

malfunction fuel injection rack mal- delivery plunger
timing function valve barrel
Adjust Repair or Repair or Replace
replace replace

Reduced Improper clearance Defective Intake/exhaust Fatigued or

compression of intake/exhaust intake/exhaust valve stem broken valve
pressure valves valve seat seizure spring
Adjust Reshape or replace Replace Replace

Pressure
leak through
cylinder
Replace

Seizure, breakage Flaws or Flaws

and wear of piston wear of or wear
ring piston of liner
Replace Replace Replace

Overheat Refer to “Overheating”

Trouble shooting - 168 -

 Overheating

Driven unit normal? Hydraulic pressure source Set relief pressure of control valve

Cooling Insufficient Sagged Broken or Clogged heat Incresed exhaust

system cooling water V-belt worn V-belt exchanger pressure
Add water Adjust Replace Clean Clean

Pressure cap Clogged heat- Reduction in cool-

Thermostat
clogging and exchanger ing water pump
malfunction
malfunction tubes performance
Clean or replace Replace Clean Replace

Heat exchanger
malfunction
Clean

Excess intake Clogged air Clogged

air resistance cleaner intake air pipe
Clean or replace Clean

Excess exhaust Clogged Clogged Clogged cylinder

resistance muffler exhaust pipe head exhaust outlet
Clean Clean Clean

Leakage through Cracked cylinder

Cylinder head
head gasket head
Replace Replace

Improper fuel Defective fuel

Fuel system
injection timing injection valve
Repair Clean or replace

Injection OPEN/ Improper valve Improper fuel

CLOSE timing clearance injection timing
Adjust Adjust

Piston Seizure likeliness

Replace

EDV

- 169 - Trouble shooting

 Black smoke is produced.

Driven machine normal? Hydraulic pressure source Set relief pressure of control valve

Insufficient output Refer to “Insufficient output.”

Fuel Improper fuel

Replace

Fuel pump Too early injection timing Excess injection volume Uneven injection volume
Adjust or replace Adjust Adjust or replace

Governor Improper adjustment Malfunction of lever and linkage

Adjust Repair or replace

White smoke is produced.

Fuel Water intrusion in fuel Intrusion of low-quality fuel or impurities

Replace Replace

Lube oil Improper SAE grade

Replace

Excess intake air risistance Clogged air cleaner Clogged intake air pipe
Repair or replace Clean or replace

Fuel pump Too late injection timing

Adjust or replace

Oil pressure drop Defective valve Damaged or worn Damaged or worn

stem sealing valve stem valve guide
Replace Replace Replace

Breather oil rise Seizure, breakage, or Flaws or wear Flaws or wear

wear of piston ring of piston of liner

Leakage through cylinder

head gasket

Over-cooling Thermostat malfunction

Trouble shooting - 170 -

 Starter motor will not turn
or output less power. trouble of driven machine ]
[ Except engine seizure and

Disconnection & Battery Grounding Disconnected Coupler

faulty connection terminal termainal connection
Repair Repair Repair Repair

Battery Specific gravity Voltage Damaged battery

Charging Add electrolyte or Replace
charge

Key switch Damaged or rusted Switch inner contactor Damaged switch

starter motor terminal
Replace Replace
Replace or repair

Safety relay Damaged or Faulty really functioning

rusted terminals Replace
Replace or repair

Startor motor Damaged Magnet switch, Defective Burnt Short

or rusted malfunction & brush coil circuited
terminal defective contactor
Replace Replace Replace
Replace or repair or repair starter motor

Clutch slip
Replace

Hydraulic pressure source

Hydraulic system will not

operate or to slow function

Lube oil quantity Insufficient Deterioration Viscosity

Add Lube oil Replace Recommended Hydro-oil

Piping Trouble in piping (Aeration cavitation)

Correct

Gear pump Worn spline in flange Broken shaft Worn gears and housing
Replace Replace Replace

Filter Clogging
Clean or replace

- 171 - Trouble shooting

 Battery is dead or not
[During operation]
chargeable.

Poor charging Discharged

Defective Discon- Coupler Key

Battery Grounding ON condition
wiring and nected connec- switch
terminal terminal
connection wiring tion
Repair
Repair
Wiring Short-circuit
Battery Battery Replace
terminal

Electric Alternator
Key switch ON Damaged Switch appliance
Turn ON or rusted inner
terminals contactor
Repair or replace Replace Damaged
diode
Electric Alternator Short-circuited Replace
appliance or disconnected
lead wire
Short-
Replace circuited coil
Replace
Sagged fan belt Faulty IC regulator alternator
Adjust Replace alternator

Damaged diode
Replace

Defective brush
Repair or

Burnt coil
Replace alternator

Short-circuited
Replace alternator

Trouble shooting - 172 -

Appendix

● Standard table of tightening torque

Specification Screw Strength Tightening Torque kg⋅m

Cylinder block bearing cap
- Main bolt M18 × 2 12.9 Initial 30 kg.m + rotating torque 90°
- Side bolt M12 × 1.5 10.9 8

Flywheel housing
- Tightening bolt M12 × 1.5 10.9 10
M10 12.9 7.5
- Cover bolt M8 8.8 2.2
Counter weight M16 × 1.5 10.9 Initial 14 kg⋅m + rotating torque 90°
Crank pulley M16 × 1.5 10.9 21
Vibration damper M10 10.9 6
Flywheel M16 × 1.5 12.9 26
Cooling fan M8 8.8 2.2
Connecting rod cap M16 × 1.5 10.9 Initial 10 kg⋅m + rotating torque 90°
Cylinder head M15 × 2 12.9 8 kg.m + 15 kg⋅m + angle 90°+ angle 90°
Cylinder head cover M8 8.8 2.2
Fuel injection nozzle holder M28 CK60 7 ±0.5
Fuel injection pipe M14 × 1.5 2.5
Cam shaft timer M10 10.9 9
Rocker arm bracket M10 10.9 6.5
Lock nut (adjusting screw) M12 × 1 8.8 5
Oil pump cover M8 8.8 2.2
Oil pump M8 8.8 2.2
Oil cooler M12 10.9 5
Oil pan M8 8.8 2.2
Oil pan plug M26 × 1.5 - 8
Exhaust manifold M10 10.9 5.0
Intake manifold M8 8.8 2.2
Fuel injection pump (cylinder block) M10 10.9 6.5
Fuel filter M12 × 1.5 8.8 8
Starting motor M12 × 1.5 8 8
Alternator bracket M14 8.8 12
Oil pressure switch PT1/8 2
Water temperature switch M14 8.8 2
Plug screw M12 × 1.5 5
M14 × 1.5 8
M16 × 1.5 8
M18 × 1.5 10
M22 × 1.5 10
M24 × 1.5 12
M26 × 1.5 12
M30 × 1.5 15
AM10 × 1.0 5
AM14 × 1.5 8

- 173 - Appendix
● Standard bolt tightening torque table
Refer to the following table for bolts other then described above

Degree of strength
3.6 4.6 4.8 5.6 5.8 6.6 6.8 6.9 8.8 10.9 12.9
Diameter (4A) (4D) (4S) (5D) (5S) (6D) (6S) (6G) (8G) (10K) (12K)
×
pitch (mm) Limit value for elasticity (kg/mm2)
20 24 32 30 40 36 48 54 64 90 108
Tightening torque (kg.m)
M5 0.15 0.16 0.25 0.22 0.31 0.28 0.43 0.48 0.5 0.75 0.9
M6 0.28 0.30 0.45 0.4 0.55 0.47 0.77 0.85 0.9 1.25 0.5
M7 0.43 0.46 0.7 0.63 0.83 0.78 1.2 1.3 1.4 1.95 2.35
M8 0.7 0.75 1.1 1 1.4 1.25 1.9 2.1 2.2 3.1 3.8
M8 × 1 0.73 0.8 1.2 1.1 1.5 1.34 2.1 2.3 2.4 3.35 4.1
M10 1.35 1.4 2.2 1.9 2.7 2.35 3.7 4.2 4.4 6.2 7.4
M10 × 1 1.5 1.6 2.5 2.1 3.1 2.8 4.3 4.9 5 7 8.4
M12 2.4 2.5 3.7 3.3 4.7 4.2 6.3 7.2 7.5 10.5 12.5
M12 × 1.5 2.55 2.7 4 3.5 5 4.6 6.8 7.7 8 11.2 13.4
M14 3.7 3.9 6 5.2 7.5 7 10 11.5 12 17 20
M14 × 1.5 4.1 4.3 6.6 5.7 8.3 7.5 11.1 12.5 13 18.5 22
M16 5.6 6 9 8 11.5 10.5 17.9 18.5 18 26 31
M16 × 1.5 6.2 6.5 9.7 8.6 12.5 11.3 17 19.5 20 28 33
M18 7.8 8.3 12.5 11 16 14.5 21 24.2 25 36 43
M18 × 1.5 9.1 9.5 14.5 12.5 18.5 16.7 24.5 27.5 28 41 49
M20 11.5 12 18 16 22 19 31.5 35 36 51 60
M20 × 1.5 12.8 13.5 20.5 18 25 22.5 35 39.5 41 58 68
M22 15.5 16 24.5 21 30 26 42 46 49 67 75
M22 × 1.5 17 18.5 28 24 34 29 47 52 56 75 85
M24 20.5 21.5 33 27 40 34 55 58 63 82 92
M24 × 1.5 23 25 37 31 45 38 61 67 74 93 103

Others:
1. The above torque rating have been determined to 70 % or so of the limit value for bolt elasticity.
2. Tension is calculated by multiplying tensile strength by cross section of thread.
3. Special screws should be tightened to 85 % or so of the standard value.
For example, a screw coated with MoS2 should be tightened to 60% or so of the standard value.

Appendix - 174 -
● Tightening torque for plug screw

Allow-
Compo- Specifica-
Item Inspection item able Repair Remarks
nent tions
Limit
Worn inside diameter of ø111 ~
- - -
cylinder liner ø111.022
Cylinder There must be Difference in projection
Liner projection 0.03 ~ 0.08
block projection with nearby liner: ø0.15
and Flatness of warped upper Repair it with a
0.05 For a length of 200 mm
liner surface of cylinder block surface grinder
Engine Hydrostatic test Replace if
4
parts (one minute) (kg/cm2) leaking oil
Valve seat Intake 0 ~ 0.3 - Replace the
Cylinder depression Exhaust 0 ~ 0.3 - valve seat
head Replace the
Cylinder head height 109.9 ~ 110.1 108.4
and cylinder head
valves Hydrostatic test Replace if Water Temperature
4
(one minute) (kg/cm2) leaking oil 70 °C
Measure at a spot 13
ø110.801 Replace the
Piston O.D. mm from the bottom
~ ø110.959 liner
surface of the piston
Replace if the
Clearance between the wear exceeds
0.041 ~ 0.221 0.3
piston and liner the specified
amount
Top ring 3.50 Replace the
Second ring 3.06 ~ 3.08 piston if the
Pistons Piston ring
groove width
groove
exceeds the
width Oil ring 4.04 ~ 4.06 specified
amount
Main
Piston protrusion from the Measure under the
drive
upper surface of the 0 ~ 0.12 edge of the top part
compon
cylinder block which is not worn
ents
Allowable weight Replace the
±15 g 96 g ↓
difference among pistons piston
Top ring 0.30 ~ 0.50 1.5
Piston ring Replace the Standard gauge
Second ring 1.10 ~ 1.30 1.5
gap ring I.D.: ø108
Oil ring 0.25 ~ 0.55 1.5
Top ring 0.105 ~ 0.150 0.3
Piston Piston ring Replace the Usable limit for
Second ring 0.050 ~ 0.082 0.15
rings side gap ring or piston standard gap
Oil ring 0.35 ~ 0.062 0.15
Install the
rings at 120°C
Ring gap direction
from each
other

- 175 - Appendix
 Allow-
Compo-
Item Inspection item Specifications able Repair Remarks
nent
Limit
Replace the
Piston pin O.D. ø41.994 ~ ø42
piston pin
Piston Replace if the
ring Clearance between the wear exceeds
0.055 ~ 0.071
piston and bushing the specified
amount
Unevenly worn journal Repair it with a
0.01
and pin grinder Measure in vertical
Use the and horizontal
ø83.966 ~ directions
Journal O.D. ø83 undersize
ø83.988
bearing
ø70.971 ~ Each (0.25, 0.5,
Pin O.D. ø70
ø70.990 0.75, 1.0)
Ovalness of journal and
0.008 0.025
pin
Allowable concentricity
0.01 0.03
of journal and pin
Allowable inclination of
Main 0.01 0.03
journal and pin
drive
compon Crankshaft and bearing Replace the
Crank 0.052 ~ 0.122 0.25 Measure on crown
ents clearance valve spring
shaft
Replace the
Crankshaft free play 0.15 ~ 0.325 0.25
thrust bearing
Adjust Measure at No. 4
Deflection of crankshaft 0.1 ↓ deflection with a (Supporting No. 1
press and 7)
Crankshaft balance 60 or
60 ↓
(g.cm) less
There should be
Tightening torque of
Apply oil to the no foreign material
journal bearing 30
bolt on the bearing cap
cap bolt (kg.m)
mounting surface
Tighten the metal
cap and unscrew
Journal bearing crush 0.08 ~ 0.110
one stud bolt for
measurement
Replace the oil
Worn oil seal (Back side
seal if there are
of crankshaft)
any oil leaks

Appendix - 176 -
 Allow-
Compo-
Item Inspection item Specifications able Repair Remarks
nent
Limit
Connecting rod free Replace
0.170 ~ 0.248 0.50
play connecting rod
Clearance between
Replace the
connecting rod bearing 0.034 ~ 0.098 0.25
bearing
and crank pin
Install the
Clearance between
bearing and
small end bush and 0.050 ~ 0.081 0.12
loosen one bolt
piston pin
for measurement
Tighten the
Main bearing cap and
drive Connecting Connecting rod bearing 0.30 ~ 0.50 loosen one stud
compon rod crush Height
bolt for
ents
measurement
Lateral clearance of big Replace
0.50
end and small end connecting rod
Allowable weight
difference among 18 g ↓
connecting rods
Remove foreign
Connecting rod bearing Apply oil to the materials from
18
cap bolt torque (kg·m) bolt the connection
surface
ø11.969 ~
Intake ø11.949 Replace the guide
Valve stem ø11.980 Replace valve
when replacing the
O.D. ø11.944 ~ and valve guide
Exhaust ø11.914 valve
ø11.955
Valve
Valves Valve stem Intake 0.02 ~ 0.049 0.10
system
and valve Replace
Exhaust 0.045 ~ 0.074 0.15 Replace valve
guide whichever one
and valve guide
Valve head Intake 4.6 ~ 5.0 4.1 is more worn
thickness Exhaust 4.33 ~ 4.83 3.83

- 177 - Appendix
 Allow-
Compo-
Item Inspection item Specifications able Repair Remarks
nent
Limit
Intake - Free length of inside
72.43 mm -
spring
Intake - Set length of inside 46.3 mm/
-
spring (P1/P2) 32.8 mm
Intake - Load on inside spring ±1.0 kg/
16.0 kg/29.5 kg
(P1/P2) ±2.5 kg
Intake - Free length of outside
68.17 mm -
spring
Intake - Set length of outside
46.3 mm/32.3 mm -
spring (P1/P2)
Intake - Load on inside spring ±2.0 kg/
Valve 39.0 kg/71.5 kg
(P1/P2) ±5.0 kg Replace valve
spring
Exhaust - Free length of inside spring
(ships) 72.43 mm -
spring
Exhaust - Set length of inside
46.3 mm/32.3 mm -
spring (P1/P2)
Exhaust - Load on inside spring ±1.0 kg/
16.0 kg/29.5 kg
(P1/P2) ±2.5 kg
Exhaust - Free length of outside
68.17 mm -
spring
Exhaust - Set length of outside
46.3 mm/32.8 mm -
spring (P1/P2)
Exhaust - Load on inside spring ±2.0 kg/
39.0 kg/71.5 kg
Valve (P1/P2) ±5.0 kg
system Intake - Free length of inside
-
spring
Intake - Set length of inside
-
spring (P1/P2)
Intake - Load on inside spring
-
(P1/P2)
Intake - Free length of outside
61.9 mm
spring
Exhaust
Intake - Set length of outside
valve 46.8 mm/32.8 mm
spring (P1/P2)
spring
Intake - Load on inside spring ±2.5 kg/
(For 47.0 kg/90.5 kg
(P1/P2) ±4.5 kg Replace valve
marine
Exhaust - Free length of inside spring
genera- -
spring
tor
Exhaust - Set length of inside
model) -
spring (P1/P2)
Exhaust - Load on inside spring
-
(P1/P2)
Exhaust - Free length of outside
61.9 mm
spring
Exhaust - Set length of outside
46.3 mm/32.8 mm
spring (P1/P2)
Exhaust - Load on inside spring ±2.5 kg/
46.8 kg/32.8 kg
(P1/P2) ±4.5 kg

Appendix - 178 -
 Allow-
Compo-
Item Inspection item Specifications able Repair Remarks
nent
Limit
ø25.005 ~ Replace the
Rocker arm bushing I.D. ø25.083
ø25.035 bushing
Diameter of rocker arm ø24.967 ~ Replace the
ø24.930
shaft ø24.990 shaft
Replace the
Rocker arm oil gap 0.015 ~ 0.068 0.14
bush and shaft
I.D. of valve tappet ø20.000 ~
- ø20.H7
assembly on the block ø20.021
Replace the
Tappet clearance 0.035 ~ 0.077 0.15
tappet
I.D. of bush assembly on ø70.070 ~ Replace the
ø69.464
the block (thrust) ø70.090 bushing
I.D. of bush assembly on ø70.000 ~ Replace the
ø69.192
Valve the block (middle) ø70.030 bushing
Timing
system Camshaft bearing ø69.910 ~
-
diameter ø69.940
Camshaft bearing oil gap Replace the
0.060 ~ 0.120 0.24
(thrust) cam or bushing
Camshaft bearing oil gap Replace the
0.130 ~ 0.180 0.24
(middle) cam or bushing
Axial free play of the
0.24 ~ 0.86 -
camshaft
Backlash (crank gear -
0.143 ~ 0.292 -
camshaft gear)
Backlash (camshaft idler
0.112 ~ 0.370 -
gear - camshaft gear)
Intake valve clearance 0.25 ±0.05 -
Exhaust valve clearance 0.35 ±0.05 -
Check for oil
Oil pressure leaks and the
4.8 or below 3.5
(normal speed) (kg/cm2) clearance of
Oil
each part
pressure
Lubrica- Use the
Oil pressure (no load)
tion 0.8 ~ 1.4 0.6 recommended
(kg/cm2)
system oil
Max. allowable oil No
Oil - 105°C
temperature temperatures
tempera-
higher than this
ture Oil pressure (no load) - 120°C
are allowed

- 179 - Appendix
 Allow-
Compo-
Item Inspection item Specifications able Repair Remarks
nent
Limit
Axial clearance of oil pump
0.055 ~ 0.105 -
gear
Replace the
Clearance between gear gear or cover
shaft and oil pump cover 0.032 ~ 0.077 -
hole
Clearance between drive Replace the
Oil pump
gear bushing O.D. and 0.040 ~ 0.094 - bushing or
drive hole cover
ø16.950 ~ Replace the
Gear shaft O.D. ø ø17e7
ø16.968 gear shaft
Drive gear bushing O.D. ø28.000 ~ Replace the
Lubrica- ø ø28e7
(kg/cm2) ø28.033 bushing
tion
Oil pressure adjustment
system 4.0 ~ 4.8 0.8
valve
Bypass valve for oil filter Replace the
1.8 ~ 2.3 0.8
element (kg/cm2) valve
Valve
Bypass valve for full-flow
opening 4.0 ~ 4.8
oil filter (kg/cm2)
pressure
Relief valve for the oil
8.5 ~ 11.5
pump (kg/cm2) Replace the
Adjustment valve for the valve
1.5 ~ 1.8
spray nozzle (kg/cm2)
Clean and
Oil filter Damaged oil filter cartridge
replace

Appendix - 180 -
Governor Actuator
Controller
Governor Actuator

Definition
The governor detects the engine rpm using a magnetic pick-up sensor to adjust the flow rate of the injection
pump and maintain the desired rpm.
The governor activates the engine’s fuel injection pump when the accelerator pedal is pressed while the vehi-
cle is in operation and adjusts the speed of the vehicle.
The governor detects the engine speed, compares it with the set speed and sends out an output signal to
open or close the fuel injection pump accordingly until the actual speed reaches the set speed.
In terms of operating the vehicle, the driver monitors the speedometer and if there is a desired speed, this cor-
responds to the governor’s speed input, while the governor’s output adjusts the accelerator in order to main-
tain the desired speed.

Appearance and Installation

This is a picture of the governor actuator installed
which electronically controls the injection pump
assembled with the generator engine.

EDL11180001

Operating Principles
In this system, when adjusting the engine output,
the controller is adjusted to set and activate the
IDLE and RUN RPM, while the electronic governor
is operated to adjust the injection pump and engine
output.

• The moving core is activated to adjust the rpm.

-1-
Product Specifications
1. General specifications

Item GN11 (DWA-2000) GN12 (GNSA-2002)

Operating voltage (kg/lit) DC 24V DC 24V
Max. fuel quantity (°C) Adjust Adjust
Production capacity (40°C) (cst) 200 ~ 1,000 KW 150 ~ 250 KW
Allowable humidity (wt%) 100% 100%
Operating current (°C) 1.5 A 2.0 A
Max. operating current (°C) 4.5 A 3.1 A
Rack operating power (°C) 58.7 N 27.5 N
Rack operating range (ASTM) 20 mm 21 mm
Engine injection pump specs. Right rack type Right rack type

2. Mechanical specifications

Item GN11 (DWA-2000) GN12 (GNSA-2002)

Product dimensions 107.1 x 180.4 x 196.5 112 x 205 x 101
Product weight 4.9 kg 2.6 kg
Installed engine (Bosch type) P 3000, P 7000 AD Series
Material for exterior AL (ALDC-12) AL (ALDC-12)
Material for core Pure iron Pure iron
Coil size and no. of turns Ø0.85 / 715 Ø0.6 / 790

-2-
3. Outside view and main components of governor

7 3 1
2
6

4
8

EDL11180002

1) Frame : The body of the governor. Made of ALDC-12 with high corrosion resistance.
2) Ball link assembly : A bearing assembly which connects the injection pump rack and governor
actuator operating lever.
3) Stop plate : A part assembled with the ball link assembly. It serves to stop the engine by
means of the emergency stop lever.
4) Static core assembly : A welded assembly composed of several layers of pure iron. A coil is wound
around a bobbin, press fitted into the frame of the static core and the assem-
bly, and then fixed in place with an epoxy resin.
5) Moving core assembly : A welded assembly composed of several layers of pure iron. When the gover-
nor controller adjusts the engine, the moving core assembly is activated to
control the fuel and adjust the speed.
6) Operating lever : A lever which connects the shaft and ball link assembly.
7) Stop lever : An emergency stop lever which stops the engine manually when the engine
cannot be stopped by the control panel. (Material: P.O. sheet)
8) Coil : A copper wire made of 0.85 ￠ LG B enamel and wound 715 turns around a
bobbin. It is connected to the governor controller and acts as an electromag-
net.

-3-
Control Unit (1)
The engine speed control unit used by Doosan is an electronic control unit designed to be able to respond
quickly and accurately to changes in the instantaneous load.
This control unit is designed to receive a signal from the magnetic pick-up sensor (speed sensor) of the
engine when a fluctuation occurs in the engine load and then be automatically fine-tuned to the changes in the
engine rpm, thereby providing high reliability and satisfying adverse environmental engine conditions.
The main feature of this device is that it includes functions for adjusting the amount of starting fuel and the
fluctuations in the speed. It thereby helps to reduce engine emissions. It also has a function for parallel engine
operation, a protective function for when the battery polarity is reversed, and functions designed to ensure
safety during short circuits in the actuator circuit, battery power cut-off or failure of the magnetic pick-up sen-
sor.

Description of Functions
In order for the controller or actuator to function normally, the output signal value of the magnetic pick-up sen-
sor must be 0.5 ~ 120V, and this signal is connected to "C" and "D" on the controller. Terminal "D" is con-
nected to the negative ("-") battery terminal "E" inside the controller terminal.
When the signal from the magnetic pick-up sensor reaches the controller, it is converted into an analog speed
signal and amplified.
In the event that the controller fails to receive the output value from the magnetic pick-up sensor during oper-
ation, the controller’s output circuit shuts off all current flowing to the actuator.
The controller’s integrated circuit receives the signal from the magnetic pick-up sensor based on the set
speed value. This range is 8 : 1 and can be adjusted with the 25-turn potentiometer. This speed setting output
value becomes the input value traveling to the dynamic control section. With the help of this dynamic control
circuit, most of the engine and fuel systems perform evenly and stably.

CAUTION
For the connection to the magnetic pick-up sensor, either two wires twisted together or
shielded wire should be used, but be careful that this shield is not grounded to the engine.
If grounded to the engine, an incorrect speed signal may be delivered to the speed controller.

The controller’s circuit may be affected by adjustments to the gain and stability. In order to increase the oper-
ating responsiveness of the actuator within the governor, turn the gain clockwise to adjust it. The adjustment
range for the gain is approximately 33 : 1.
If the stability is turned in the clockwise direction, the actuator, i.e. governor reaction time increases.
While the engine is running, the starting fuel in the controller can be adjusted from an almost closed state to a
completely open state. When the engine is started, the adjusted position of the speed is determined initially by
the set idle value and the speed ramping circuit. When the engine has finished speeding up, the engine is
kept at the set speed while satisfying the speed fluctuation rate of the controller.
The controller’s output circuit switches the current for activating the actuator at a frequency of around 500 Hz.
This is because no visible changes appear in the output curve for the actuator since the switching frequency is
much higher than the natural frequency of the actuator.
The transistors in the output section are switched in order to achieve effective control of the output, thereby
reducing power consumption within the controller. The output circuit delivers up to 10 A of continuous current
from the 12V or 24V battery system at 25.
The actuator responds to the average value of the current based on the position of the fuel control lever.

-4-
The performance of the speed controller is stable in its standard state. In order to switch this to the droop mode, ter-
minals "K" and "L" must be connected to one another, and the amount of change must be adjusted with the adjust-
ment control lever. In addition, the droop range increases when terminals "G" and "H" are connected.
The engine speed controller includes functions for protecting the actuator and the engine, as well as addi-
tional functions. For example, the controller circuit includes a protective circuit for minimizing overspeeding
which may occur when an excessive load is applied to the engine while starting or running the engine. The
current controller also includes a load divider and automatic parallel feeder which, when used, enable parallel
operation.

-5-
Specifications
Item Details Specifications
Simultaneous Operation /
±0.25 % or less
Relative Normal Stability
Speed Range / Governor 1 K ~ 7.5 KHz continuously
Speed deviation based on changes in temp. Max. ±1%
Idle Adjustment (Clockwise) 1,200 Hz or less
Idle Adjustment (Counterclockwise) 4,100 Hz or less
Performance Droop Range Adjustable between 1 ~ 5%
Max. Droop Adjustment
Fluctuation of 875 ±75 Hz / 1.0 A
(With Terminals K-L Connected)
Min. Droop Adjustment
Fluctuation of 15 ±6 Hz / 1.0 A
(with Terminals K-L Connected)
Speed Trim Range ±200 Hz
Remote Variable Speed Range 500 ~ 7.5 Hz
J 100 ±15 Hz / Volt @ 5.0 K
Terminal L 735 ±60 Hz / Volt @ 65 K
Sensitivity N 148 ±10 Hz / Vo1t @ 1 Meg
P 10 V DC supply @ 20 ma.
Speed Switch Adjustment Range 1,000 ~ 10,000 Hz
Ambient Operating Temperature Range -40 ~ 85°C
Environmental
Relative Humidity Up to 95 %
Conditions
Surface Treatment Corrosion resistance
12 or 24V DC (instantaneous and back
Supply
voltage protection) *
Polarity " - " ground
Power Consumption 50 mA of continuous current to actuator
Input Power
Actuator Current at 25°C (Inductive Load) Continuous min. 2.5 A, max. 10 A **
Speed Sensor Input Voltage 0.5 ~ 120V
Speed Switch Relay Contact
10 A
(N.O. and N.C.)
Vibrations 1 G @ 20 ~ 100 Hz
Reliability
Testing 100 % functionality test
Dimensions Refer to outside view feature
Type Weight 820 g
Installation Installed vertically

CAUTION
* The droop is based on the 4,000 Hz speed detection frequency from no load to full load, as
well as changes of 1 A in the actuator current. When the speed sensor signal is high, the
amount of droop decreases, and when the amount of change in the actuator is large, the
amount of droop changes significantly. For details about droop operation, refer to the
description of droop.
** Protects against back voltage using a diode. A 15 A fuse must be installed on the battery
anode.
*** There is a protective device which cuts off current flowing to the actuator in the event of a
short circuit. Once this short circuit is removed, the device automatically returns to normal.

-6-
Components
DWC-2000

154
6.25

9.5

15

Over speed
1 2 3 4 5 6 7 8 9 Run
Reset
Crank
Overspeed Run Crank Speed Test
Gain
D1
Model : DWC-2000
Input : DC24V ON OFF Stability
Part No. :
Serial No.:
Starting
139

GHANA CONTROL
826-1 Kuro 3-Dong, Duro-Gu Seoul 152-053 KOREA(DONG-IL TECKNO-TOWN)
MADE IN KOREA Fuel
D2
Speed
ON OFF Ramping
Idle Idle
Speed Trim Droop
Droop
Autuator Pick-up Battery
- +
AUX 10V

A B C D E F G H J K L M N P
15

32
10V POWER
ACTUATOR AUX.
ADD JUMPER FOR 12V
BATTERY OR ACTUATOR
CURRENTS ABOVE 5A
GND

Magnetic CLOSE FOR DROOP

Pick up

CW
FUSE
BATTERY CLOSE FOR IDLE
15A MAX
SPEED TRIM
OPTIONAL ACTUATOR CONTROL-5K
CABLE SHIELDING TO
MEET CE DIRECTIVE

EC8OM008

-7-
GAC-ESD5550

6.00 (152)
5.25 (133)
O 0.27 (7)

C1 OFF ON C2
LEAD CIRCUIT SOFT COUPLING
ON OFF

OVERSPEED
OVERNORS
GA MERICA 1 2 3 RESET TEST
C ORP
OVERSPEED

SPEED CONTROL UNIT

MODEL : ESD5550 SPEED

S/N
GAIN
MADE IN AGAWAM, MA U.S.A

STABILITY
6.05 (165)

6.00 (152)

STARTING SPEED
E2
FUEL RAMPING
E1 E3
DEAD TIME
CAUTION
ENGINE SPEED CONTROL DROOP COMPENSATION
COMPONENT WHEN INSTALLING
OR SERVICING REFER TO
JUMPER
PRODUCT PUBLICATION

PICK-UP _ + IDLE
10V
ACTUATOR BATTERY
AUX OUTPUT
A B C D E F G H J K L M N P

OPTIONAL ACTUATOR ACCESSORY POWER 1.03 (26)

CABLE SHELDING TO SUPPLY
MEET CE DIRECTIVE ACCESSORY INPUT
* ADD JUMPER FOR 12V
BATTERY OR ACTUATOR
ACTUATOR CURRENTS ABOVE 5A
CW GROUND REFERENCE
MAGNETIC PICK-UP CLOSE FORDROOP

SPED TRIM
_ CONTROL - 5K CLOSE FOR IDLE
+ S1

BATTERY FUSE 15A

EA6M4004

CAUTION
If the length of the wires is over 3 m, shielded wire must be used. One end must be grounded
using shielded wire.
The speed control unit must be firmly installed in the control cabinet or engine just as with
other sensitive control equipment.
If there is concern that the controller may come into contact with water or condensation, the
controller must be installed vertically.

-8-
Description of Controller Terminology
1. Starting Fuel
Controls the amount of starting fuel during the initial ignition. When rotated clockwise, the amount of fuel
increases.
2. Speed Ramping
Controls the time required to reach the maximum rpm. When rotated counterclockwise, the time required
for reaching the rated rpm decreases.
3. Idle
Adjusts the idle rpm of the equipment. When rotated clockwise, the engine rpm increases.
4. Gain
Stabilizes fluctuations in speed occurring in the engine.
5. Stability
Stabilizes fluctuations in speed caused by the engine load.
6. Speed
Adjusts the engine rpm. When rotated clockwise, the engine rpm rises.
7. Overspeed
Adjusts the engine overspeed rpm. When rotated clockwise, the maximum rpm rises.
8. Droop rpm
Used when running the generator in parallel.
9. Reset
Used when resetting the overspeed controller.
10. Test
Used when checking or setting the overspeed.
11. Terminals A and B
Connected to the actuator in the engine injection pump. (No polarity)
12. Terminals C and D
Connected (no polarity) to the magnetic pick-up sensor.
Shielded wire must be used. It must also not be connected to the magnetic pick-up sensor for any other
purposes.
13. Terminals E and F
Connected to the battery (E R - terminal, F R + terminal).
14. Terminals G and M
Terminals for maintaining the idle rpm.
15. Terminals K and L
Terminals for droop.
16. Terminals H, J, N and P
Auxiliary terminals.

-9-
Wiring
Please refer to the chart above for the basic electrical wiring. When connecting the actuator and battery to ter-
minals A, B, E and F, the wire thickness must be at least 1.3 mm2. If the wires are long, they must be thicker in
order to reduce drops in voltage.
For the positive (+) battery terminal "F," a 15 A fuse must be used as shown in the picture.
The ground cable of the magnetic pick-up sensor connected to terminals "C" and "D" must either use two
wires twisted together for its entire length or be shielded.
The shielded part of the wire for the magnetic pick-up sensor must be connected to terminal "D." The shielded
part must be insulated so that it is not grounded to the engine. Otherwise, an incorrect frequency signal may
be delivered to the speed control unit.
The voltage of the magnetic pick-up sensor must be at least 1V while the engine is running.

How to Adjust the Engine Performance (For New Controllers)

1. Before starting the engine
(1) Set the gain and stability potentiometers of the controller to the central positions.
(2) Starting fuel
Turn the potentiometer as far clockwise as possible. (The position in which the most fuel is supplied)
(3) RPM ramping
Turn it as far counterclockwise as possible. (The position in which the reaction speed is quickest)
(4) Turn the idle potentiometer as far clockwise as possible.
(5) Connect terminals G and M. (To maintain the idle rpm after starting the engine.)
2. After starting the engine
Once the engine is started, move the actuator to the maximum fuel supply position, then maintain the idle
rpm after starting it.
(1) Check the state of ignition and adjust the starting fuel and speed ramping suitably.
(2) If the engine appears unstable after starting it, turn the gain and stability potentiometers counterclock-
wise to adjust them until it stabilizes.
(3) After disconnecting terminals G and M, use the speed potentiometer to adjust the maximum rpm.
(4) After reconnecting terminals G and M, adjust the idle rpm to 750 rpm, disconnect the connecting wires
and then check and adjust the maximum rpm.
3. Setting the engine rpm
If the speed potentiometer of the controller is turned clockwise, the setting value of the engine rpm
increases. In order to do so, a 5K potentiometer must be installed between terminals "G" and "J."
4. Adjusting the characteristics of the actuator
Do the following after setting the engine to the rated no-load speed.
(1) Turn the gain potentiometer clockwise until the engine characteristics become unstable. Slowly turn
the potentiometer clockwise until the engine stabilizes again. In order to obtain an accurate setting
value, turn the potentiometer counterclockwise slightly.
(2) Turn the stability potentiometer clockwise until the engine characteristics become unstable. Slowly
turn the potentiometer counterclockwise until the engine stabilizes again. In order to ensure accuracy,
turn the potentiometer counterclockwise slightly.

- 10 -
 (3) If the engine is running with load, the gain and stability must be adjusted finely. Generally, this should
be done in an unloaded, stable state.

CAUTION
In the event that it continues to appear unstable or demands higher performance in spite of
being adjusted, refer to the section on troubleshooting.

5. Adjusting the starting fuel

Exhaust smoke occurring after the engine is started can be minimized as follows.
(1) Idle the engine and connect terminals "M" and "G."
(2) Use the idle potentiometer on the controller to adjust it to the minimum rpm at which the engine is sta-
ble.
(3) Turn the starting fuel potentiometer counterclockwise until the engine speed drops. Increase the
potentiometer slightly in order to set the idle rpm to a suitable speed.
(4) There are two ways of increasing the engine rpm using the SPEED potentiometer on the speed con-
troller.
Method 1) Accelerating the rated speed immediately after starting the engine (used in generators)
Disconnect terminals "M" and "G" and start the engine, then adjust the speed ramping
potentiometer in order to minimize the exhaust smoke while the engine accelerates from
the idle rpm to the rated rpm.
Method 2) After starting the engine, keeping the engine at the idle rpm for a certain amount of time
until it is accelerated to the rated speed
a) Use the switch to connect terminals "M" and "G." Turn the speed potentiometer counter-
clockwise to adjust the engine rpm. But if excessive exhaust smoke is produced while
accelerating the engine, adjust the starting fuel potentiometer counterclockwise. But if it
takes an excessive amount of time to start the engine, adjust the potentiometer clockwise
gradually.
b) In order to minimize the amount of exhaust smoke while accelerating from the idle rpm to
the rated speed, adjust the speed ramping potentiometer with the switch open.
6. Setting the idle rpm
The idle speed increases when the idle potentiometer on the controller is turned clockwise. When the
engine is set to the idle speed, this controller must be in the "droop" state in order to be able to drive sta-
bly.
7. Droop operation
Droop is used when running the engine generator in parallel, so do not use it when running the engine in
isolation.
The value increases when the selection switch is set to the DROOP position and the droop potentiometer
is turned clockwise.
In other words, the greater the load applied to the engine in this position, the more the speed drops.
The droop range is determined by the amount of change in the current flowing to the actuator when the
engine load changes from no load to full load.
The droop range can be determined by means of internal adjustment of the controller alone and is usually
set to within 10%.
After adjusting the droop range, you can reset the previously set value of the rated speed. After measuring
the engine rpm, reset the speed as necessary.

- 11 -
8. Auxiliary input
Auxiliary terminal "N" receives signals from the load divider, automatic parallel feeder or other auxiliary
devices in the governor system. Connect auxiliary devices for the speed controller directly to this "N" ter-
minal. Use shielded wires when connecting wiring. When the automatic parallel feeder is used inde-
pendently from the load divider, a 3 m resistor must be used between terminals "N" and "P" in order to
adjust the voltage of the engine speed controller and parallel feeder.
The engine rpm drops when an auxiliary device is connected to terminal "N," so be sure to reset the con-
troller.
A jumper must be used between terminals "G" and "J" or the frequency must be adjusted when the engine
speed controller is operating at the maximum acceptable frequency.
When using this device, the acceptable frequency range of speed control is increased to over 7,000 Hz.
9. Auxiliary supply
Power can be supplied to auxiliary devices in the governor system at terminal "P" at an even voltage of
+10 V, with a maximum current of 20 mA.
Terminal "G" is the reference potential terminal for terminal "P." If terminal "G" is short-circuited, the
engine speed controller may be damaged.
10. Remote speed adjustment
A speed adjustment potentiometer is required in order to continuously adjust the engine speed remotely
over a certain speed range.
Refer to the following chart in order to select a potentiometer to suit the uses based on the required speed
range. If the required speed range is not in this chart, select a potentiometer for a range which is one level
higher.
In order to obtain the correct speed range, additional fixed resistors can be attached to both ends of the
potentiometer. Connect the potentiometer for setting the speed range according to the following wiring
connection diagram.

CAUTION
The generator set supplied by Doosan does not include a speed potentiometer for remote
control. The consumer must install one themselves if they desire remote control. In order to
obtain engine stability at a very low speed setting, a droop potentiometer can be used to
obtain a small amount of droop.
On the other hand, when the speed setting is at its highest, the actuator runs almost stably
regardless of the set droop value.

< Capacity and Wiring Connection Diagram

for Remote Control Potentiometer > G J K L

Speed range Potentiometer value

900 Hz 1K

2,400 Hz 5K

3,000 Hz 10 K

3,500 Hz 25 K CW
EA6M4005
3,700 Hz 50 K

- 12 -
Troubleshooting
1. When the system does not work
When the engine actuator does not work, you can deduce the fault by performing the following four-step
voltage test.
Be sure to check the polarity when performing measurements.

Step Terminal Specifications Possible cause

1. DC battery power not connected, check for dam-
Battery supply voltage aged fuse
1 F (+) & E (-)
(12 or 24V DC) 2. Low battery voltage.
3. Faulty wiring connection.
1. Large gap between magnetic pick-up sensor and
ring gear (Check gap)
1.0V AC
2. Faulty wiring in magnetic pick-up sensor
2 C&D (when starting the
(Check whether the resistance between terminals C
engine)
and D is 30 ~ 1,200)
3. Fault in magnetic pick-up sensor
10V DC 1. Short circuit in terminal P (causes fault in controller)
3 P (+) & G (-)
(Internal supply voltage) 2. Fault in magnetic pick-up sensor
1. Low setting value for controller speed adjustment.
1.0 ~ 2.0V DC
2. Open or short circuit in actuator wiring.
4 F (+) & A (-) (when starting the
3. Fault in controller
engine)
4. Fault in actuator

- 13 -
2. System not working properly
In the event that the system is not running properly, perform the following test.

Item Details Specifications

Engine 1. Do not run the engine 1. The actuator will move to the position for
overspeeds 2. Apply a DC power supply to maximum fuel supply. Then disconnect the
the actuator. magnetic pick-up sensor connected to ter-
minals C and D.
(1) If the actuator moves to the position for
maximum fuel supply: There is a prob-
lem in the controller.
(2) If the actuator is in a neutral fuel posi-
tion: This is due to the wrong speed
signal for the engine speed
Manually maintain the speed 1. When the voltage is between 1.0 ~ 2.0V DC
required for engine operation.
(1) The speed potentiometer is set higher
Measure the DC voltage
than the required speed.
between terminals A (-)
and F (+) of the speed controller. (2) There is a fault in the engine speed
controller.
2. The actuator or connecting device is
restricted when the voltage exceeds
2.0V DC
3. When the voltage is less than 1.0V DC
(1) There is a fault in the speed controller.
4. The gain value is too low
The actuator Is not 1. Measure the battery voltage 1. Replace the battery if the voltage is less
working properly while the engine is running. than 7V in a 12V system or less than 14V
in a 24V system.
2. If terminals A and F are 1. Fault in the actuator or battery wiring
connected momentarily, the 2. Restricted by the actuator or connecting
actuator should move to the link
position for maximum fuel
3. Faulty actuator
supply.
4. Check for a blown fuse in the actuator or a
short circuit in the actuator wiring.
Operating at a 1. Measure the voltage at out- 1. If the measured voltage has a difference of
speed less than put terminals A and B of the less than 2V with the battery voltage, the
that required by actuator while the engine is fuel control is being obstructed such that it
the engine running. cannot reach the maximum fuel supply
position, presumably due to interference
from the actuator linkage.
2. The speed setting is too low

- 14 -
Control Unit (2)

Components
DWG-2013

9 8 7 6 5 4 3 2 1

± Crank ° Run ¯ Over speed

Power Pick-up Crank Run Over speed Starting
Fuel ¦
Test
Speed
Ramping
§
­ ¬ «
Idle ¨

Droop ©
£ ¤ ¥
Speed Gain Stability ON
D1 D2
OFF

Frame Actuator Pick-up

Battery
- +
Speed Trim Droop Idle
AUX 10V
ª
GND A B C D E F G H J K L M N P
®

DV2213203B

- 15 -
Installing (Mounting) the Controller and Cautions
1. Install the controller vertically on the face of the control panel, away from water or moisture, and be careful
that heat from heating elements near the controller is not transferred to it.
2. Also, in the event that it is exposed to moisture for an extended period of time (over one month or dew
condensation), it may not reach the rated rpm due to a change in the resistance value of the internal cir-
cuit caused by exposure to moisture, so dry it off sufficiently before using it.
3. Do not rely exclusively on the function of the actuator in the electronic governor to prevent overspeeding. It is
recommended to install a second, independent engine stopping device, such as a fuel shutoff solenoid.
4. Regarding setting each Doosan engine to the average set range depending on the type of engine, the
indications for the set range on the front of each adjustable resistor recommend the settings within the set
range.

EMC (Electromagnetic Compatibility)

In order to minimize damage to the controller due to unnecessary nearby electromagnetic waves, either
mount the controller on a grounded metal surface or use a shielded metal case. All wires should be
shielded and the shielded part should be grounded to a single point. We cannot provide guarantees for
any EMC-related product quality issues arising in the case that the above-mentioned installation method
for preventing electromagnetic waves is not performed.

Description of Control Mode Items

In order to minimize damage to the controller due to unnecessary nearby electromagnetic waves, either
mount the controller on a grounded metal surface or use a shielded metal case. All wires should be shielded
and the shielded part should be grounded to a single point. We cannot provide guarantees for any EMC-
related product quality issues arising in the case that the above-mentioned installation method for preventing
electromagnetic waves is not performed.
1. Items for auxiliary (emergency) control mode
(1) Speed control resistor: Controls the engine’s running speed.
(2) Gain control resistor: Controls the gain (sensitivity).
(3) Stability control resistor: Controls the stability (responsiveness).
(4) Starting fuel control resistor: Controls the amount of fuel when the engine is started.
(5) Speed ramping control resistor: Controls the time it takes to reach the rated speed after starting the engine.
(6) Idle control resistor: Controls the initial engine speed.
(7) Droop control resistor: Controls the amount of droop (%) during droop operation.
(8) Differential control switch (dip switch): A control switch for selecting differential functions.
(9) Overspeed lamp control resistor: Controls the activation timing of the engine speed lamp and relay.
(10) Run lamp control resistor: Controls the activation timing of the engine operation lamp and relay.
(11) Crank lamp control resistor: Controls the activation timing of the initial speed indicator lamp and relay.
(12) TB1: A terminal block for external input/output wiring connections.
(13) TB2: An output terminal for the engine overspeed relay contact. (Capacity - 2 A/125V AC).
(14) TB3: An output terminal for the engine operating speed relay contact. (Capacity - 2 A/125V AC).
(15) TB4: An output terminal for the initial engine speed relay contact. (Capacity - 2 A/125V AC).

- 16 -
Adjustment (Tuning) Order and Method
1. The potentiometer’s guide range on the front of Starting
Fuel
the case is the adjustment range applied to
Doosan Infracore (Inc.) engines.
Speed
2. When adjusting the potentiometer, use a flat- Ramping
blade precision screwdriver of the right size.
(Be careful not to damage the resistor)
Idle
3. Check whether the wiring connections of all
external devices are correct before starting the DV2213193B
engine.

Droop

DV2213193C

4. Adjusting the Engine Start-up Characteristics

(1) Connect the G-M terminals (turn the initial engine speed (idle) switch ON). Starting Fuel

IMPORTANT
Purpose of adjustment: Adjusting to the most economical amount of fuel based on the state
of the engine installed.
Recommended direction: 1 o’clock to 5 o’clock
Problems when adjusted incorrectly: In the 7 o’clock to 1 o’clock direction, there is not
enough fuel, which may cause faulty starting. In the 5 o’clock or higher direction, fuel
efficiency worsens during starting and the amount of exhaust gas may increase.

(2) Adjust the speed ramping potentiometer in the 9 o’clock to 12 o’clock direction.

IMPORTANT
The farther it is turned clockwise, the longer it takes to reach the rated (run) speed.
(Up to 10 seconds or more)
If the value is too low, overshoot or hunting may occur due to sudden increases in speed.
Fuel efficiency may worsen and the amount of exhaust gas may increase.
(3) Start the engine: Turn on the start motor.
5. Adjusting the engine operating speed and initial speed (idle)
(1) Adjust the engine operating speed (frequency).

IMPORTANT
After starting the engine, disconnect the G-M terminal. (Turn the initial speed switch OFF)
Adjust the speed (frequency) with the speed potentiometer while in an unloaded state.
Clockwise: RPM increases / counterclockwise: RPM decreases

- 17 -
 (2) Adjusts the initial engine speed.

IMPORTANT
After turning the initial speed switch ON again, use the idle potentiometer to adjust the speed
to 800 rpm.
Purpose of adjustment: Adjusting the initial amount of fuel for starting the engine and for the
preheating function after starting the engine.
Recommended direction: 12 o’clock to 3 o’clock. There are differences in the direction for
each engine model or rated rpm but we recommend an engine rpm of 800.

IMPORTANT
Problems when adjusted incorrectly: The initial starting performance is degraded and
excessive fuel consumption occurs while preheating.
One must not overlook the fact that the idle speed is one of the main factors which
determines the start-up characteristics of the engine.
Hence, after adjusting the potentiometer, the initial speed must be adjusted regardless of
whether or not idle mode is used.
6. Adjusting the Governor Characteristics

(1) After disconnecting the G-M terminal (initial

speed switch OFF), adjust it when the
engine reaches the operating speed (run
speed).
(2) Adjust the gain. Speed Gain Sta bility

IMPORTANT
Turn the gain potentiometer clockwise
until the engine becomes unstable in
an unloaded state. DV2213196B
Slowly turn the gain potentiometer
counterclockwise and set it at the
position that the rpm becomes in the
most stable state.
For the sake of stability, turn the gain
potentiometer around 20 arcminutes
(10°) in the counterclockwise direction.

7. Adjusting the stability

(1) Turn the stability potentiometer clockwise until the engine becomes unstable in an unloaded state.
(2) Slowly turn the stability potentiometer counterclockwise and set it at the position that the rpm
becomes in the most stable state.
(3) For the sake of stability, turn the stability potentiometer around 20 arcminutes (10°) in the counter-
clockwise direction.

- 18 -
8. Other adjustments
(1) Adjusting the ON timing of the engine oper-
ation (run) lamp. Crank Run Over Speed

IMPORTANT
Turn the run potentiometer
counterclockwise at the engine
operating speed until the engine run
lamp turns on.
In order to prevent the lamp from
DV2213196C
blinking (turning on/off when the load
changes after setting the rated speed),
turn it another 90° in the
counterclockwise direction.
(2) Adjusting the ON timing of the initial speed lamp (crank lamp).

IMPORTANT
Turn the crank potentiometer counterclockwise at the crank speed until the crank lamp turns on.
In order to prevent the lamp from blinking (turning on/off when the load changes after setting
the rated speed), turn it another 90° in the counterclockwise direction.

(3) Adjusting the ON timing of the engine overspeed lamp.

IMPORTANT
Push the test button at the engine operating speed and slowly turn the overspeed
potentiometer counterclockwise until the engine overspeed lamp turns on and the engine
shuts off. It will be set to a speed around 15% higher than the engine operating speed.

IMPORTANT
After all adjustments are complete, restart the engine and check whether the start-up, no load
and load characteristics are stable.
In order to prevent the lamp from blinking (turning on/off when the load changes after setting
the rated speed), turn it another 90° in the counterclockwise direction.

9) Adjusting the starting fuel (minimizing exhaust gas)

(1) Crank speed switch ON  adjust crank speed to 800 rpm  turn the starting fuel potentiometer coun-
terclockwise until the engine speed drops.  For the sake of stability, turn it another 15° in the clock-
wise direction.

CAUTION
If the amount of exhaust gas is not excessive when starting the engine, we recommend
adjusting the starting fuel potentiometer to a higher setting in the 5 o’clock direction.
If set too low, startability worsens and immediately after starting the engine, overshoot may
occur and cause the engine to exceed the set overspeed value.

- 19 -
10) When the engine will not start
(1) If there are no problems with the wiring connections  adjust all control values to the "factory setting."
(Refer to DV2213211A)
 Restart the engine.
(2) If the problem is not resolved: There may be a problem with the controller hardware so replace the
controller.

Idle

Droop

ON
D1 D2
OFF
Battery Speed Trim Droop Idle
Frame Actuator Pick up - + AUX 10V
GND A B C D E F G H J K L M N P

9
10 10V Output

Jumper
Actuator 5
8 Aux Input

1 1.5߮ 2C 2

3 1

4 5ࠗ ON

Mignetic 7
OFF

Pick Up Droop Switch

2
ON

1.5߮ 2C
+

3 6
OFF

Battery 24V - Idle Switch

Power Switch Fuse(10A)

EEX190002

- 20 -
External Wiring Connections

• Refer to the wiring connection diagram to connect them.

• All wiring must be over the specified 1.5 mm2 and be shielded.
• When using shielded wiring, all shielded wires not indicated on the wiring connection diagram must be
grounded to the frame.
1. Twisted cables must be used for the actuator wiring.

IMPORTANT
After connecting the wiring, the resistance between A-B must be 3.5 ~ 4.5 .

2. The cables for the magnetic speed sensor must be "shielded wires," and the shielded part must be con-
nected to terminal D as well.

IMPORTANT
If this shielded part is grounded to the engine or not grounded, a distorted speed signal may
be entered and cause problems such as hunting, so be sure to ground it.

3. Be careful not to reverse the polarity of the battery connected to terminals E and F, and be sure to install a
10 A fuse between the positive (+) battery terminal and terminal F.

IMPORTANT
After connecting them, be sure to check whether the voltage between the terminals is DC 24V
(±4 V). Also, ground terminal E to the frame. (Wiring connection no.10)

4. Connect a 5 kW resistor externally as shown in the picture to enable the engine speed to be fine-tuned
within a range of around "set speed ± 210 Hz."
5. When using a 12V battery or an actuator with a current consumption over 5 A, use a jumper to connect
terminals G and H.
6. A selection switch for switching between the crank speed mode and run speed mode.
7. The droop mode selection switch.

IMPORTANT
ON (connected): droop mode / OFF (disconnected): isochronous mode

8. Connects the signal coming from the auxiliary device used in the parallel operating system to terminal N.

IMPORTANT
Use shielded wires.
9. Accessory power supply: Terminal P, which supplies rated power of +10[V], 20[mA], can be used as a
power supply for external auxiliary devices and applied in a variety of different ways.

IMPORTANT
However, it should only be used within the range of the rated capacity. Be careful to avoid
short circuits, and in the event that the capacity is exceeded, it may cause critical damage to
the controller.

- 21 -
 CAUTION
Incorrectly connected wires or abnormal battery voltage can cause critical damage to the
controller so be sure to inspect them before use.

Mounting and Connecting the Magnetic Speed Sensor

1. The optimal gap between the magnetic speed sensor and ring gear is 0.45 mm. In order to achieve this,
tighten the sensor until it makes contact with the ring gear, then turn it another 3/4 turns in the reverse
direction to obtain a suitable gap.
2. The speed sensor signal can be checked by measuring the voltage (AC) between terminals C-D while the
engine is running.
3. The sensor voltage applied to the controller must be over AC 3V.

Adjusting the Speed Externally

1. By connecting the speed adjustment potenti-
ometer externally as shown in the picture, you G J K L

can adjust the engine speed remotely and

externally within a certain speed range. Refer
to the chart to set the resistance value accord-
ing to the required speed range.
2. When the engine speed is set to the minimum
speed in remote control mode, it causes a
decrease in speed due to the instability and CW
load on the system. Hence, when using the DV2213106A
minimum speed setting, use the droop potenti-
ometer to adjust the amount of droop to a low
level (turning the potentiometer counterclock-
wise), thereby enabling engine stability to be
maintained.
On the other hand, when the speed setting is
at its highest, the governor runs almost iso-
chronously regardless of the set droop value.

Engine rpm Converted for Number of

Potentiometer
Speed Range Ring Gears
Value
160 152 146
900 Hz 1K 337 rpm 355 rpm 370 rpm
2,400 Hz 5K 900 rpm 947 rpm 986 rpm
3,000 Hz 10 K 1,125 rpm 1,184 rpm 1.230 rpm
3,500 Hz 25 K 1,315 rpm 1,381 rpm 1,438 rpm
3,700 Hz 50 K 1,387 rpm 1,460 rpm 1,520 rpm

- 22 -
3. State of adjustment at time of factory release

300611-00683
Overspeed 1,725 rpm (based on 160 gear teeth)
Run lamp Maximum CW
Gain Mid-range (facing 12 o’clock)
Stability Mid-range (facing 12 o’clock)
Starting Fuel Full CW (Maximum Fuel)
Speed Ramping Facing 9 o’clock
Droop Full CCW (Minimum)
E.M. Speed Adjustment (160 gear teeth)
Speed Adjustment 4,000 Hz (1,500 rpm)
Idle Adjustment 2,133 Hz (800 rpm)

CW: Clockwise, CCW: Counterclockwise

300611-00684
Overspeed 1,725 rpm (based on 160 gear teeth)
Run lamp Maximum CW
Gain Mid-range (facing 12 o’clock)
Stability Mid-range (facing 12 o’clock)
Starting Fuel Full CW (Maximum Fuel)
Speed Ramping Facing 9 o’clock
Droop Full Full CCW (Minimum)
E.M. Speed Adjustment (160 gear teeth)
Speed Adjustment 4,800 Hz (1,800 rpm)
Idle Adjustment 2,133 Hz (800 rpm)

CW: Clockwise, CCW: Counterclockwise

- 23 -
 300611-00685
Overspeed 2,070 rpm (based on 160 gear teeth)
Run lamp Maximum CW
Gain Mid-range (facing 12 o’clock)
Stability Mid-range (facing 12 o’clock)
Starting Fuel Full CW (Maximum Fuel)
Speed Ramping Facing 9 o’clock
Droop Full Full CCW (Minimum)
E.M. Speed Adjustment (152 gear teeth)
Speed Adjustment 3,800 Hz (1,500 rpm)
Idle Adjustment 2,026 Hz (800 rpm)

CW: Clockwise, CCW: Counterclockwise

300611-00686
Overspeed 2,070 rpm (based on 160 gear teeth)
Run lamp Maximum CW
Gain Mid-range (facing 12 o’clock)
Stability Mid-range (facing 12 o’clock)
Starting Fuel Full CW (Maximum Fuel)
Speed Ramping Facing 9 o’clock
Droop Full Full CCW (Minimum)
E.M. Speed Adjustment (152 gear teeth)
Speed Adjustment 3,800 Hz (1,500 rpm)
Idle Adjustment 2,026 Hz (800 rpm)

CW: Clockwise, CCW: Counterclockwise

- 24 -
Droop Parallel Operating Mode (Manual Parallel)

• Definition of droop: A reduction in the speed setting following an increase in the load

(No Load Speed - Full Load Rated Speed) * 100

DROOP(%) =
• Full Load Rated Speed

• Purpose of droop: Droop is used with the purpose of load sharing in the parallel operating system among
generators.
• If there is no droop function in the parallel system, the generator may overload or motorize.
• Applying droop: In order to use droop, turn on the droop selection switch connected to terminals K-L.
• When in droop mode, the speed decreases due to an increased load, but you can use the "Droop" poten-
tiometer (7) to determine the amount (%) of droop.

IMPORTANT
Turning it clockwise increases the amount of decrease. (Increases the amount (%) of droop)
The amount of droop generally used is less than 10%. In order to maintain stability in speed
droop governors, the minimum amount of droop required is at least 2.5%. The value of the
rated speed already set based on the adjusted amount of droop can change so check the
engine speed and readjust the speed as necessary.

Accessory Input (Automatic Parallel)

• Accessory terminal N receives signals from the load sharing unit, auto synchronizer or other accessories
in the governor system.
• Use shielded wires when connecting wiring.
• The engine speed drops when an accessory is connected to terminal N so the speed adjustment potenti-
ometer must be reset.
• When the control device is operating at the maximum acceptable frequency, a jumper or frequency trim
control may be required between terminals G and J. When using this device, the acceptable frequency
range of speed control is increased to over 7,000 Hz.

Controller Lamp Display (Diagnosis) Functions

• Power : The lamp turns on when a battery power supply is connected and an internal control voltage
(DC 12V) has been generated. This means that the main controller is running.
• Pick Up : The lamp turns on when the magnetic speed sensor signal entering terminals C-D is over
AC 3.0V.
• Crank : The lamp turns on and the relay activates when the set rated speed (crank speed) is
reached.
• Run : The lamp turns on and the relay activates when the set rated speed (run speed) is reached.
• Overspeed : When the engine speed reaches the set overspeed, the lamp turns on, the relay activates
and the actuator output is blocked.

- 25 -
System Troubleshooting (Instability)

1. Instability at rapid intervals (hunting): Applying SW D1 and D2

(1) The differential function activates when D1 is placed in the ON position.
(2) This can increase the responsiveness to changes in speed (rpm), thereby enabling quicker response
to changes in speed.
(3) Slight hunting may occur at rapid intervals due to sensitive response to external frequency noise.
In such cases, turn D1 off and readjust the gain and stability.
(4) If the instability persists in spite of doing so, turning off SW D2 on the device can help to stabilize the
engine.
(5) After taking such measures, readjust the gain and stability again in order to optimize the system. This
will help to reduce and eliminate instability.
2. Instability at slow intervals (hunting)
The main factors involved in hunting at slow intervals have many causes but generally, it occurs when tun-
ing is not optimized due to the slight differences in mechanical characteristics in each engine. Such hunt-
ing can mostly be resolved by readjusting the gain and stability within the controller.

IMPORTANT
Refer to the information on the order of adjustment.

3) If the problem is not resolved with the methods above

(1) Loss of control function due to a fault in the controller itself - replace the controller.
(2) Fault in an external mechanical device (actuator, fuel injection device, turbine, etc.) - adjust the
mechanical device.

- 26 -
When the System is Not Working

In the event that the engine governor system is not working properly, you can deduce the cause by performing
the test in the following chart.
Here, (+) and (-) represent the polarities of the measuring instrument. Using the method in the chart below, if
the test results are normal, there may be a problem in the actuator or the actuator wiring connections so the
actuator must be inspected.

Measured Time of
Step Normal value Presumed cause of fault Troubleshooting
terminals measurement
1 F (+) & E (-) E/G stopped DC 24V Battery failure Check battery line,
2 F (+) & E (-) E/G starting DC 15 or higher Faulty connection replace battery.

Defective speed sensor

300 ~ 1,200 
Damaged or incorrectly
3 C&D E/G stopped using test ohm-
connected speed sensor
meter Check sensor line.
wiring
Replace speed sen-
1.5V or higher sor.
Gap between speed sen-
when measured
4 C&D E/G starting sor and ring gear too wide.
with tester AC
Defective speed sensor
voltmeter
Check line for short circuit
if measured value is less
3.8 ~ 4.5  than 3.8  Check actuator line for
5 A&B E/G stopped using test ohm- Check line for open circuit short or open circuit.
meter if measured value is over Replace actuator
4.8 
Defective actuator
6 P (+) & G (-) Key S/W ON DC 9.5 ~ 10.5V Faulty control device Replace controller.
DC 9 ~ 15V Low speed setting. Check speed settings.
While in when normal Short or open circuit in Check actuator line.
7 F (+) & A (-)
operation DC 1 ~ 3V when actuator wiring connection Check actuator and
abnormal Actuator replace if faulty.

- 27 -
Digital Speed Controller

Product Overview and General Specification

1. Product information
Digital speed controller (DSC-1000) is applicable to generator (vehicles and vessels) engines as a high
performance embedded electronic control system designed based on PID control for fast and precise con-
trol of engine speed with an enhanced micro controller unit (MCU) that minimizes analog circuits vulnera-
ble to user environments.
This product features PID auto setting functions along with battery voltage, pick-up sensors and actuator
condition checking. It also has a black box function that manages engine operation records when faults
are detected for users to have more convenience in operating this precise digital speed controller.

Product features
• Rigid and stable case structure and easily recognizable front design
• Readily understandable GUI (graphic user interface) with graphic LCD displays
• Easy and simple setup with 8 button keys without manual controls by users
• Fast setting available by migrating initial settings depending on types of the engines
• Listing fault messages (over speed, pick-up error, etc.) and recording messages
• RS232 and CAN ports available for communication
• Digital inputs and PID auto setup functions for PID control parameters
• Application of digital clock for fault timing and engine operating hours

- 28 -
2. Product appearance
Digital Speed Controller is made of a rigid aluminum case taking into account anti-shock, electromagnetic
resistance and environmental protection. An embedded system containing graphic LCD and high perfor-
mance MCU is inside the controller and a heat sink is located on the outside of the case for protection and
precise control of actuator operating elements.
A terminal block is located on the bottom and right of the front side for easy connection to external
devices. Over speed, run and crank signals are displayed on the front LED and contact points (a or b) are
also available for outputs on external controllers or indicators.
RS232 and CAN communication is available and DSUB-9 connector enables universal use of RS232
communication.
Users can easily input and adjust values for parameter inputs using 8 button keys. In addition, graphic
LCD shows graphic displays, bar graphs and design symbols so that users can readily identify the control
information while external LED displays important conditions of the engine.

Product Front View

EDL11160002

- 29 -
3. Product specification

No. Item Description

1 MCU 16-bit DSC dsPIC33FJ256
Graphic LCD 128*64
2 Display
LED: 6 ea
3 Keypad 8 Button Keys
4 Output 3 Contact Points (a and b)
5 Input RMS 3V (Min)
6 Memory 128 Mb
RS232 57600 bps
7 Communication
CAN (J1939)/250 kbps
8 Rated Power DC 24V (12V ~ 30V)
9 Current Consumption 120 mA
10 Operating Temperature -20 ~ 70°C
11 Storing Temperature -30 ~ 80°C
12 Operating Humidity 0 ~ 95%

3 2 1

Pin No. Description

1 -
2 -
5 4 3 2 1
3 -
D-SUB Cable Rear View 4 - 9 8 7 6
5 GND
6 +3.3V
7 /MCLR
D-SUB Female
8 PGC2
9 PGD2
Connector

EDL11160081

No. Item Part No. Name

1 D-SUB Cable
2 Pick It 850329-00502 Toolkit Cable
3 USB Cable

- 30 -
4. Product system diagram

System Configuration for Digital Speed Controller

+10V

Toolkit Cable

Aux Input

Speed
Trim
Idle
Switch

* All of the GND(Earth) Mark

must to wiring to GND
Droop
Switch
* CAN and R232 Communication Line
must to concect with shield Cable

EEX190001

5. Product I/O signals

No. Terminal I/O Type Terminal Functions

Outputs are actuator control signals.
Actuator
1 Output Wiring should be 18AWG (105°C) or better. (However, terminals A
(A, B)
and B can be used regardless of their polarities)
Inputs are RPM sensor signals.
Terminal D should be connected to the ground in connection with
Pick-Up
2 Input the shield cable. Gap between the RPM sensor and the gear tooth
(C, D)
should be adjusted between 0.9 and 1.1 mm (sensor inputs should
be at least 3V AC RMS).
Battery It is a power input terminal for the controller and inputs are DC
3 Voltage Input +24V/15A. The positive pole of the battery should be connected to
(-E, +F) the terminal F. (Back voltage protection circuit is built in.)
It has a ground signal and is connected to the ground of the poten-
4 Input (G)
tiometer.
Speed
Inputs are RPM trim signal values and the voltage level is between
5 Trim Input (H)
0 and 5V. It is connected to the output of the potentiometer.
(G, H, J)
Outputs are DC +5V and it is connected to VCC of the potentiome-
6 Input (J)
ter.

- 31 -
No. Terminal I/O Type Terminal Functions
Terminal K receives droop function selecting information.
Droop Terminal L has a ground signal and the switch is connected to ter-
7 Input
(K, L) minals K and L. Once the terminal K is connected to the ground,
droop starts to operate.
Idle Terminal M receives idle function selection signals.
8 Input
(M) Once it is connected to the ground, idle operation starts.
Terminal N receive load sharing and synchronization signal for par-
AUX
9 Input allel operation.
(N)
The signal level is an input between DC -5 and +5V.
10V Outputs are +10V/20 mA ratings and it can be used for various pur-
10 Output
(P) poses including power to external auxiliary devices.
The second crank contact point is a shared terminal while terminals
Crank
1 and 2 are for the contract point b and terminals 2 and 3 for the
Contact
11 Output contact point a. The contact point a starts to operate when the digi-
Point
tal speed controller reaches at the RPM delivering control signals
(1, 2, 3)
to the actuator after the engine is activated.
The fifth run contact point is a shared terminal while terminals 4
Run Con-
and 5 are for the contact point b and terminals 5 and 6 for the con-
12 tact Point Output
tact point a. The contact point a starts to operate when the engine
(4, 5, 6)
reaches its designated normal speed RPM.
Over
The eighth over speed contact point is a shared terminal while ter-
Speed
minals 7 and 8 are for the contact point b and terminals 8 and 9 for
13 Contact Output
the contact point a. The contact point a starts to operate when the
Point
engine reaches its designated over speed RPM.
(7, 8, 9)
CAN Terminal 10 is for CAN-L communication and 11 is for CAN-H com-
14 I/O
(10, 11) munication. CAN-H and CAN-L are used for CAN communication.
Power When DC+24 V power is supplied to the controller, the LED turns
15 Output
LED on in red on the power level.
Pick-Up When the controller receives normal input signals from the pick-up
16 Output
LED sensor, the LED turns on in red on the pick-up level.
The 2- and 3-terminal contact point a starts to operate and the LED
Crank turns on in red on the crank level when the digital speed controller
17 Output
LED reaches at the RPM delivering control signals to the actuator after
the engine is activated.
The LED turns on in red on the run level when the engine reaches
Run
18 Output its designated normal speed RPM with 5- and 6-terminal contact
LED
point a starting to operate.
Over The LED turns on in red on the over speed level when the engine
19 Speed Output reaches its designated over speed RPM with 8- and 9-terminal
LED contact point a starting to operate.
Error The LED turns on in red on the error level when abnormal events of
20 Output
LED the controller occur.
D-SUB 9PIN (male) is connected to the host through RS232 com-
21 RS232 I/O
munication port.
The GND part and the ground should be earthed in shared connec-
22 Ground Ground
tion.

- 32 -
6. Product dimension

170
19 130
165
153
140
6

4- 6

EDL11160004

- 33 -
Installation
Digital Speed Controller should be connected to the pick-up sensor attached on the engine and the actuator.
Speed trim, droop, idle and aux terminals can be used for additional functions in connection with surrounding
circuits. Contact points a or b can also be used to operate external devices using crank, run and over speed
functions. RS232 and CAN port allow communication with PCs or external host computers for data transfer
and monitoring functions.
1. Connecting to the engine
(1) Battery, pick-up and actuator connection diagram

Toolkit Cable

RS232

5 4 3 2 1

9 8 7 6

Pin No. Description Pin No. Description

1 - 6 +3.3V
2 - 7 /MCLR
3 - 8 PGC2
Shield Cable -
4 9 PGD2
5 GND

Generator Control Unit

Fuse
+24 V/15A

Governor Actuator
MC

Battery
Magnetic Speed Pick-Up DC +24 V

EEX190003

- 34 -
(2) Connecting to batteries
Battery voltage is DC +24V and the battery is connected to the controller matching E (-) and F (+) with
the respective polarities of the battery. E (-) is connected to (-) of the battery and F (+) to (+) of the bat-
tery. Depending on cases, wiring can be done in a serial connection to the contact point a of MC and
the fuse (DC +24V/15 A) when connecting to system panels or generator control devices.
(3) Connecting to actuators
The actuator is also called governor and controls the amount of the fuel spray to the engine cylinder.
The controller is connected to the actuator attached on the engine by connecting two wires of the con-
troller terminal to A and B of the actuator regardless of their polarities. Wiring should be 18AWG
(105°C) or better and the outside should be wrapped by plastic tubes for insulation or insulated mesh
lines.
(4) Connecting to pick-up sensors
The pick-up sensor lets users know the engine speed and is connected to terminals C and D that can
receive signals of AC RMS 3V or higher. Wiring should be twisted or shielded cables connected to the
ground together with the terminal D. Gap between the pick-up sensor and the gear tooth should be
adjusted between 0.9 and 1.1 mm.
(5) Operating sequence for digital speed controller
• Power On/Off : It means that DC +24V power is either supplied or terminated through E (-) and F
(+) of the battery matching with their respective polarities.
• LCD On/Off : It means to turn on or off the LCD display alone while DC +24V power is supplied
through E (-) and F (+) of the battery matching with their respective polarities and
the controller is in operation.
Operating sequence for the controller

Step 1) When DC +24V power is supplied to the controller, the controller starts to operate. It indi-
cates that power LED turns on and the power is being normally supplied.

Step 2) Inputs for speed trim, droop and idle functions are received.

Step 3) The controller checks the signals of the speed pick-up sensor.

Step 4) Actuator control signals are output together with designated values of other information for
crank, run and over speed functions according to the PID control values.

Step 5) The controller checks the operation condition and displays LED outputs and fault messages
according to the detected information.

Controller Over Speed

ON H
Pin Name
Crank Idle Run L
DSC ON/OFF OFF
BAT DC +24V
Pick-Up
Droop, Idle
Actuator
Crank Idle Run
LED
Output
Crank Idle Run
Contact

Time Chart for Operation of the Controller EDL11160006

- 35 -
2. Connecting to speed trim, droop, idle and other inputs
(1) Speed trim, droop, idle and other inputs diagram

Toolkit Cable

RS232

5 4 3 2 1

9 8 7 6

Pin No. Description Pin No. Description

1 - 6 +3.3V
2 - 7 /MCLR
3 - 8 PGC2
4 - 9 PGD2
5 GND

+10 V
External
Power
Supply

-5 ~ 5 V
Speed Trim
Potentionmeter
Idle
Toggle SW
AUX Input
Load Sharing
Synchronous
Unit

Droop
Toggle SW

EEX190004

(2) Connecting to speed trim

Speed trim is an analog voltage signal port for input to fine-tune the engine speed. A potentiometer is
used for precise adjustment of the resistance values. The potentiometer needs to be connected to ter-
minals G, H and J. Terminal G should be connected to the ground and it is recommended to use
shielded cables. Terminal H is connected to G depending on the current consumption of the actuator
(for actuators with 5A or higher). J is an input terminal for fine-tuned voltage values between 0 to 5V.

- 36 -
(3) Connecting to droop
The switch is connected to terminals K and L. Signals indicating whether droop function works or not
serve as inputs to the controller by keeping K and L either open or close. Inputs can be done by toggle
or converting switches.
(4) Connecting to idle
The port on one side of the switch is connected to terminal M and the port on the other side to the
ground. Connection between terminal M and the ground becomes either open or close by keeping the
switch open or close. When connection between the terminal and the ground becomes close, the con-
troller will have idle function. Inputs can be done by toggle or converting switches.
(5) Connecting to aux
AUX is a terminal for control signal inputs from load sharing devices or synchronization devices
through terminal N. It shares load from the generator in parallel operation and receives signal inputs
from synchronization devices for the controller to control changes to load. Input signal level is between
DC -5 and 5 V and it is recommended to use shielded cables for signal wires.
(6) Connecting power to external devices
It can supply power output of 10 V/20 mA to external devices through terminal P. Users can easily use
this terminal when external auxiliary devices need power supply.
However, power supply of 20 mA or higher should not be used and care should be given to prevent
short circuits.

- 37 -
3. Connecting to crank, run, over speed and communication
(1) Crank, run, over speed and communication connection diagram
It is used to deliver operation information to external devices by activating contact point (a or b) when activat-
ing crank, run or over speed functions.
RS232 and CAN communication is connected to external PCs or hosts so that the controller can
transmit system settings or operation information.

N
AC220V
L

Crank
Lamp

Run
Lamp

Over Speed
Lamp

CANL CAN
CANH Node

Toolkit Cable RS232

EDL11160008

(2) Connecting to crank terminals

Terminals 1, 2 and 3 are the ones for crank output contact point and the contact point will be in opera-
tion when the controller activates the crank function. The second crank contact point is a shared termi-
nal while terminals 1 and 2 are for the contact point b and terminals 2 and 3 for the contact point a.
Contact points a and b start to operate when the controller reaches at the RPM delivering control sig-
nals to the actuator after the engine is activated. The diagram shows wiring to operate AC220V lamp.
The shared terminal is for 220V inputs and the crank lamp turns on when the contact point a starts to
operate.

- 38 -
(3) Connecting to run terminals
Terminals 4, 5 and 6 are the ones for run output contact point and the contact point will be in operation
when the controller activates the run function. The fifth crank contact point is a shared terminal while
terminals 4 and 5 are for the contact point b and terminals 5 and 6 for the contact point a.
Contact points a and b start to operate when the engine reaches its designated normal speed RPM.
The diagram shows wiring to operate AC220V lamp. The shared terminal is for 220V inputs the run
lamp turns on when the contact point a starts to operate.
(4) Connecting to over speed
Terminals 7, 8 and 9 are the ones for over speed output contact point and the contact point will be in
operation when the controller activates the over speed function. The eighth over speed contact point
is a shared terminal while terminals 7 and 8 are for the contact point b and terminals 8 and 9 for the
contact point a.
Contact points a and b start to operate when the engine reaches its designated over speed RPM. The
diagram shows wiring to operate AC220V lamp. The shared terminal is for 220V inputs the over speed
lamp turns on when the contact point a starts to operate.
(5) Connecting to CAN communication
Terminal 10 is for CAN-L communication and terminal 11 for CAN-H communication. CAN-H and
CAN-L are used for CAN communication with remote control and monitoring of the controller opera-
tion. The communication code is based on J1939.
(6) Connecting to RS232 communication
D-SUB 9pin (female) is for RS232 communication for connection to external PCs or hosts.
It can configure system parameters of the controller or communicate with analytic applications.

- 39 -
Configuration and Operation
The controller can be configured and operated by input keys according to the menus on the LCD display by
selecting proper ones and assigning values in the selected menu to input control information to the system.
Input information should immediately apply to the controller system once updated.
1. Input keys
The controller has 8 input keys including LCD, Mode, Menu, Enter, Up, Down, Left and Right.
Each key as respective functions as follows:

LCD LCD key turns on and off the display.

Mode Mode key switches the display to either operation mode or wave form display.

Menu Menu key lets users change the menu display and go back to the previous menu.

Enter Enter key applies designated values on the LCD display to the system.

Up key lets users go up or increase values in the selected menu on the LCD display.

Down key lets users go down or decrease values in the selected menu on the display.

Left key lets users move to the left in the selected menu.

Right key lets users move to the right in the selected menu.

- 40 -
2. LCD display menu
The overall menu tree of the controller is as follows:

MENU Low Battery

Menu Display

Logo Display Main Display

MENU
MENU

MENU MENU

MENU
UP
LEFT RIGHT
DOWN

RPM Display

MENU Low Battery Menu Display

Logo Display Main Display

MENU
MENU

MENU
MENU

MODE

UP
LEFT RIGHT
DOWN

RPM Display

Overall LCD Menu Tree Diagram

EDL11160049

- 41 -
(1) LCD displays after powered on
When DC +24 V power is supplied to the battery terminal (E (-), F (+)) of the controller, the power LED
in the front side of the controller turns on in red and the error LED turns on in red where there are fault
conditions. At this moment, the LCD display is not activated and Doosan logo will appear for 1 second
followed by the operation display after pressing the LCD button.
The controller will start control based on information from pick-up sensor and other input devices and
designated parameter values. At this moment, where breakdowns of the surrounding devices or sys-
tem errors occur, the LCD display will show such errors and processing messages.
Step 1) DC +24V power supply to the terminals E (-) and F (+)
When DC +24V power is supplied to the terminals E (-) and F (+), the controller will start to operate
with the LCD display off. After pressing the LCD button, Doosan logo will appear for 1 second as
shown below followed by the controller operation display. Then, the LCD display will switch between
on and off by pressing the LCD button.

Doosan Logo
EDL11160051

Step 2) The operation display will show 1 second after the logo appears.

DROOP GIDLE
TRIMG AUX

Displays year and time

Displays the remaining
fuel of the actuator
Displays set RPM

Displays the operation

hours
G while theGG
G
system
G
is G
on

Displays
G operating
G GRPM

Operation Display
EDL11160052

- 42 -
(2) LCD main menu display
Displays main menu screen of the controller
The main menu of the controller has 10 sub-menus.

Main Menu of the Controller 1 to 2

EDL11160053

1 Engine type
The controller can start operation once the initial system values are configured.
Users can load preset values depending on types of the engines by selecting the type.

2 System setup
It consists of sub-menus related to system settings including RUN/IDLE/OVERSPEED/CRANK/
GEARNUMBER.

3 PID gain setup

It consists of sub-menus to designate Kp, Ki and Kd parameter values related to the engine PID
control.

4 PID auto setup

It offers function for automatic designation of Kp, Ki and Kd parameter values related to the
engine PID control.

5 Date/Time setup
It offers function for users to move to the screen for designating year, month, day and hour.

6 Alarm list
It offers function for users to move to the alarm display for the alarm list.

7 Actuator test
It offers menu to test the impedance (XL) of the actuator and any problems in operating load cur-
rent. It displays current and voltage according to the duty values.

8 Default setup
It offers menu to apply designated default values to the selected engine.

9 System info
It offers menu that shows information of the controller. Such information includes the serial num-
ber, software version, last update date, alarm count and engine runs.

10 LCD setup
It offers menu to configure LCD operating conditions including brightness, auto on/off and off
hours.

- 43 -
 11 System monitor
It offers menu to monitor the controller operation. It shows values for Engine RPM, Valve Duty,
Valve Current, Aux RPM Input, Pickup Voltage and Bat Voltage.

(3) Engine type setup menu

This menu offers function to configure setting values of the controller depending on types of the
engines in advance and apply such preset values to the selected engine.

EDL11160014

(4) System setup menu display of the controller

It consists of sub-menus for the system configuration items of the controller including the one for con-
figuring RUN/IDLE/OVERSPEED/CRANK/GEAR NUMBER related to RPM setting. Depending on
additional functions, users can designate values for STARTING FUEL/SPEED RAMPING/ACTUA-
TOR MAX/LOW BATTERY.

EDL11160015

1 Set run rpm

Users can designate normal speed (target RPM) of the engine.
Users need to input different normal speed values depending on the specification of the selected
engine.

2 Set idle rpm

Users can designate the idle speed values of the engine as RPM.
Users need to input values to control the idle operating speed of the engine.

3 Set over speed

Users can designate RPM values to activate engine protection function when the speed exceeds
the normal level (target RPM) and reaches the overspeed range that may cause problems to the
engine.
When the engine RPM reaches the over speed RPM range, the engine immediately stops with
error messages and alarms.

4 Cranking rpm
Users can designate RPM values to activate the actuator when the engine starts to operate.

- 44 -
5 Gear number
Users can input the number of flywheel teeth in the engine to the controller so that the controller
can calculate the accurate RPM depending on the values of the pick-up sensor from the engine.

6 Starting fuel
Users can designate the amount of fuels used when the engine starts to operate and the operat-
ing current for the controller to activate the actuator changes based on these values.

7 Aux. speed
Users can adjust values to ensure safe operation of the engine based on the AUX signal values
when AUX is enabled.

8 Speed ramping
Users can input ratio values of speed changes when the speed increases or decreases in the
idle condition of the engine.

9 Max current
Users can designate the maximum operating current for the actuator of the engine.

10 Low battery
It measures the battery voltage supplied to the controller. When the measured values are lower
than the present voltage values, it will be alarmed. Usually, the acceptable battery voltage is
between 20 and 22V (without load).

11 Droop gain
Users can designate the droop values applicable to maximum load based on the current con-
sumption of the actuator.

12 F-load curr
Users can designate the maximum current values when the generator is in full load.

13 N-load curr
Users can designate the operating current values of the actuator when the generator has no
load.

- 45 -
(5) PID gain setup menu
Users can input Kp, Ki and Kd values as
inputs to the PID control of the engine. Kp
means proportional values while Ki means
integral of the proportional values and Kd
means differential of the proportional val-
ues.

EDL11160016

(6) PID auto setup menu

The menu offers function for automatic
designation of the P, I and D parameter
values related to the engine PID control.
After starting the engine, select DRIVE
UNIT MENU in the main menu while the
engine has no load and then PID auto
setup menu, press Enter. Then, the system
message shows "Auto Setup Mode PID
setting?" with YES or NO option. If you EDL11160017

select YES, the controller will repeatedly

change the RPM to automatically calculate
the optimized P, I and D values.
If the controller identifies the optimized P, I
and D values within 30 cycles, it will display
"PID Auto Setup Complete, OK". When you
press Enter, it will apply tuned P, I and D
values and close the menu.
If the controller fails to identify the opti-
mized P, I and D values within 30 cycles, it
will display "PID No Successful, OK".
When you press Enter, it will apply the final
P, I and D values and close the menu.

(7) Date/Time setup menu

Users can designate year, month, day,
hour and minute for the controller and the
designated time will be used to monitor the
system and manage fault messages.

EDL11160018

- 46 -
(8) Alarm list menu
This menu displays year, month, day, hour
and minute for the errors in the controller
and types of the faults in codes which are
used in troubleshooting.

EDL11160019

(9) Default setup menu

When you cannot identify the type of the
control engine by the controller, this menu
offers the most common parameter setting
values. For default setup, select YES and
then press Enter button. If you don't want
to implement this function, press No but-
ton. If you press YES, all the configuration
values will be changed to the default ones EDL11160020
of the engine.

(10)System info menu

The controller displays its information
including the serial number, software ver-
sion, last update date, alarm count and
engine runs.

EDL11160021

- 47 -
3. Engine configuration
(1) Engine type configuration
Users can store control setting information depending on types of the engines in the internal memory
of the controller. If you select your engine type, applicable parameters will be automatically configured
accordingly. This feature is available for 16 different types of engines.
Designated parameters by engine type (Configuration values by engine type)

Gear Starting
No. Menu Name Run rpm Over Speed PID Value
Teeth Fuel
DB58 1,500 rpm Optimal
1 1,500 rpm 1,725 rpm 129 65%
(50 Hz) 129T Value
DB58 1,800 rpm Optimal
2 1,800 rpm 2,070 rpm 129 65%
(60 Hz) 129T Value
DE08 1,500 rpm Optimal
3 1,500 rpm 1,725 rpm 102 65%
(50 Hz) 102T Value
DE08 1,800 rpm Optimal
4 1,800 rpm 2,070 rpm 102 65%
(60 Hz) 102T Value
DE08 1,500 rpm Optimal
5 1,500 rpm 1,725 rpm 140 65%
(50 Hz) 140T Value
DE08 1,800 rpm Optimal
6 1,800 rpm 2,070 rpm 140 65%
(60 Hz) 140T Value
DE08 1,500 rpm Optimal
7 1,500 rpm 1,725 rpm 146 65%
(50 Hz) 146T Value
DE08 1,800 rpm Optimal
8 1,800 rpm 2,070 rpm 146 65%
(60 Hz) 146T Value
DL11 1,500 rpm Optimal
9 1,500 rpm 1,725 rpm 152 65%
(50 Hz) 152T Value
DL11 1,800 rpm Optimal
10 1,800 rpm 2,070 rpm 152 65%
(60 Hz) 152T Value
DV15 1,500 rpm Optimal
11 1,500 rpm 1,725 rpm 160 65%
(50 Hz) 160T Value
DV15 1,800 rpm Optimal
12 1,800 rpm 2,070 rpm 160 65%
(60 Hz) 160T Value
DV18 1,500 rpm Optimal
13 1,500 rpm 1,725 rpm 160 65%
(50 Hz) 160T Value
DV18 1,800 rpm Optimal
14 1,800 rpm 2,070 rpm 160 65%
(60 Hz) 160T Value
DV22 1,500 rpm Optimal
15 1,500 rpm 1,725 rpm 160 65%
(50 Hz) 160T Value
DV22 1,800 rpm Optimal
16 1,800 rpm 2,070 rpm 160 65%
(60 Hz) 160T Value

- 48 -
 Engine configuration procedure
Step 1) Press Menu button of the control-
ler and then you can see DRIVE
UNIT MENU.
Step 2) Select Engine Type by using Up
and Down buttons in DRIVE UNIT
MENU and then press Enter button.
Step 3) Go to Engine Type Menu and EDL11160022
select your engine type using Up
and Down buttons. Then, press
Enter button. At this moment, set-
ting values according to the
selected type of the engine are
designated and will be used as
information for the controller to
control the actuator.

Selection List by Engine Type EDL11160056

(2) System setup configuration

Main setting items of the controller includes GEAR NUMBER, CRANKING RPM and SET RUN RPM.
You need to designate setting values to these items. Other system setup items are optional and there-
fore you can designate values for those items as necessary.
Configuring set run rpm
Step 1) Press Menu button of the controller and then you can see DRIVE UNIT MENU.
Step 2) Select System setup menu in DRIVE UNIT MENU using Up, Down, Left and Right buttons
and then press Enter button.
Step 3) Select SET RUN RPM in SYSTEM SETUP menu and then press Enter button.
Use Up and Down buttons to increase or decrease the normal operating speed of the engine
and then press Enter button.

 

EDL11160057

- 49 -
Configuring set idle rpm
Step 1) Press Menu button of the controller and then you can see DRIVE UNIT MENU.
Step 2) Select System setup menu in DRIVE UNIT MENU using Up, Down, Left and Right buttons
and then press Enter button.
Step 3) Select SET IDLE RPM in SYSTEM SETUP menu and then press Enter button.
Use Up and Down buttons to increase or decrease the idle operating speed of the engine
and then press Enter button.

 

EDL11160058

Configuring set over speed

Step 1) Press Menu button of the controller and then you can see DRIVE UNIT MENU.
Step 2) Select System setup menu in DRIVE UNIT MENU using Up, Down, Left and Right buttons
and then press Enter button.
Step 3) Select SET OVER SPEED in SYSTEM SETUP menu and then press Enter button. Use Up
and Down buttons to increase or decrease the over speed values of the engine and then
press Enter button.

 

EDL11160059

- 50 -
Configuring cranking rpm
Step 1) Press Menu button of the controller and then you can see DRIVE UNIT MENU.
Step 2) Select System setup menu in DRIVE UNIT MENU using Up, Down, Left and Right buttons
and then press Enter button.
Step 3) Select CRANKING RPM in SYSTEM SETUP menu and then press Enter button. Use Up and
Down buttons to increase or decrease the RPM values at which the controller starts to con-
trol the actuator when the engine starts to operate and then press Enter button.

 

EDL11160060

Configuring gear number

Step 1) Press Menu button of the controller and then you can see DRIVE UNIT MENU.
Step 2) Select System setup menu in DRIVE UNIT MENU using Up, Down, Left and Right buttons
and then press Enter button.
Step 3) Select GEAR NUMBER in SYSTEM SETUP menu and then press Enter button.
Use Up and Down buttons to increase or decrease the number of gear teeth in the engine
and then press Enter button.

 

EDL11160061

- 51 -
Configuring starting fuel
Step 1) Press Menu button of the controller and then you can see DRIVE UNIT MENU.
Step 2) Select System setup menu in DRIVE UNIT MENU using Up, Down, Left and Right buttons
and then press Enter button.
Step 3) Select STARTING FUEL in SYSTEM SETUP menu and then press Enter button. Use Up
and Down buttons to increase or decrease the percentage for the amount of fuel sprayed
when the engine starts and then press Enter button.

 

EDL11160062

Configuring speed ramping

Step 1) Press Menu button of the controller and then you can see DRIVE UNIT MENU.
Step 2) Select System setup menu in DRIVE UNIT MENU using Up, Down, Left and Right buttons
and then press Enter button.
Step 3) Select SPEED RAMPING in SYSTEM SETUP menu and then press Enter button. Use Up
and Down buttons to increase or decrease the ratio of changes to the speed when increasing
from the idle speed or decreasing from the increased speed and then press Enter button.

 

EDL11160063

- 52 -
Configuring max current
Step 1) Press Menu button of the controller and then you can see DRIVE UNIT MENU.
Step 2) Select System setup menu in DRIVE UNIT MENU using Up, Down, Left and Right buttons
and then press Enter button.
Step 3) Select MAX CURRENT in SYSTEM SETUP menu and then press Enter button.
Use Up and Down buttons to increase or decrease the limit of the maximum current con-
sumption of the actuator and then press Enter button (Max. 10 A).

 

EDL11160064

Configuring low battery

Step 1) Press Menu button of the controller and then you can see DRIVE UNIT MENU.
Step 2) Select System setup menu in DRIVE UNIT MENU using Up, Down, Left and Right buttons
and then press Enter button.
Step 3) Select LOW BATTERY in SYSTEM SETUP menu and then press Enter button.
Use Up and Down buttons to input voltage values at which low battery alarms are activated
and then press Enter button.

 

EDL11160066

- 53 -
Configuring droop gain
Step 1) Press Menu button of the controller and then you can see DRIVE UNIT MENU.
Step 2) Select System setup menu in DRIVE UNIT MENU using Up, Down, Left and Right buttons
and then press Enter button.
Step 3) Select DROOP GAIN in SYSTEM SETUP menu and then press Enter button.
Use Up and Down buttons to increase or decrease the RPM values with adjusted ratio to
decrease at the maximum load when the generator is in parallel operation and then press
Enter button.

 

EDL11160065

Droop Function
Droop function is indicated in percentages as follows: RPM with no load is subtracted by RPM with
maximum load and then divided by RPM with no load.

RPM with no load - RPM with maximum load

Droop% =
RPM with no load

(Example for 3% droop)

Assuming that RPM with no load is 1,800 and RPM with maximum load is 1,854 then the percentage
will be 3%. It means that the generator output will be changed by 33.3% as the frequency changes by
1% due to the actuator control.

1,920 rpm 64 HZ
1,890 rpm 63 HZ
61.8 No Load
1,860 rpm 62 HZ 60.9 50% Load
1,830 rpm 61 HZ 60.0 100% Load
1,800 rpm 60 HZ
1,770 rpm 59 HZ
3% Droop

0% 50% 100%
EDL11160067

- 54 -
(Example for 7% droop)
Assuming that RPM with no load is 1,800 and RPM with maximum load is 1,926 then the percentage
will be 5%. It means that the generator output will be changed by 14.3% as the frequency changes by
1% due to the actuator control.

64.2 No Load
1,920 rpm 64 HZ
62.1 50% Load
1,890 rpm 63 HZ
1,860 rpm 62 HZ 60.0 100% Load

1,830 rpm 61 HZ
1,800 rpm 60 HZ
1,770 rpm 59 HZ
7% Droop

0% 50% 100%
EDL11160068

F - load curr
Step 1) Press Menu button of the controller and then you can see DRIVE UNIT MENU.
Step 2) Select System setup menu in DRIVE UNIT MENU using Up, Down, Left and Right buttons
and then press Enter button.
Step 3) Select F - LOAD CURR. in SYSTEM SETUP menu and then press Enter button. Use Up and
Down buttons to input the maximum current values of the actuator for the generator with full
load and then press Enter button.

 

EDL11160069

- 55 -
 N - load curr
Step 1) Press Menu button of the controller and then you can see DRIVE UNIT MENU.
Step 2) Select System setup menu in DRIVE UNIT MENU using Up, Down, Left and Right buttons
and then press Enter button.
Step 3) Select N - LOAD CURR. in SYSTEM SETUP menu and then press Enter button. Use Up and
Down buttons to input the operating current values of the actuator for the generator with no
load and then press Enter button.

 

EDL11160070

(3) PID gain setup configuration

Configuring PID gain Kp, Ki and Kd values
Step 1) Press Menu button of the controller and then you can see DRIVE UNIT MENU. Use Up,
Down, Left and Right buttons to select PID gain setup menu and then press Enter button.
Step 2) Use Up and Down buttons in PID GAIN SETUP to select PROPORTIONAL, INTEGRAL or
DERIVATIVE and then press Enter button.

 

EDL11160071

- 56 -
 Configuring PID sampling time
Step 1) Press Menu button of the controller and then you can see DRIVE UNIT MENU. Use Up,
Down, Left and Right buttons to select PID gain setup menu and then press Enter button.
Step 2) Use Up and Down buttons in PID GAIN SETUP to select SAMPLING TIME and then press
Enter button. Use Up and Down buttons to input SAMPLING TIME values and then press
Enter button.

 

EDL11160072

(4) PID auto setup value configuration

Step 1) Select your type in Engine Type menu and then start the engine with the preset configuration
values maintaining it with no load.
Step 2) During the normal operation, press Menu button of the controller and then you can see
DRIVE UNIT MENU. Use Up, Down, Left and Right buttons to select PID auto setup menu
and then press Enter button.
Step 3) The menu offers function for automatic designation of the P, I and D parameter values
related to the engine PID control. Select PID auto setup menu in DRIVE UNIT MENU and
then press Enter button to see the system message "Auto Setup Mode PID setting?" with
YES or NO options.

EDL11160073

- 57 -
 Step 4) Press YES and then the system
message "PID AUTO SETUP
MODE" will appear. As PID auto
setup was initiated during the
operation, PID auto tuning is
already in progress.

EDL11160038

Step 5) PID tuning repeats a process to obtain PID values and a window to indicate whether the pro-
cess succeeded or failed will appear in several minutes (approx. 4 to 6 minutes). If the pro-
cess succeeded, the system message window will appear together with OK button. If you
press Enter button, you will go back to normal operation window and the auto-tuned values
will apply to the normal operation that will be continued.
Step 6) If auto-tuning failed to identify optimized P, I and D values within 4 to 6 minutes, the system
message window will display failure. If you press Enter button, you will go back to normal
operation window. If you want to repeat the process, you need to start with Step 1 again.

EDL11160039

(5) Date/Time value configuration

Step 1) Press Menu button of the controller and then you can see DRIVE UNIT MENU.
Use direction buttons to select Date/Time setup menu.
Step 2) Use Up, Down, Left and Right buttons to input year, month, day and hour and then press
Enter button.

EDL11160040

- 58 -
(6) Alarm list
Step 1) Press Menu button of the controller and then you can see DRIVE UNIT MENU.
Use direction buttons to select Alarm List menu and then press Enter button.
Step 2) Use Up, Down, Left and Right buttons in ALARM LIST menu to confirm the fault messages.

EDL11160041

Alarm code table

Alarm Identified Alarm Out-

Alarm Item Description
Code put
When the battery voltage continues to be
LCD alarm message,
E01 Battery Low lower than Low Battery voltage values for
Error LED lamp
more than 5 seconds
When the battery maintains its voltage LCD alarm message,
E02 Battery High
exceeding 30VDC for more than 5 seconds Error LED lamp
Problems in sensor signals when the engine LCD alarm message,
E03 Pick-up Error
starts (Engine RPM lower than 600) Error LED lamp
Problems in sensor signals during the engine LCD alarm message,
E04 Pick-up Error
operation (Engine RPM 600 or higher) Error LED lamp
Actuator Disconnection in the actuator or the connect- LCD alarm message,
E05
Current Short ing circuits Error LED lamp
Actuator Short-circuits in the actuator or the connecting LCD alarm message,
E06
Current Broken circuits Error LED lamp
Engine RPM exceeding the configured over LCD alarm message,
E07 Over Speed
speed values Error LED lamp
Damages to components in the actuator out- LCD alarm message,
E08 FET Drive Error
put section inside the controller Error LED lamp

- 59 -
(7) Actuator test
The menu offers function to test whether there is any problem in operating load current of the actuator
attached to the engine. It indicates voltage and current for on/off.
(8) Default setup functions
Step 1) Press menu button of the controller and then you can see DRIVE UNIT MENU.
Use Up, Down, Left and Right buttons to select Default setup menu and then press Enter
button.
At this moment, the system message "Initialization system setting?" will appear.
Step 2) Use Left and Right buttons to select either YES or NO in System Message and then press
Enter button.

EDL11160077

Default setup will change the configuration values of the engine to the default values. In order to initi-
ate default setup, you need to select YES and then press Enter button. Press No button if you don't
want to.

(9) System info functions

Step 1) Press menu button of the controller and then you can see DRIVE UNIT MENU.
Use Up, Down, Left and Right buttons to select System info menu and then press Enter but-
ton.

EDL11160078

The menu displays information of the controller and the information includes the serial number, soft-
ware version, last update date, alarm count and engine runs.

- 60 -
(10) LCD setup functions
Step 1) Press Menu button of the controller and then you can see DRIVE UNIT MENU.
Use Up, Down, Left and Right buttons to select LCD setup menu and then press Enter but-
ton.
Step 2) Use Up and Down buttons to select menus including LCD BRIGHTNESS and LCD CON-
TRAST for adjustment and then press Enter button. Use Up and Down buttons to input set-
ting values and then press Enter button.

EDL11160079

(11) System monitor Functions

Step 1) Press Menu button of the controller and then you can see DRIVE UNIT MENU.
Use Up, Down, Left and Right buttons to select System monitor menu and then press Enter
button.
It offers menu to monitor the controller operation. It shows values for Engine RPM, Valve
Duty, Valve Current, Aux RPM Input, Pickup Voltage and Bat Voltage.

- 61 -
4. How to operate
(1) Operating sequence for digital speed controller
Step 1) Supply DC +24V power to the battery terminals (E (-), F (+)) of the controller.
Step 2) Configure parameter values required for selection of the engine type and control of the
engine.
Step 3) Install the controller on the generator system and complete circuit wiring.
Step 4) The controller will activate the actuator with power supply and pick-up sensor input.
(2) Detailed operating sequence
Step 1) Supply DC +24 V power to the battery terminals (E (-), F (+)) of the controller.
Power supply to the controller can be done by direct connection to the battery or power sup-
ply controlled by external control devices. Fuses (15 A/24V) are required for power supply to
the controller through the terminal.
When the controller displays Low Battery Fault message, you need to charge the battery or
replace it with the one having normal voltage before starting the controller.
Step 2) Configure parameter values required for selection of the engine type and control of the
engine.
There are 3 ways to configure parameters required for the controller:
1. Using default setup
2. Designating the engine type in Engine Type menu
3. Configuring each parameter in System setup menu
For more information, see Chapter 3. Configuration and Operation.
Step 3) Install the controller on the generator system and complete circuit wiring.
Once the configuration is completed, the controller will be in Stand By condition preparing to
receive input information from pick-up sensor and surrounding terminals and operate.
Step 4) The controller will activate the actuator with power supply and pick-up sensor input. When
the power is supplied and the pick-up terminal delivers normal sensor inputs as the engine
starts, the controller activate the actuator.

- 62 -
Troubleshooting
1. Alarm list check
Where there are problems in the system operation, you need to review the alarm list menu of the control-
ler and then check the engine and the system in reference to the alarm codes.

Alarm Alarm
Alarm Condition Output Control Measures
Code Item
When the battery voltage LCD alarm message Check the battery line
continues to be lower than
Battery
E01 Low Battery voltage val-
Low Error LED lamp Replace the battery
ues for more than
5 seconds
When the battery main- Alarm message pop-up
Check the battery line
Battery tains its voltage exceeding on LCD
E02
High 30V DC for more than 5
seconds Error LED on Replace the battery

Problems in sensor sig- Alarm message pop-up Check the RPM sensor and
Pick-up nals when the engine on LCD connecting circuits
E03
Error starts.(Engine RPM lower Error LED on Replace the RPM sensor
than 600) Actuator control signal off
Problems in sensor sig- Alarm message pop-up Check the RPM sensor and
Pick-up nals during the engine on LCD connecting circuits
E04
Error operation (Engine RPM Error LED on Replace the RPM sensor
600 or higher) Actuator control signal off
Check the disconnection in
Actuator Disconnection in the actu- Alarm message pop-up the actuator and connect-
E05 Current ator or the connecting cir- on LCD ing circuits
Open cuits
Error LED on Replace the actuator
Check the disconnection in
Actuator Short-circuits in the actua- Alarm message pop-up the actuator and
E06 Current tor or the connecting cir- on LCD
connecting circuits
short cuits
Error LED on Replace the actuator
Alarm message pop-up
Engine RPM exceeding Check the speed setting
Over on LCD
E07 the configured over speed
Speed Error LED on Adjust PID setting values
values
Actuator control off
Alarm message pop-up Check the actuator and
Damages to components on LCD connecting circuits
FET Drive
E08 in the actuator output sec- Error LED on Replace the controller
Error
tion inside the controller Actuator output power
cutoff

(1) When problems described in alarm codes E03, E04, E07 or E08 occur, the engine is not available for
safe operation and therefore the engine will stop as the controller will turn off the actuator for safety.
(2) When problems described in alarm codes E03, E04, E07 or E08 occur, the engine will not be able to
restart as long as the alarm is not released.
(3) When alarms occur, you can release them by turning off the power of the controller.

- 63 -
2. System checks and measures
For initial installation, it is recommended for you to check any disconnection in circuits before taking mea-
sures described here (see Chapter 2. Installation for how to install the controller).
You can check the controller for failure diagnosis in accordance with the following procedure.
Step 1) Check the battery voltage whether it is higher than the Low Voltage setting value.
If normal, supply power to the controller and then operate it. If the voltage is lower than the set-
ting value, you need to charge the battery or replace it before operating the system.
Step 2) Check the input resistance in the DC +24V input terminals (-E, +F) of the battery whether the
resistance is higher than approx. 10K Ohm. If the resistance does not meet this condition, do not
supply power to the controller and contact our A/S center for service request.
Step 3) Check whether the power LED turns on or not after supplying power to DC +24V input terminals
(-E, +F) of the battery. If the LED does not turn on, cut the power off and contact our A/S center
for service request.
Step 4) Check whether the power LED turns on and Doosan logo appears on the LCD display after sup-
plying power to DC +24V input terminals (-E, +F) of the battery.
If you cannot see the logo, press LCD key button to check the LCD display once again.
If you cannot still see the logo, cut the power off and contact our A/S center for service request.
Step 5) Check the controller terminals (C & D) with AC meter or oscilloscope to check whether signal
inputs of AC RMS 3V or higher are detected. If no signal detected, check whether the pick-up
sensor maintains the gap between 0.9 and 1.1 mm and then check whether the pick-up sensor
has resistance of 110 Ohms (±10%). If you cannot still detect no signal, replace the pick-up sensor
and then operate the controller.

- 64 -
 Digital Panel for Marine Engines
Service Manual
Ver.1.0

Doosan Infracore

HY-DP-MANUAL-001
▶ Contents

1. General Information
1.1 Product Information ---------------------------------------------------------- 3
1.2 Components and Optional Accessories --------------------------------------- 3
1.3 Product Specification ---------------------------------------------------------- 4
2. Product Installation
2.1 Cautions ------------------------------------------------------------------------ 5

2.2 Stationary Type ----------------------------------------------------------------- 6

2.3 Mount Type --------------------------------------------------------------------- 7

3. Part Names, Operation and Settings

3.1 Front Side --------------------------------------------------------------------- 8

3.2 Back Side ---------------------------------------------------------------------- 8

3.3 External Connection Terminals ------------------------------------------------ 9

3.3.1 Power Connector ------------------------------------------------------- 9

3.3.2 Signal Connector ----------------------------------------------------- 10

3.3.3 CAN Communication Connector -------------------------------------- 11

3.3.4 External Buzzer Connector -------------------------------------------- 11

3.3.5 CCTV Connector ------------------------------------------------------- 11

3.3.6 USB Connector --------------------------------------------------------- 12

3.4 Fuse and Internal Buzzer ------------------------------------------------------- 12

3.4.1 Fuse -------------------------------------------------------------------- 12

3.4.2 Internal Buzzer --------------------------------------------------------- 12

3.5 Key Switch -------------------------------------------------------------------- 12

3.6 Start/Stop Button ------------------------------------------------------------- 13

3.7 Function Keys ------------------------------------------------------------------ 14
3.7.1 Detailed Settings ------------------------------------------------------ 15
3.8 Display Structure --------------------------------------------------------------- 16
3.8.1 Engine Speed (Tachometer) ------------------------------------------- 16
3.8.2 Engine Water Temperature ------------------------------------------- 17
3.8.3 Engine Oil Pressure ------------------------------------------------ 17
3.8.4 Exhaust Gas Temperature ------------------------------------------- 17
3.8.5 Gearbox Oil Pressure ---------------------------------------------- 18
3.8.6 Battery Voltage ------------------------------------------------------- 18
3.8.7 Check Sensor Light --------------------------------------------------- 18
3.8.8 Engine Alarm --------------------------------------------------------- 19
3.8.9 Engine Stop ---------------------------------------------------------- 19

HY-DP-MANUAL-001 1
▶ Contents
3.9 Spare Sensor ----------------------------------------------------------------- 20
3.10 Event Summary -------------------------------------------------------------- 21
3.11 System Booting and Functional Check -------------------------------------- 22
4. Multi Panel Structure
4.1 Multi Panels ------------------------------------------------------------------- 23
4.2 How to Install Multi Panels -------------------------------------------------- 24
4.3 Multi Panel Settings --------------------------------------------------------- 25
5. Digital Panel Manager
5.1 Digital Panel Manager --------------------------------------------------------- 26
5.2 PC Communication Connection --------------------------------------------- 26
5.3 Software Installation and Execution ----------------------------------------- 27
5.4 Display Structure and Detailed Functions ---------------------------------- 29
5.4.1 Menu Structure ------------------------------------------------------- 29
5.4.2 Operation Record Files ----------------------------------------------- 30
5.4.3 Setting Functions by Permission Level ------------------------------ 33
5.4.4 Default Settings ----------------------------------------------------- 35
5.4.5 Event Settings ------------------------------------------------------- 36
5.4.6 Sensor Mapping Tab ------------------------------------------------ 37
6. Maintenance
6.1 Maintenance ----------------------------------------------------------------- 38
6.2 Troubleshooting -------------------------------------------------------------- 38
7. Warranty and A/S Service
7.1 Warranty ----------------------------------------------------------------------- 39
7.2 A/S Service Information ----------------------------------------------------- 39
8. Appendix
8.1 List of Engine Models -------------------------------------------------------- 40

HY-DP-MANUAL-001 2
1. General Information
1.1 Product Information
The name of the product model is a digital panel applicable to ships, generators and other various
marine engines. The product is intended to improve problems of existing analog panels and allow users
to check engine controls and conditions by means of a digital visualization product. It provides
information in analog graphic gauges and digital displays for enhanced user experiences.

1.2 Components and Optional Accessories

Components Optional Accessories

① CCTV (Analog)
① Digital Panel

② Stationary Bracket ③ Mounting Bracket

② Coaxial Cable (Shielded)

④ Key x 2 ⑤ Stationary Parts x 2

Digital Panel
Manual

⑥ Manual

HY-DP-MANUAL-001 3
1. General Information

1.3 Product Specification

Digital Panel Specification

No. Item Description

1 Microprocessor • Cortex-A8, dsPIC33FJ256

2 Software • Windows CE 6.0 R2

• 10.2” Color TFT LCD

3 Display • 800 * 480 (Pixels)

• 16:9

• 256MB (Flash)
4 Flash Memory
• 8GB (MicroSD card)

5 RAM • 512MB

6 Operating Voltage • DC 24V (16 to 30V)

7 USB • USB 2.0 1 Port

8 Operating Temperature • - 20℃ to 70℃

9 Internal Buzzer • Piezo Buzzer 98dB

• J1939 CAN Communication

10 Communication
• RS232

11 Dimensions • W 343.5 x H 270.5 x D 120

[Table 1-1]

HY-DP-MANUAL-001 4
2. Product Installation
2.1 Cautions
 Unskilled personnel should read this manual before use.

 Do not use or keep the product close to combustible sprays or inflammable.

 Use soft and dry cloth to clean the monitor.

 Turn off the product, pull out the harness cable and then contact our service center when you
see smoke from the monitor or have strange smells.

 When you see an alarm on, you always need to check the product before operation.

 Do not disassemble the product cover at discretion (warranty does not cover unauthorized
disassembly).

 Excessive impact may damage the display although a reinforced display is used.

 Use connectors matching each other when connecting them to the back of the product.

 Do not contact or remove connectors while the power is on. It may cause electric shock or lead
to malfunction.

 Do not exercise excessive force when rotating to ON/OFF with the key inserted.

 Do not use the product with wet hands.

 Use protective caps for back side connectors that are not used.

HY-DP-MANUAL-001 5
2. Product Installation

2.2 Stationary Type

- Stationary types are installed in the steering or engine room by using stationary brackets delivered
with the product.
※ Mounting Hole Spec: M6 bolt

Wave Washer
Rotation Lock

Fix Handle
Fixing
Hole Mounting Hole

Bracket

[Fig. 2-1] Stationary Type Diagram

▶ Installing stationary type digital panel

① Check whether the steering or engine room has

engine harness wiring. Bracket connected
with the rotation lock

② Use the mounting hole to fix the bracket in a

place within reach of the engine harness wiring.
[Fig. 2-2]

③ Place the product inside the bracket connected

with the rotation lock to connect it with the
rotation lock.

④ Put the wave washer in the fix handle and connect

it with the fix handle to the direction indicated by ④
an arrow and adjust the viewing angle of the LCD.

※ Where there are things to which the product can

Spare Holes
be fixed, use spare holes with the bolt or other
[Fig. 2-3]
accessories.

HY-DP-MANUAL-001 6
2. Product Installation

2.3 Mount Type

- Mounting types are installed in a steering or engine room by using optional mounting brackets
(2pcs).
※ Bolt Spec: ① M6 ② M8, Length - 12mm
②
①

Mounting Bracket

[Fig. 2-4] Mounting Type Diagram

▶ Installing mounting type digital panel

① Check whether the steering or engine room has engine harness wiring.
② As shown in Fig. 2-6, fix the mounting brackets to both sides of the panel.
③ Check the location within reach of the engine harness wiring and the mounting location and then
mount the panel using proper bolts.
④ Finish gaps between the product and the structure depending on the mounting conditions and
connect the engine harness (you may connect the engine harness first depending on conditions).

Adjust the bracket

depending on the
thickness of the
② ② panel and then fix
it.
③ ③

Available thickness

12 to 25t

[Fig. 2-5]

HY-DP-MANUAL-001 7
3. Part Names, Operation and Settings

3.1 Front Side

② ② No. Name Reference

① LCD -

① ② Function Keys Page 14

③ Key Switch Page 12

④ Start/Stop Button Page 13

③ ④
[Table 3-1]

[Fig. 3-1]

3.2 Back Side

No. Name Reference

① Power Connector Page 9

② Signal Connector Page 10

① ③ ③ CAN Page 11
④ ⑤

⑥ ④ External Buzzer Page 11

⑨ ⑤ USB Page 12
② ⑦ ⑧
⑥ Fuse Page 12

[Fig. 3-2] ⑦ CCTV (Optional) Page 11

⑧ GPS (TBC) -

⑨ Internal Buzzer Page 12

[Table 3-2]

HY-DP-MANUAL-001 8
3. Part Names, Operation and Settings

3.3 External Connection Terminals

- External connection terminals are used for inputs and outputs of engine control
signals and each sensor signals.

3.3.1 Power Connector

- Power connector supplies power and power signals.

No. Pin Description Notes

1 Alternator In Battery Voltage
2 - -
3
Battery (+) (DC 24V) Fuse Input
4
5 Starter Signal -
6 Valve Battery (+) - [Fig. 3-3]
7 - -
8 Starter Signal -
9 Starter Signal -
10 DC 12V Out -
11 DC 5V Out -
12 GND
Power
13 GND
14 Battery (+) (DC 24V) Fuse Input

[Table 3-3]

HY-DP-MANUAL-001 9
3. Part Names, Operation and Settings

3.3.2 Signal Connector

[Fig. 3-4]

No. Pin Description Notes No. Pin Description Notes

1 Exhaust Gas Temperature - 19 Spare Analog Input 3 -

Sensor 1 (+)
2 Engine Water Temperature - 20 Pickup Sensor (+) -
Sensor
3 Engine Oil Pressure Sensor - 21 - -

4 *Engine Oil Temperature Sensor - 22 - -

5 *Boost Air Pressure Sensor - 23 GND Sensor

Valve
6 *Fuel Level Sensor - 24 Valve Out Control
Signal

7 Spare Analog Input 2 - 25 Exhaust Gas Temperature -

Sensor 2 (+)
8 Spare Analog Input 4 - 26 Exhaust Gas Temperature -
Sensor 2 (-)
9 Spare Digital Input 1 - 27 - -

10 - - 28 - -

11 Fuel Leakage Switch - 29 - -

12 GND Sensor 30 - -

13 Exhaust Gas Temperature - 31 - -

Sensor 1 (-)
14 - - 32 - -

15 Gearbox Oil Pressure Sensor - 33 - -

16 *Engine Water Level Sensor - 34 - -

17 *Boost Air Temperature Sensor - 35 GND Sensor

18 Spare Analog Input 1 - - - -

* Sensor for IMO Tier 3 [Table 3-4]

HY-DP-MANUAL-001 10
3. Part Names, Operation and Settings
3.3.3 CAN Communication Connector
• CAN harness (optional) connection
• CAN1/CAN2: for multi panels
• CAN3: PC communication, firmware download

No. CAN1 CAN2 CAN3

1 +12V Out +12V Out +12V Out

2 GND GND GND

3 CAN1_H CAN1_H CAN2_H

4 CAN1_L CAN1_L CAN2_L

[Fig. 3-5]
5 Battery (+) Battery (+) PC_RXD1

6 GND GND PC_TXD1

[Table 3-5]

3.3.4 External Buzzer Connector

• Additional connection for external buzzer harness
• Generating external buzzer alarms for warnings

No. Name 1 2

1 Battery (+) – Fuse Output

2 Alarm Out [Fig. 3-6]

[Table 3-6]

3.3.5 CCTV Connector (Optional)

• CCTV cable (optional) connection
• Installation available up to 2 devices with channels 1 & 2
1 1
No. Name

1 CCTV Signal In
[Fig. 3-7]
[Table 3-7]

HY-DP-MANUAL-001 11
3. Part Names, Operation and Settings

3.3.6 USB Connector

• USB memory can be inserted for data backup.

[Fig. 3-8]

3.4 Fuse and Internal Buzzer

3.4.1 Fuse
• Shut down the power for overcurrent exceeding 6A
Press
• Press the fuse button for 10 seconds to restore fuse
operation.
[Fig. 3-9]

3.4.2 Internal Buzzer

• Generate alarms for sensor problems

[Fig. 3-10]

3.5 Key Switch

- Key switch is used to boot and turn off the digital panel system or stop the engine.

1) Use the key contained in the product to insert it and

rotate to the right by 90º (ON) (when the key is ON,
the key should remain inserted).
2) When the key is ON, the product will boot and the
gauge display will appear in about 17 seconds.
3) Rotate the key to the left by 90º (OFF) to turn it off. Key
• When rotating the key to the left (OFF) while the [Fig. 3-11]
power is on, the display will show a popup
message for 300 seconds. The engine will stop and
the event will be saved after 300 seconds.
• When the popup window appears, rotate the key
to the right (ON) to remove the window and keep
the engine on.
Key Switch
[Fig. 3-12]

HY-DP-MANUAL-001 12
3. Part Names, Operation and Settings

3.6 Start/Stop Button

- Start/Stop button is used to start/stop control for the engine.

1) Press the button for more than 3 seconds while the key is ON,
the engine will start (the button LED will flash when pressing
the button).
2) Press the button for more than 3 seconds while the key is ON
and the engine is in operation to stop the engine. Start/Stop Button
※ You can reduce the time down to 1 second for emergency
[Fig. 3-13]
response.
→ You can change the time setting in Digital Panel Manager.

HY-DP-MANUAL-001 13
3. Part Names, Operation and Settings

3.7 Function Keys

- Function keys are used to adjust LCD brightness, stop alarming (mute), configure CCTV, Digit, Home
and other settings, move to and select menus, and reset the system.

⑥
①

⑦
②

③ ⑧

④ ⑨

⑤ ⑩

[Fig. 3-14] Function Keys

No. Function Key Action Feature

LCD Brightness • LCD brightness adjustable for 5 different levels (when rebooting the
①
Adjustment system, the previous setting will be maintained).

② Alarm Mute • Turn off the buzzer sound

③ CCTV • Switching between CAM1 and CAM2 (optional)

• Press once: number light will be on for 3 seconds and turn the display off.
④ Digit Display • Press DIGIT for 3 seconds: the number light will continue to be on
• Press while the display is off: the number light will turn off.

• Move to main gauge display.

⑤ Home
• Move to main display without saving when pressing it in page mode.

• Engine Model setting

• Master/Slave setting and ON/OFF setting to start the slave
⑥ Configuration • ON/OFF setting for over speed testing
• ON/OFF setting for spare sensor light
• USB backup and time (year/month/hour) settings

⑦ Up/Down • Move the cursor up and down in setting window

⑧ Select • Select menus or functions in the setting window

• Move to spare sensor display (display page 2) / Move to event summary

⑨ Page
display (display page 3)

⑩ System Reboot • Rebooting for system errors (press it for more than 3 seconds to reboot)

[Table 3-8]
HY-DP-MANUAL-001 14
3. Part Names, Operation and Settings

3.7.1 Detailed Settings

[Fig. 3-15] Detailed Settings

▶ Setting Functions and Descriptions

- Press button and then use or button to move to functions to be changed.
- Press button to go back to gauge display (changes will be automatically saved).

No. Function Description Function Key

1 Engine Model • Engine model setting (refer to the appendix for the
list of engine models)

2 Master / Slave • Master/Slave setting for multi panels

3 Slave Engine Start • ON/OFF setting to start the slave

4 OverSpeed Test Mode • ON/OFF setting for over speed (1,400RPM or faster) test

5 Spare Sensor Alarm • ON/OFF setting for spare check sensor light

6 USB Back Up • USB backup for event save files

7 Date Setup • Date and time setting

[Table 3-9]

HY-DP-MANUAL-001 15
3. Part Names, Operation and Settings

3.8 Display Structure

Engine Speed Engine Oil Pressure

Water
Temperature

Accumulated
Exhaust Gas Engine
Temperature Operation
Hours

Gearbox Oil
Pressure
Sensor Value
(Digit)

Sensor
Check Light
[Fig. 3-16] Gauge Display Alarm Battery Voltage

• Gauge display shows various gauge data including pick up (RMP) sensor, coolant temperature,
exhaust gas temperature, engine oil pressure and gearbox oil pressure.
• It also includes battery voltage indication, accumulated engine operation hours, coolant
temperature, engine oil pressure, gearbox oil pressure, charging, coolant level, fuel leak and
overspeed alarm.

3.8.1 Engine Speed (Tachometer)

- It shows engine RPM in gauge and digital values and counts accumulated engine operation hours.

1) It shows the RPM indicated by the gauge hand in

digital values (blue) for better accuracy (however, it is

available when the ‘DIGIT’ button is on).

2) It shows accumulated engine operation hours by hour

unit (engine speed of 400RPM or faster will be counted

and the function is always on)

3) Starter Off RPM setting is available between 300 and

[Fig. 3-17] 600RPM after the engine starts (The service team can
Engine Speed Gauge configure the setting in Digital Panel Manager).

HY-DP-MANUAL-001 16
 3. Part Names, Operation and Settings
3.8.2 Engine Water Temperature
- It shows the coolant temperature in gauge and digital values.
1) It shows the temperature indicated by the gauge hand in
digital values (blue) for better accuracy (however, it is
available when the ‘DIGIT’ button is on).
2) It shows the open/short diagnosis for sensor problems.
☞ Open: ‘ERROR’ / Short (GND): ‘-----’
3) It also serves as the water temperature switch.
4) It activates alarm and warning beep when the temperature
increases up to 93℃ or higher.
[Fig. 3-18] 5) When the temperature increases up to 103℃ or higher, the
engine will stop.
Engine Water Temperature Gauge

3.8.3 Engine Oil Pressure

- It shows engine oil pressure in gauge and digital values.

- 1) It shows the pressure indicated by the gauge hand in digital

values (blue) for better accuracy (however, it is available
when the ‘DIGIT’ button is on).
2) It shows the open/short diagnosis for sensor problems.
☞ Open: ‘-----’ / Short (Power): ‘ERROR’
3) It also serves as the engine oil pressure switch.
4) It activates alarm and warning beep when the pressure is
1bar or lower (detects in 10 seconds)
[Fig. 3-19] 5) When the pressure is 0.5bar or lower, the engine will stop.
Engine Oil Pressure Gauge 6) It will not work before the engine starts.

3.8.4 Exhaust Gas Temperature

- It shows exhaust gas temperature in gauge and digital values.

1) It shows the temperature indicated by the gauge hand in

digital values (blue) for better accuracy (however, it is

available when the ‘DIGIT’ button is on).

2) It shows the open/short diagnosis for sensor problems.

☞ Open: ‘ERROR’ / Short (GND): ‘-----’

3) The alarm will be activated when the temperature is 100℃ or

[Fig. 3-20]
lower, or 600℃ or higher while the engine is in operation.
Exhaust Gas Temperature

HY-DP-MANUAL-001 17
3. Part Names, Operation and Settings
3.8.5 Gearbox Oil Pressure
- It shows gearbox oil pressure in gauge and digital values.

1) It shows the pressure indicated by the gauge hand in digital

values (blue) for better accuracy (however, it is available when

the ‘DIGIT’ button is on).

2) It shows the open/short diagnosis for sensor problems.

☞ Open: ‘-----’ / Short (Power): ‘ERROR’

[Fig. 3-21] 3) It activates alarm and warning beep when the pressure is 1bar or

Gearbox Oil Pressure lower (detects in 10 seconds).

3.8.6 Battery Voltage

- It shows battery voltage to indicate its conditions.

1) It will show in blue for voltage of 24V or higher or red for

voltage lower than 24V.

2) It activates warning beep when the voltage is 20V or lower

[Fig. 3-22] Battery Voltage (regardless of whether the engine is in operation or not).

3.8.7 Check Sensor Light

- When there are sensor errors (Open or Short), the check sensor light will turn on.

1) When the check sensor light is on, it will show in yellow.

[Fig. 3-23] Check Sensor Light

※ Open and Short gauge displays for sensor problems

Open Short

HY-DP-MANUAL-001 18
3. Part Names, Operation and Settings

3.8.8 Engine Alarm

- The alarm will be activated with buzzer beeping when problems for coolant temperature, engine oil
pressure, gearbox oil pressure, charging, coolant level, fuel leakage and over speed are detected.

① ② ③ ④ ⑤ ⑥ ⑦

[Fig. 3-24] Engine Alarm

No. Alarm Action Feature

• Alarm (buzzer) will be activated when the

① Coolant temperature (WATER TEMP)
temperature is 93℃ or higher

• Alarm (buzzer) will be activated on when

② Engine oil pressure (ENGINE OIL PRESS)
the pressure is 1 bar or lower

• Alarm (buzzer) will be activated when the

③ Gearbox oil pressure (GEARBOX OIL PRESS)
pressure is 1 bar or lower

• Alarm (buzzer) will be activated when the

④ Charging (CHARGE)
battery voltage is lower than 27V

• Alarm (buzzer) will be activated when the

⑤ Coolant level (WATER LEVEL)
level is 30% or lower.

• Alarm (buzzer) will be activated when oil

⑥ Fuel leakage (FUEL LEAKAGE)
leak occurs (default setting is ‘disabled’)

• Alarm (buzzer) will be activated when the

⑦ Engine over speed (OVER SPEED)
speed exceeds 115% of the rate speed

[Table 3-10] Alarm Features

※ How to deactivate the engine alarm

- Press SYSTEM RESET button on the right for 3 seconds, the system will reboot and the alarm
will be deactivated (rebooting is available while the ship navigates without causing problems).

3.8.9 Engine Stop

1) When the over speed exceeds 120% of the rate speed → Enable/Disable engine stop
2) When the coolant temperature exceeds 103℃ → Enable/Disable engine stop
3) When the oil pressure is 0.5bar or lower → Enable/Disable engine stop
4) When fuel leakage occurs → Enable/Disable engine stop
5) When the coolant level is 15% or lower → Enable/Disable engine stop
6) Stop Valve: the stop button will be activated by users (when the engine continues at 0
RPM for 7 seconds)

HY-DP-MANUAL-001 19
3. Part Names, Operation and Settings

3.9 Spare Sensor

- It identifies the status of spare sensor, product S/N, F/W version, and date/time. Press button
of the function key to move to spare sensor page.

Alarm On

[Fig. 3-25] Spare Sensor and SW information

Item Condition

• Alarm will be activated when the gearbox oil temperature is

Gearbox Oil Pressure
1bar or lower

*Boost Air Temperature • Current temperature

• It is normal when the boost air pressure is between 1.1bar

*Boost Air Pressure
and 2.9bar
• Alarm will be activated when the boost air pressure is 1bar
*Boost Air Pressure (Low)
or lower
• Alarm will be activated when the boost air pressure is 3bar
*Boost Air Pressure (High)
or higher
• Alarm will be activated when the engine oil temperature is
*Engine Oil Over Heat
150℃ or higher

Battery Voltage • Current voltage

Exhaust Air Temperature • Alarm will be activated when the exhaust air temperature is
(High) 600℃ or higher

• Alarm will be activated when the coolant level is 30% or

*Water Level (Low)
lower

*Fuel Level (Low) • Alarm will be activated when the fuel level is 30% or lower
* Sensor for IMO Tier 3
[Table 3-11] Spare Sensor Conditions
HY-DP-MANUAL-001 20
3. Part Names, Operation and Settings

3.10 Event Summary

- It shows the numbers of normal operations, normal stops, emergency stops and sensor errors
together with dates of recent errors.

- Press button in spare sensor page to move to event summary page.

[Fig. 3-26] Event Summary Screen

Event List

Water Over Heat *Low Fuel Level

Low Engine Oil Pressure Engine Oil Over Heat

Low Gearbox Oil Pressure Main Connector Removed

Battery Charge(Alternator) High Exhaust Gas Temperature

Fuel Leakage(Switch) *Low Boost Air Pressure

Over Speed *High Boost Air Pressure

Low Voltage Abnormal Engine Shutdown

*Low Water Level Low Engine Speed

* Sensor for IMO Tier 3
[Table 3-12] Event List

HY-DP-MANUAL-001 21
3. Part Names, Operation and Settings

3.11 System Booting and Functional Check

- You can check whether the product is properly installed or not.

▶ Normal System Booting

1) Insert the key into the key switch and rotate it to the right (ON).

Key On
2) DOOSAN logo will appear for 17 seconds while the system is
booting (refer to the image).
※ If the logo does not appear after rotating the key,
 Rotate it to the left (OFF) and then to the right (ON)
again
 Check the harness connection at the back of the panel
 Check whether the battery is discharged
3) The gauge display will appear after normal booting.
 Gauge: check whether each gauge hand is within the
normal range and ‘ERROR’ or ‘-----’ is displayed on the [Fig. 3-27] Key Switch
screen.
※ Where ‘ERROR’ or ‘-----’ is displayed on the screen
 Check the harness connection
 Function keys: check whether each function key is active
on the screen by pressing them.
 Alarm: check whether the alarm is turned on.
 Battery: check whether the battery voltage is 16V or
lower.

4) Where the initial gauge screen is normal, press START button

for 3 seconds to start the engine (the time can be reduced to 1
second. Refer to Digital Panel Manager).
5) Check whether the operation is in normal RPM (initial operation
in 400RPM or faster with the oil pressure of 1bar or higher) and
whether alarm is turned on.

[Fig. 3-28] DOOSAN Booting Logo [Fig. 3-29] Gauge Display

HY-DP-MANUAL-001 22
4. Multi Panel Structure

4.1 Multi Panels

- Panels can be installed up to 4 units except Master in the ship and you can check the ship
conditions and control those panels at any places of installation.

[Fig. 4-2] Slave 1 [Fig. 4-3] Slave 3

[Fig. 4-1] Master

[Fig. 4-4] Slave 2 [Fig. 4-5] Slave 4

HY-DP-MANUAL-001 23
4. Multi Panel Structure

4.2 How to Install Multi Panels

①
[Fig. 4-6]
Master
[Fig. 4-7] [Fig. 4-10]
Slave 1 Slave 4

② ④

③
[Fig. 4-8] [Fig. 4-9]
Slave 2 Slave 3

※ In order to install multi panels, all the necessary cables should be ready in advance (use the cables with
specification recommended by DOOSAN).
(1) Connect the CAN1 terminal of the Master panel and the CAN1 terminal of the Slave 1 panel as shown in
① (2 panels).
 Master and Slave 1 connection completed

(2) Connect Slave 1 (CAN2) and Slave 2 (CAN1) as shown in ② while maintaining connection as described
in ① (3 panels).
 Master, Slave 1 and Slave 2 connection completed

(3) Connect Slave 2 (CAN2) and Slave 3 (CAN1) as shown in ③ while maintaining connection as described
in ② (4 panels).
 Master, Slave 1, Slave 2 and Slave 3 connection completed

(4) Connect Slave 3 (CAN2) and Slave 4 (CAN1) as shown in ④ while maintaining connection as described
in ③ (5 panels)
 Master, Slave 1, Slave 2, Slave 3 and Slave 4 connection completed

HY-DP-MANUAL-001 24
4. Multi Panel Structure

4.3 Multi Panel Settings

(1) Press button of the panel to be configured as Slave.
(2) Move to ① when the setting screen appears (use or button to move).
(3) Press button to switch configuration between Master and Slave.
(4) Configure the Master panel as described above.

※ Notes
 Master mode is available for one panel only and Slave mode is available up to 4 units.
 You can permit Slaves to start the engine with Master panel only. Where you enable
Slave Engine Start setting, all Slave panels will be able to start the engine.

[Fig. 4-11] Multi Panel Setting Window

HY-DP-MANUAL-001 25
5. Digital Panel Manager

5.1 Digital Panel Manager

- Digital Panel Manager is a program that allows users to monitor the product conditions in real time
with PC. You can configure sensor values of each sensor, engine model and over speed conditions.

[Fig. 5-1] Digital Panel Manager Initial Screen

5.2 PC Communication Connection

- Before using Digital Panel Manager, prepare CAN-RS232 cables (optional) for downloading and USB-
RS232 cables (available in the market) for connection.

USB
Back of the Digital Panel

Female RS232 Male RS232

[Fig. 5-2] PC Communication Connection

HY-DP-MANUAL-001 26
5. Digital Panel Manager

5.3 Software Installation and Execution

1. Install Digital Panel Manager on your PC.

2. Run Digital Panel Manager.

3. Permission Cert – Manufacturer or research institute cert is required as shown in Fig. 5-3 to run it.
※ Cert files should be in the same folder where ‘DigitalPanelManager.exe’ is located.
※ General users do not have cert files and they will see the screen without cert.

[Fig. 5-3] Permission Cert Window <Cert Files>

4. Initial Screen – when the following initial screen appears, click Communication Settings at the top
right corner for communicating settings.
※ You can also find them in Configuration Menu at the top left corner.

Click
Communication
Settings

[Fig. 5-4] Main Screen of the Program

HY-DP-MANUAL-001 27
5. Digital Panel Manager

5. Configure the port connected to RS232 in Communication Port Settings.

Communication
Port Settings

[Fig. 5-5] Communication Port Settings

6. When the panel is connected to RS232, COMx Connected at the bottom right corner will turn on in
green. When the product is connected to Digital Panel Manager, ON-LINE will turn on in green.

PC
Communication Product
Connection Connection
Status Status

[Fig. 5-6] Communication Port and ON-LINE Connection

HY-DP-MANUAL-001 28
5. Digital Panel Manager

5.4 Display Structure and Detailed Functions

5.4.1 Menu Structure
- Descriptions of menus at the top left corner are as follows:

[Fig. 5-7] Menu Structure

Structure Description

Open Load setting files

Files Save Save settings as a file

Exit Exit the program

Transmit data settings in the current tab to the

Transmit Current Information
product

Transmit All Information Transmit data settings in all tabs to the product

Advanced Read Device Data Transmit data settings in all tabs to the product

Hour Meter Settings Configure the operation hours of the product

Open Operation Record Files Open the operation record files of the product

Delete Operation Record Files Delete the operation record files of the product

Configuration Communication Settings Configure the RS232 connection port

[Table 5-1] Menu Structure

HY-DP-MANUAL-001 29
5. Digital Panel Manager

5.4.2 Operation Record Files

- You can check the operation record files saved in the product (users are not
allowed to use this function).

1. Menu → Advanced → Click Open Operation Record Files.

[Fig. 5-8] Advanced Menu

2. Click .ODX files with dates that you want to check and then press Open button.

[Fig. 5-9] Open Operation Record Files

HY-DP-MANUAL-001 30
5. Digital Panel Manager
3. The window in which you can check the operation records will be activated. You can see
Files and Advanced Menu at the top left corner.

[Fig. 5-10] Operation Record Menu

[Fig. 5-11] Menu → Files [Fig. 5-12] Menu → Advanced

Structure Description

Open Files Open operation record files

Files
Exit Exit the window

Save Current Data as Convert current data to Excel files and save
Advanced
Excel Files them.

[Table 5-2] Operation Record Menu

HY-DP-MANUAL-001 31
5. Digital Panel Manager

4. Click + on the alarm event list at the top left corner of the operation window.

Click

[Fig. 5-13] Activate Operation Record Window

5. The list of each sensor will be activated. In order to check the records of the sensor that
you want to, click + on the list (where there are records, + will appear).

클릭

[Fig. 5-14] List of the Operation Record Sensors

HY-DP-MANUAL-001 32
5. Digital Panel Manager
6. When clicking the date of operation records by each sensor, you can see the graphs of
those records. If you want to save those records in Excel files, select Advanced → Save
current data in Excel files.

[Fig. 5-15] Operation Record Graphs

5.4.3 Setting Functions by Permission Level

- It shows detailed descriptions about manufacturer/research institute cert.
※ Where manufacturer/research institute authentication file and service cert files are in
the same folder, the former will have the priority.

① Manufacturer/research institute cert – activates all tabs.

Activate

[Fig. 5-16] Manufacturer/Research Institute Cert

HY-DP-MANUAL-001 33
 5. Digital Panel Manager
② Service Authentication – default setting (battery voltage control inactive) / Deactivate all tabs except
event settings.

Deactivate

[Fig. 5-17] Service Authentication

③ End User Authentication – Deactivate all taps except start button action time (you can still check the
current information).

Deactivate

[Fig. 5-18] General User Authentication

HY-DP-MANUAL-001 34
5. Digital Panel Manager

5.4.4 Default Settings

- It shows description about the default setting tab in the initial main screen.
※ End users can configure start button action time only.

⑩ ⑪

①
⑤

② ⑥
⑦
Engine Model ③
⑧
Setting ④

[Fig. 5-19] Default Setting Screen

No. Default Setting

① Select engine models

② Calibrate battery values after applying 15V and 25V respectively

③ Configure starting reaction time when pressing the start button (1s to 3s)

④ Timer setting for Stop Solenoid is from 7 seconds to 15 seconds

Configure alarm action conditions against engine over speed and minimum battery
⑤
charging voltage

⑥ Configure engine stop conditions against engine over speed

⑦ Configure CAN communication speed

⑧ Configure criteria for starter off RPM (300 to 600RPM) when staring the engine

⑨ Monitor the engine conditions in real time

⑩ Show the current firmware version and sensor value mappings

⑪ Show the serial number of the product

[Table 5-3] Descriptions of Default Settings

HY-DP-MANUAL-001 35
5. Digital Panel Manager
5. Digital Panel Manager

5.4.5 Event Settings

- It shows description about the event setting tab.

① ⑤
② ⑥
⑦
③ ⑧
⑨
④
⑩

[Fig. 5-20] Event Setting Screen

No. Event Setting

① ON/OFF check for fuel leakage alarm (Default: off)

② ON/OFF check for spare sensor alarm (Default: off)

③ ON/OFF check for CCTV functions (Default: off)

④ Built-In Buzzer Test

⑤ ON/OFF check for engine stop by coolant overheating

⑥ ON/OFF check for engine stop by reduced engine oil pressure

⑦ ON/OFF check for engine stop by fuel leakage (Default: off)

⑧ ON/OFF check for engine stop for engine over speed

⑨ ON/OFF for engine stop by lack of coolant

⑩ ON/OFF check for the exhaust gas temperature sensor

[Table 5-4] Descriptions of Event Settings

HY-DP-MANUAL-001 36
5. Digital Panel Manager

5.4.6 Sensor Value Mapping Tab

- You can configure sensor values in this tap with manufacture/research institute permission only.
You can only check the settings with other permissions.

Click each
voltage value
[Fig. 5-21] Sensor Tab to change it.

[Fig. 5-22] Coolant Temperature

[Fig. 5-23] Exhaust Gas Temperature

[Fig. 5-24] Engine Oil Pressure

[Fig. 5-25] Gearbox Oil Pressure

[Fig. 5-26] Engine Oil Temperature

[Fig. 5-27] Boost Air Pressure

[Fig. 5-28] Boost Air Temperature

HY-DP-MANUAL-001 37
6. Maintenance

6.1 Maintenance
- To maintain the performance of the device, regular maintenance is required.

1. Use soft cloth to clean the LCD without damaging it.

1) Clean the LCD after turning the power off.
2) Do not use cleaners with acids or ammonia.
3) Do not use neutral detergents to remove oil stains.
4) Use cloth slightly wet in clean water to remove salt residuals or dust particles for natural
drying. If there remain stains, clean them with soft cloth (microfibers) once again.
2. Check whether the connectors or harnesses at the back of the device are properly connected or
whether they have dust or other foreign substances.
3. Check whether cables are damaged.
4. Request for checking when the software needs upgrade as follows:
- When the manufacturer releases official software for performance improvements

6.2 Troubleshooting
- It describes possible measures for users to resolve problems while using the device.

1. The device is not turned on.

1) Check whether harness cables at the back of the product are properly connected.
2) Where harness cables have too much dust or moisture, remove them and clean the dust or
moisture. Connect them once again after a while.
3) Check whether the fuse button at the back of the product is pulled out.
4) Check whether the battery is discharged.
2. You can see lines or shaking on the screen.
1) Reboot the product.
2) As the LCD is connected inside the product, do not disassemble it and contact the service
team.
3. You can see distortions on CCTV screens.
1) Check whether CCTV connectors or connectors at the back of the product are properly
connected.
2) Check whether cables are worn out.
4. You can see alarm or hear warning beeps at the bottom of the product screen.
1) Check where the alarm occurs and then take measures as necessary (if you need to confirm
which alarm occurs, refer to Page 20 of this manual).
5. You cannot control buttons.
1) Check whether there are foreign substances at the panel buttons.
2) As the button connecting parts may be damaged, do not disassemble the product and
contact the service team.

HY-DP-MANUAL-001 38
7. Warranty and A/S Service

7.1 Warranty
As this manual contains important contents related to safety, use and maintenance of the product. So
please read this manual carefully and then use the product in a proper manner.

Those who are not familiar with the product should keep this manual close to it.

We are not responsible for human injuries or property damages caused by the following reasons:

 Where you use the product for purposes other than the ones described in this manual

 Where you alter the product or its components at discretion

 Where you disassemble the product at discretion to resolve problems

 Where you use accessories or parts not supplied or recommended by us

※ Where you use accessories or parts manufactured by other companies, please contact our service
center to check their compatibility.

7.2 A/S Service Information

- When you request A/S service, please let us know the model name, breakdown conditions and your
contact information.
- Please ask the seller.

HY-DP-MANUAL-001 39
8. Appendix

8.1 List of Engine Models

- List of compatible engine models

Number of
Engine Gear Teeth Rate Speed Over Speed

DB58TI L066TIH 129 2,200 115% 2,530

D1146 L136 140 2,200 115% 2,530
L136T 140 2,200 115% 2,530
D1146T
L136TL 140 2,500 115% 2,875
D1146TI L136TI 140 2,200 115% 2,530
L086TIH 140 2,200 115% 2,530
D1146TIB L086TIM 140 2,300 115% 2,645
L086TIL 140 2,500 115% 2,875
DE12T MD196T 152 2,000 115% 2,300
DE12TI MD196TI 152 2,000 115% 2,300
L126TIH 152 2,000 115% 2,300
DE12TIB
L126TIM 152 2,100 115% 2,415
V158TIH 160 1,800 115% 2,070
D2848LB V158TIM 160 2,100 115% 2,415
V158TIL 160 2,300 115% 2,645
V180TIH 160 1,800 115% 2,070
D2840LB V180TIM 160 2,100 115% 2,415
V180TIL 160 2,300 115% 2,645
V222TIH 160 1,800 115% 2,070
D2842LB V222TIM 160 2,100 115% 2,415
V222TIL 160 2,300 115% 2,645
4V158TIH 160 1,800 115% 2,070
4VD2848LB 4V158TIM 160 2,100 115% 2,415
4V158TIL 160 2,300 115% 2,645
4V222TIH 160 1,800 115% 2,070
4VD2842LB 4V222TIM 160 2,100 115% 2,415
4V222TIL 160 2,300 115% 2,645

HY-DP-MANUAL-001 40