Professional Documents
Culture Documents
Service Training
Engine BG / CS Engineering
Con-Rod
CRS
• Valve Train • Valve, R/A, Cam, • The air for burning is supported, the gas
4
Tappet carry out after burning
7
Exhaust
Pipe
3
Piston
3
Con-Rod
3
3
F.W.H
CRS Pulley
5
CP Pump
5 6 6 6 1 6 3
ECU Oil Cooler Oil Filter Oil Pan(Sump) Cylinder CRS
Oil Filter
Block
5
Fuel Injection System
Fuel device is that inject fuel into the cylinder though nozzle as high compressed.
According to control system, mechanical engine and electrical engine.
• Priming pump
Electrical Engine
At initial operation, fuel comes from fuel tank
Common Rail System • Electric Injector and supply to injection pump
7 • ECU • Fuel filter
Pressure Rail pressure
High
6 limiter valve
8 sensor
pressure
pump
CP3
5 Rail
3 Gear
pump Filter
4 Flow limiter
Filtering Equipment filter out the impurities in the
Metering
unit ZME
9 •Common Rail fuel tank
Other actuators Other sensors
1
Injector
2 Control unit
Accelerator
pedal
0 •High pressure pump • Fuel tank
Engine
1 speed
(crank) The conservation of fuel
1 Tank
Prefilter
1 Engine
speed
High pressure
Low pressure
(cam)
6
Way of Air-Breather
If a lot of air can contain displacement of fixed size, the intake, which is first stroke, can
increase power due to much fuel can burn. So the engine can assort according to way of
air-breather
The number of air Block diagram of
Way of air-breather Detail Description particle per volume Intake/Exhaust
7
Moving parts
Piston moves downward by high temperature and pressure combustion gas which is
burned fuel and air. At obtained rotation energy this moving forward to valve system,
lubrication system and cooling system by gears for safely continuation operating
Injector
Description of Part’s Function
Intake
Exhaust Port
Port • PISTON
1 Make combustion, and moves
Rocker-
Combustion 7 Arm downward by combustion gas for Con-
Gas
Cylinder Rod Moving
Liner
• CONNECTING ROD(Con-Rod)
Piston Connect piston(Rectilinear Movement)
Valve and CRS(Rotation Movement)
Piston Pin
2 8
• CRANKSHAFT(CRS)
Convert from rectilinear movement to
Crank Shaft rotation movement and forward to
Con-Rod
energy to outside
4 Gear 6
Tappet
4 • CAMSHAFT
Cam Determine the valve timing
3 Shaft (Intake and Exhaust)
5 • GEAR
Forward energy by engagement gear
8
Lubrication and Cooling System
The oil supply to engine moving parts for oil film creation and preventing the wear.
Moving parts is cooled down by engine oil and other parts is cooled by coolant for
maintain the suitable temperature
Major parts Functional Desdription
Lubrication System
• OIL PUMP • The supplying oil to engine parts
Cooling System • Water pump • The forcibly circulating the cooling water. The connected with
CRS with belt or gear
Thermostat
• Thermostat • The device for opening and closing cooling water line by water
temperature. The water temperature control moderately.
9
Combustion at Expansion Stoke (1/3)
Procedure of expansion stoke ; As a short time(1/1000 seconds), fuel inject into the
combustion for burning
Compression Stroke
(High Air Temperature)
1. Fuel injection
3. Combustion
→ Start Burning as all-at-onceness
4. Diffusion combustion
Exhaust Stroke
10
Combustion at Expansion Stoke (2/3)
11
Combustion at Expansion Stoke (3/3)
Because too short mixed time, Fuel and Air mix as lack of uniformity.
The NOX, Soot, CO. HC is created because the burning is progressing at anywhere in
combustion as all-at- onceness
12
The basic unit regarding Engine
▶ Torque : Moment
Power = Torque x Rev Count
13
Power Up Engine Instruction
Main Engineering Change regarding Power-up Development
Increase robustness of identified weak points for increase durability though fatigue analysis
Apply designed part as a minimum of stress concentration
Reflect Voice of Customer(VOC) about convenience and safety
Main Design Points
1
• Increase Hardness of confirmed weak point for increase durability though fatigue analysis
Increase
Durability • Reinforce Cylinder Block, Head, CRS and Con-Rod
• Change the piston pin’s shape and coated piston ring face for durability for abrasion and safety factor for
increased power
• Change the Ex. Manifold’s material for increasing heat-resisting temperature and add the supporting
bracket for preventing leakage and crack
• Increase the durability of cooling fan belt and bearing
2
• Change the mounting bracket’s shape : improve the engine holding
Convenience • Add a water jacket heater port : improve convenience regarding jacket heater connection
• Change turbocharger location : improve the generator assembly and prevent interference with
wiring when a lifting
3 • Change fuel strainer location : Keep away from T/C to prevent firing
Safety • Change the fuel line’s material : The terms of CE,NFPA(USA ‘fire service act) and NEGA(Japan’s fire
service act)
• Belt Cover : The terms of CE ( Apply at April of 2014 )
4 • Re-line up at interval of 50 kwe
Performance • Improve cooling performance : Satisfy the tropical terms (Radiator Inlet Temperature : 52℃)
• Unify the turbocharger and injection timing with 50Hz and 60Hz except DV15 high power
15
V12 Engine Development Scope
Fuel System
• Fuel Filter increase capacity
• Fuel pipe is made with steel
Belt Train
• Belt’s lifespan increase
16
V12 Engine Development Scope
Turbocharger
Turbocharger
Bracket
20
Intake Air Bend
Insulation Space
Air Bend
Air Outlet Air Bend
- Pipe
Air Outlet Pipe
21
FUEL PIPE & FUEL FILTER
23
Radiator & Intercooler System Design
24
Options of Power-up Model
Radiator • Tropical → Higher ATB 52℃
• Standard → Higher 43℃
Air cleaner
25
Power Up Engine Specification
Engraving Location and Serial Number Form
27
Engine Model Name
Model Form
1 2 3 4 5 6
D P 2 2 2 L A
Description
1 Fuel Specification 2 Engine Purpose 3 Engine Displacement
28
Engine Output Power for Each Model
Standby
449 / 610 510 / 693 552 / 750 612 / 832 - 664 / 903 723 / 983
(kWm/PS)
1500rpm
(50Hz)
Prime
408 / 555 464 / 630 502 / 682 556 / 756 - 604 / 821 657 / 894
(kWm/PS)
Standby
513 / 697 556 / 756 615 / 836 661 / 899 737 / 1002 782 / 1063 828 / 1126
(kWm/PS
1800rpm
(60Hz)
Prime
466 / 634 505 / 687 559 / 760 601 / 817 670 / 911 711 / 967 753 / 1023
(kWm/PS
29
Engine Specification_DP158L
Engine Type Water Cooled, 4 Cycle, V-Type Block, Turbocharger & Intercooler
Cyl. Liner Type Wet Liner
Cyl. No.-Bore(ø ) X
8 – 128 X 142
Stroke(mm)
Displacement(cc) 14,618
Compression Ratio 15 : 1
Injection Timing(BTDC) 23˚± 1˚ 18˚± 1˚ 23˚± 1˚ 18˚± 1˚
Firing Order 1-5-7-2-6-3-4-8
Inj. Nozzle Opening
280
Pressure (Kg/㎠)
Direction of
Count Clockwise
revolution(Fly Wheel)
Ring Gear Teeth 160
Engine Weight(Kg) 1,155
30
Engine Specification_DP180L
Engine Type Water Cooled, 4 Cycle, V-Type Block, Turbocharger & Intercooler
Cyl. Liner Type Wet Liner
Cyl. No.-Bore(ø ) X
10 – 128 X 142
Stroke(mm)
Displacement(cc) 18,273
Compression Ratio 15 : 1
Injection Timing(BTDC) 21˚± 1˚ 19˚± 1˚ 21˚± 1˚ 19˚± 1˚
Firing Order 1-6-5-10-2-7-3-8-4-9
Inj. Nozzle Opening
280
Pressure (Kg/㎠)
Direction of
Count Clockwise
revolution(Fly Wheel)
Ring Gear Teeth 160
Engine Weight(Kg) 1,250 (with fan)
31
Engine Specification_DP222L
Engine Type Water Cooled, 4 Cycle, V-Type Block, Turbocharger & Intercooler
32
V-Type Engine Cooling System
Engine Cooling System _ Diagram
34
Engine Cooling System _ Diagram
Cyl. Block
Heater Connection
Port(M30 x 1.5) Water Pump
- To Heater
35
Engine Cooling System _ Thermostat
[Operation Theory]
▪ The coolant temperature is below the normal
temperature
• The thermostat is closed and the coolant is
bypassed and directly flow into the water
pump
▪ The coolant temperature reaches the normal
temperature or is higher than the temperature
• The thermostat is fully open and the bypass
circuit is closed. So coolant flows into the
radiator
[ Operation Temperature]
▪ Initial Opening Temperature : 71℃
▪ Fully Opening Temperature : 85℃
1. To Radiator
2. Thermostat (By-Pass Valve)
3. To Water Pump
4. From Cyl. Block (Cooling Pipe)
36
Engine Cooling System _ Coolant Management
[Coolant Capacity]
Coolant Capacity(ℓ)
Engine Model
Inside of Engine With Radiator
DP158L Approx. 20 Approx. 79
DP180L Approx. 21 Approx. 79
DP222L Approx. 23 Approx. 114
[Coolant Management]
▪ Coolant to using engine should be used cleaned tap water
▪ The 40~50% of antifreeze and 3~5% anticorrosive agent is mixed
Antifreeze 40~50% + Anticorrosive Agent(Inhibitor) 3~5% + Coolant (Cleaned Tap
Water) 50%
37
Engine Cooling System _ The Measurement of Coolant Concentration
[The Measurement of Coolant Concentration]
▪ If the engine coolant temperature is within a range of 10~55℃, drain the coolant and fill the plastic cup
▪ Soak the test sheet in the coolant and take it out after 3~5 seconds, Shake the sheet to remove remaining
coolant
▪ Wait for 45 seconds until the test sheet changes its cooler
※ Measurement time should not exceed 75 seconds. The color changes as time passes
39
V-Type Lubrication System
Lubrication System _ Function of Engine Oil
▪ Function of Lubrication
41
Lubrication System _ Diagram
42
Lubrication System _ Engine Oil
44
V-Type Fuel System
Fuel System _ Diagram
1. Fuel Tank
2. Fuel Strainer
3. Feed Pump
4. Injection Pump
5. Fuel Supply Line
6. Air Vent Hole
7. Fuel Filter
8. Injection Nozzle
9. Over Flow Valve
10. Fuel Return Pipe
46
Fuel System _ Diagram
47
Fuel System _ Fuel Filter
[Air Ventilation]
▪ Air ventilation is implemented after fuel system maintenance
(Fuel Filter, Injection Pump, Injection Nozzle…)
▪ Loosen the air bleeding plug(B) on the fuel filter(CCW)
▪ Operate the priming pump by hand to bleed air inside the fuel circuit.
▪ Operate the priming pump until the air is discharged completely though
visual checking
48
Fuel System _ Injection Nozzle
49
Fuel System _ Inj. Nozzle Test
50
Fuel System _ Actuator
[Structure of Actuator]
52
Fuel System
Speed _ Governor
Controller Controller Wiring
SYSTEM
53
Fuel System _ Governor Controller Wiring
54
Fuel System_ Precaution about External Wiring
55
Fuel System_ Precaution about External Wiring
56
Fuel System _ Governor Controller
57
Fuel System _ Governor Controller Type
Part Number
Engine Model
(Color)
No Base Engine
Ring Gear
As-Is To-Be RPM
Teeth
65.11220-7011 (Red)
58
V-Type Electrical System
Electronic System _ Circuit Diagram
60
Electronic System _ Alternator
[Alternator Exterior ]
Output Current(A)
Voltage(V) Speed(RPM)
COLD HOT
[Alternator Check]
[Voltage During Operation ]
Measurement Point Voltage
Terminal B – Body DC27V ~ 29.5V
Terminal B Terminal L – Body DC28V ~ 29.5V
Terminal Terminal R - Body DC3V ~ 5V
L
[Starter Exterior ]
63
Electronic System _ Starter
ㅡ VDO ㅡ DOOSAN
65
Electronic System _ Cooling Water Temp Switch
66
Electronic System _ Oil Pressure Switch
Pressure(bar) Resistance(Ω)
0 5 ~ 13
2 48 ~ 56
4 84 ~ 92
6 119 ~ 129
▪ ( ) : Reference Valve
▪ Warning Pressure : 0.5bar ± 0.2bar
▪ Maximum Pressure : 30bar
(2 Sec. as a short time)
67
Electronic System _ Pick-Up Sensor
68
V-Type Engine
Disassemble/Re-assemble
Engine disassemble _ Discharging Coolant
Oil Cooler
Drain Hole
(D)
Cylinder Block
Drain Hole
(C)
70
Engine disassemble _ Discharging Engine Oil
Oil Drain
Valve ▪ The drain valve(A) is located bottom of oil pan opens and
(A)
discharge it to container
- Make sure that engine oil cooled, Caution of Burn
- When Drain Valve re-tighten, It can be damaged by over torque
▪ Discard discharged oil according to the regulations set forth by
the relevant authorities.
71
Engine disassemble _ Disassemble Injection Pump
Tightening Order
[The tightening order of Block Side Bolt(A) ]
▪ Tighten left and right bolt at torque of 11.2Kg.m
73
Engine Assemble _ Cam Shaft
74
Engine Assemble _ Piston & Ring
▪ Install the 1st (D) / 2nd (E) / Oil Ring(F) with the piston ring
plier
- Ensure that the ‘Y’ mark of the piston ring faces the top
surface of the piston
▪ Make the piston ring positioned dislocated to 120°
▪ Assemble snap rings(B) with the opening of the snap
rings facing 12 o’clock
75
Engine Assemble _ Connecting Rod
10Kg.m + 90˚+10˚
76
Engine Assemble _ Cylinder Head
77
Engine Assemble _ Valve Clearance Adjustment (DP158)
Number of Cyl 1 2 3 4
Valve In Ex In Ex In Ex In Ex
#1 TDC ● ● ● ●
#6 TDC ○ ○ ○ ○
Number of Cyl 5 6 7 8
Valve In Ex In Ex In Ex In Ex
#1 TDC ● ● ●
#6 TDC ○ ○ ○ ○ ○
1 12 5 8 3 10 6 7 2 11 4 9
6 7 2 11 4 9 1 12 5 8 3 10
80
Engine Assembly _ Injection Timing Checking
Number of Cyl 1 2 3 4 5 6
Valve In Ex In Ex In Ex In Ex In Ex In Ex
#1 TDC ● ● ● ● ● ●
#6 TDC ○ ○ ○ ○ ○ ○
Number of Cyl 7 8 9 10 11 12
Valve In Ex In Ex In Ex In Ex In Ex In Ex
#1 TDC ● ● ● ● ● ●
#6 TDC ○ ○ ○ ○ ○ ○
81
Engine Assemble _ Injection Timing Checking
1. Remove the FWH Cover 2. Turn the crank pulley so that the mark on pointer
provided on injection pump coincides with matching
mark(FB) on the flange surface of the driving gear
3. Check the injection Timing degree the V-Type edge of the flywheel housing sight hole.
It is different between Spec and real degree, Injection Timing Adjustment implement
82
Engine Assemble _ Injection Timing Adjustment
Bolt Fix
1
3
5
4
83
Engine Assemble _ Injection Timing Adjustment
3
5
4
84
Engine Assemble _ Injection Timing Adjustment
6. Tap the bolt to align the flange(FB) line and pointer line
7. After Tapping, tighten all bolt with torque 3.1Kg.m as turning the flywheel
Misalign Align
85
Controller Adjustment
Adjustment Controller _Installation and Precaution
87
Adjustment(Tuning) Order and Method
88
Adjustment(Tuning) Order and Method
90
Adjustment(Tuning) Order and Method
91
Controller External Wiring
▪ For every wiring, use 1.5㎟ or larger shielded cable.
▪ While using shielded cable, every shielded (cable not displayed in side
figure) must be grounded to the frame.
▪ As for actuator wiring, use twisted cable(A-B resistance : 3.5~4.5Ω)
▪ As for magnetic speed sensor cable, "shielded" cable must be used, and
the shielded area must be connected to terminal D If this shielded area is
grounded to engine or not grounded, it could cause hunting
▪ Make sure that the polarity of battery connected to terminal E & F is not
switched and install 10A fuse between battery (+) and terminal F. Ground
terminal E to the frame.
▪ Idle Switch is optional
▪ The signal from auxiliary unit used for parallel operation system should be
connected to
▪ terminal N.As for using 12 battery, connected terminal G & H
Droop Full CCW (minimum) Full **CCW (minimum) Full CCW (minimum) Full CCW (minimum)
Adjustment (160 gear teeth) (160 gear teeth) (152 gear teeth) (152 gear teeth)
Speed
4000Hz (1500rpm) 4800Hz (1800rpm) 3800Hz (1500rpm) 4053Hz (1800rpm)
Adjustment
Idle
2133Hz (800rpm) 2133Hz (800rpm) 2026Hz (800rpm) 2026Hz (800rpm)
Adjustment
▪ CW : Clockwise
▪ CCW : Count Clockwise
93
Controller Trouble Shooting
TEST NORMAL ESTIMATED CAUSE of CORRECTIVE
STEP TERMINAL
PERIOD READING ABNORMAL READING ACTION
6 P(+) / G(-) KEY S/W ON 9.5V ~ 10.5V Controller device defect Replace controller
94
Controller Trouble with
Trouble shooing Shooting
Multi-Tester
• SPECIFICATION
• Measure Tester
1) E - F (BATTERY – KEY ON)
KEY OFF
95
Controller Trouble with
Trouble shooing Shooting
Multi-Tester
2) C – D (PICK UP SIGNAL)
3) A – B (ACTUATOR)
96
Trouble Shooting
Trouble Shooting _ Starter
98
Trouble Shooting _ Starter(4.5Kw)
Solenoid Terminal M
◆ Solenoid resistance must measured low resistance test, the wire short check in field
99
Trouble Shooting _ Starter(6 & 7Kw)
Solenoid Terminal S
Relay Terminal S
Solenoid Terminal M
Measurement
Check Point Normal range Failure type Remark
Point
Solenoid S
Solenoid Operation failure
Terminal 0.093±0.015 Ω Checking Wiring
Resistance by short
& M Terminal
◆ Solenoid resistance must measured low resistance test, the wire short check in field
100
Trouble Shooting _ Starter Gear Check
Pinion Milling
[Alternator Check ]
[Voltage During Operation ]
Measurement Point Voltage
Terminal B – Body DC27V ~ 29.5V
Terminal B Terminal L – Body DC28V ~ 29.5V
Terminal Terminal R - Body DC3V ~ 5V
L
• Engine : V-TYPE ENGINE • Fuel Strainer Filter be blocked • The strainer filter is assembled for
preventing foreign object
• Failure Description :
Engine is stopped by alarm
repeatedly
[Excessive foreign
103
object in Strainer filter]
Trouble Shooting _ Cooling Water mixed in Oil
[Root Cause]
The cooling water and oil mixed in oil . Cylinder Liner damaged
pan . Crack inside of Cyl.Block
. Cyl.liner O-Ring damaged
104
Trouble Shooting _ Engine oil mixed in Cooling Water
[Root Cause]
. Oil leakage from damaged oil cooler
. When engine operation, the oil mixed into cooli
Engine oil mixed in Cooling Water ng water due to high oil pressure
105
Trouble Shooting _ Excessive White Smoke
[Tip]
. High Injection Timing (Spec 10 → Real 16˚)
- Reduce the smoke and increase the power
- it can damage at Engine due to increase
exhaust temperature, occur abnormal
sound
. Low Injection Timing (Spec 16 → Real 10˚)
- Excessive smoke and reduce the power
6 4
5
1. Remove the idle sub spring cap nut(❶), Loose the spring fix Nut(❷), Turn
8 the idle sub spring(❸) as direction of CW until hunting disappearing
1
2. If hunting disappear, turn the Idle rpm adjustment screw(❺) as direction of
CCW, for adjustment the idle rpm
3. If hunting doesn’t improve, the bellow method follow
4. Remove screw plug(❹)
5. Turn the idle rpm adjustment screw(❺) as direction of CW until control
lever(❻) can reach fully the left side
3 2
6. Though the hole, which remove the cap nut(❹), insert flat-head screw
drive and turn CCW direction until the completely tighten.
- Must remember the number of clicker
7. If the clicker is within a range of 5~6, turn as CW direction 2~3 range again
7 8. Check the engine rpm and adjust the idle sub spring(❸) and idle
adjustment screw(❺) for setting idle rpm. Check the hunting
107
Trouble Shooting _ Hunting( Electronic Governor) Adjustment
[Failure Description]
The engine RPM fluctuate irregularly, and it can’t solve controller adjustment
[Root Cause]
1. Ball Bearing is damaged in Link
ELECTRIC GOVERNOR - Poor Moving
2. Shaft Bearing damaged
- Poor rotating
Shaft Bearing
108
Trouble Shooting _ Hunting( Electronic Governor) Check
109
Trouble Shooting _ Corrosion of Cylinder Liner
Cooling water is made up water of good quality and suitable antifreeze and the
exact amount of an anticorrosive agent
▪ Cooling Water for using engine must use the clean tap water(Do not use underground water
which excessive contained Calcium)
▪ Cooling water should mixed 40~50% of antifreeze and 3~5% anticorrosive agent for corrosion
preventing
Cooling Water(Clean Tap Water) 50% + Antifreeze 40~50% + Corrosive Agent 3~5%
▪ It have to check the concentration of antifreeze and corrosive agent when engine oil change.
If the concentration is lack, it must be makeup
▪ Cooling water must changed 1 time every 2 years and clean the water line
110
Trouble Shooting _ Cylinder Line Corrosion
→ If all diesel engine, which use wet liner, isn’t manage cooling water, it causes liner
cavitation
→ Also antifreeze and anticorrosive agent’s concentration is lower then spec, it caused liner
cavitation
111
Trouble Shooting _ Cylinder Liner Corrosion
Liner fitting is caused vapor bubble come from moving piston and liner
112
Trouble Shooting _ Cylinder Liner Corrosion
The energy , which come from Expansion stroke, and moving piston make high frequency
at liner, The liner vibrate in cooling water and then vapor bubbles is made up
113
Trouble Shooting _ Cylinder Liner Corrosion
114
Trouble Shooting _ Cylinder Liner Corrosion
115
Trouble
CoolingShooting
system _ Cylinder Liner Corrosion
After 2086 hours operation with 5% antifreeze •After 2086 hours operation with 25% antifreeze
Antifreeze
116
Trouble Shooting _The Important of Fuel Filter
117
Trouble Shooting _The Important of Fuel Filter
118
Trouble Shooting _The Important of Fuel Filter
119
Trouble Shooting _The Important of Fuel Filter
▪ If one spoon of water include in 1 liter of fuel, the Nozzle tip can get damaged
▪ To check the corrosion in fuel filter and fuel system can confirm the water contents in fuel
▪ For preventing this failure, the water vent in fuel filter use for water venting and original parts and
change fuel filter periodically as Spec
120
Trouble Shooting _ Turbo Charger
A Turbine dead-end is damaged by foreign object
Root Cause:
Engine inner part is broken
121
Trouble Shooting _ Turbo Charger
Root Cause : A piece of fabric, Wrench, Nuts, Screws and Foreign Object from Air-Cleaner
122
Trouble Shooting _ Turbo Charger
Root Cause:
Periodic Exchange exceed about
engine oil and filter
123
Trouble Shooting _ Turbo Charger
Polluted Bearing
Root Cause :
The water and fuel enter the engine oil
124
Trouble Shooting _ Turbo Charger
Root Cause :
- Engine is suddenly shut down without cooling time and use low quality oil and
exceed periodic exchanger
- Too much carbonate is deposited on bearing housing 125
Trouble Shooting _ Turbo Charger
126
Trouble Shooting _ Bearing
Normal Condition
127
Trouble Shooting _ Bearing
A lack of squashing(
- Foreign object and burr is remained on
surface of bearing
- Assemble with a shortage of torque
- Too excessive wear Housing bore and
stretch bearing cap
128
Trouble Shooting _ Bearing
129
Trouble Shooting _ Bearing
Surface Fatigue
- Overloading
- Uneven loading
- Using out of lifetime bearing
130
Trouble Shooting _ Bearing
Corrosion
- Oxidized Engine Oil
- High Operation Temperature
- Excessive Blow-by Gas
- Cooling water enter the Engine Oil
- Use High Sulfur-Containing Fuel
- Too long oil periodic exchanger
131
Trouble Shooting _ Bearing
132
Trouble Shooting _ Bearing
133
Trouble Shooting _ Bearing
134
Trouble Shooting _ Bearing
135
Trouble Shooting _ Bearing
136
Trouble Shooting _ Bearing
137
Generator Installation Guide
Generator Engine Installation
[Engine Mounting and Installation]
▪ Generally, the Engine and Generator are coupled together and mounted in steel base frame
▪ The mounting and location and method are strongly related to the generating set’s stability and
vibration
▪ The generator set should be packaged for easily accessible.
▪ Filters, Filler Cap, Coolant Drain Plug, Oil Level Gage, Head Cover, V-Belt
▪ The Generating set should have four(4) point mounting as below figure. Also, the rubber mountings
should be installed between generating set and base frame to insulate the engine vibration.
▪ To Determine the adequate capacity of rubber mountings one and half of total generating set weight
(wet weight) should be considered)
① Engine
② Alternator
139
Generator Engine Installation
[Engine Mounting’s center of gravity]
▪ Each Rubber Mounting should be well positioned so as to give even load distribution,
▪ Which is determined by calculation the total weight of the generating set, its center of gravity, and the
location of each mounting is respect of load distribution.
▪ The calculation is refer below formula
▪ Center of gravity of Generating set can be derived by combining the center of gravity of Engine and
Generator respectively .
140
Generator Engine Installation
[Ventilation System]
▪ The basic principle of ventilation is to eject hot air from the room in induce air at the ambient temperature
outside the engine room with minimum re-circulation as below figure
▪The object is to get cool air in at the lowest possible point, push it through the radiator matrix and then out
of the engine room
▪ The temperature in the engine room should not exceed 60℃ while the temperature of the intake air to the
engine should be below 40℃
▪ if the intake air temperature is above 40℃, the power must reduce 2% per 5℃
▪ For specific power de-rating, refer to de-rating chart of the each model
[Right]
④ No obstruction to induce cool air and to
expel hot air
⑤ Adequate tip clearance of cooling fan
⑥ Partition to avoid the entry of hot air
through radiator
142
Generator Engine Installation
[Ventilation System Consideration]
[Right]
⑥ Lagging to avoid heat rise
⑦ Sufficient air intake
⑧ Cool air can be induced
⑨ Partition to avoid the entry of hot air
⑩ Right axial distance of fan shroud
143
Generator Engine Installation
[Ventilation System Consideration]
Wrong [Wrong]
Right
① Insufficient air intake
② Insufficient air intake
③ Intake air heated by Engine
④ Insufficient exhaust duct area
[Right]
⑤ Sufficient air intake
⑥ Sufficient air intake
⑦ Cool air can be induced
⑧ How air heater by engine is isolated
⑨ Sufficient exhaust duct area
⑩ Sufficient distance to end wall
144
Generator Engine Installation
[Air Inlet and Outlet Design]
▪ Air Inlet and Outlet installed in a way that the engine can get cool air at the lowest possible point
▪ The Air Inlet and Outlet matrix is 25% larger than the radiator matrix and preferably be of the same
rectangular shape
145
Generator Engine Installation
[Air Inlet and Outlet Design]
▪ If the radiator uses grill, the matrix is 80% free area
- for a radiator matrix frontal area 1㎡, air outlet and inlet opening wall area → 1㎡ x 1.25 = 1.25㎡
- If a grill is fitted then the opening should be increased to give → 1.25/0.8 = 1.56㎡
Air Inlet/Outlet
146
Generator Engine Installation
[Air Inlet/Outlet Design]
▪ The shape of Air Outlet Duct should be designed below figure and produce
▪ The shape of duct are common to inlet and outer.
▪ The Recommended dimension is T ≥ A, B ≥ A
147
Generator Engine Installation
[Fuel System]
▪ Fuel Line must be installed to avoid foreign objects infiltration into engine. Excessive fuel line restriction
should be also avoid to ensure smooth fuel flow without air bubble inside.
▪ Joint and fittings of fuel line must be leak-tight to avoid fuel leak or air infiltration, otherwise high fuel
contamination, fuel leak and fire or engine instability can occur
▪ A referenced fuel temperature is 40℃, above which power reduction of 1% will occur every 5℃ fuel
temperature rise
▪ High fuel temperature also reduces the fuel lubricity causing the wear of inner component of FIP
▪ Copper based, galvanized or zinc coated material must not be used for fuel pipe
▪ Fuel Pipe
In - Line V-Type
Fuel lines inner diameter mm >ø 10 >ø 12
Allowable fuel supply line restriction mbar < 135 < 300
Allowable fuel return line restriction mbar < 600 < 600
148
Generator Engine Installation
[Fuel System Installation Diagram]
149
Generator Engine Installation
[Fuel Tank]
▪ Copper plate, galvanized or zinc coated plate are not suitable for diesel tank
▪ A minimum distance of 500mm between the fuel suction line and fuel return should be kept
▪ An engine fuel suction line positioned 40mm above the bottom of the tank to prevent sludge and water
being brawn into the fuel supply.
[Water Separator]
▪ Doosan supply the water separator as an optional
▪ Paker 900FH for In-Line and Paker 1000 FH for 1000FH for V-type is recommended according to engine
horse power ration
▪ Water Separator must use the a wide daily temperature range and its difficult to fuel control area
Air Outlet
150
Generator Engine Installation
[Exhaust System _ Back Pressure]
▪ Purpose of Exhaust System
- The exhaust system should be to eject the exhaust gas out from engine with minimum back pressure
▪ Excessive exhaust backpressure will lead to loss of power output, Poor fuel economy, High Exhaust
temperature, Overheating and excessive smoke from the installation.
▪ The exhaust system for Doosan engines should be designed and arranged in a way that the maximum
permissible backpressure is 600mmAq (60mbar) or under
151
Generator Engine Installation
[Exhaust System _ Exhaust pipe design and installation]
▪ At least one bellows should be installed between Engine and Exhaust system
- Bellows can protect the T/C from being damaged by heat expansion of exhaust system
▪ Rain and condensate water should not enter the exhaust system in any circumstance
- a Trap with drain valve should be provided at the exhaust system near the engine
▪ the exhaust system in the engine room must be efficiently lagged with high heat resistant material.
- lagging of the exhaust manifold and T/C is not permitted.
① Bellows
② Pipe
③ Silencer
④ Pipe Support
152
Generator Engine Installation
[Exhaust System _ Multiple Exhaust System]
▪ The exhaust gases from a multiple engine installation must not be combined into a common exhaust
system
- The reason is that if one engine stopped when others are running, exhaust gases will be forced into the
other engine through exhaust pipe
▪ If a flap valve of reliable quality is fitted in each exhaust system, multi-engine installation on one exhaust
line can sometimes be accepted
5
𝐹𝑎𝑐𝑡𝑜𝑟 𝐾 = (𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑒𝑛𝑔𝑖𝑛𝑒)2
𝐷𝑇𝑂𝑇𝐴𝐿 = 𝐷 × 𝐾
D= is exhaust pipe diameter for one engine
K= is a factor(refer to above table)
153
Generator Engine Installation
[Cooling Performance _ De-rating]
154