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2013. 12
엔진BG CS팀
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Table
Appendix
Diesel Engine in General
ENGINE
Introduction to combustion in Diesel Engines
Operation Principle of 4-Stroke Engine : Conversion from thermal energy to rotation energy
• One Operating cycle is completed for every four strokes of the piston
Description Intake V/V Exhaust V/V
Intake Piston moves downward, Air go into the combustion Open Close
Piston travels to toward the top of cylinder, the air in the cylinder is
Compression Close Close
compressed
Fuel inject into compressed air, piston moves downward due to
Expansion Close Close
mixture explosion
Exhaust Combustion gas carry though exhaust valve Close Open
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
ENGINE
Fuel device is that fuel inject into the cylinder though nozzle as high compressed.
According to control system, mechanical engine and electrical engine.
• Priming pump
At initial operation, fuel comes from fuel tank
Electrical Engine
and supply to injection pump
Common Rail System • Electric Injector • Fuel filter
Filtering equipment filter out the impurities in the
6 7 Pressure Rail pressure
• ECU
High
pressure
pump 5
limiter valve
8
Rail
sensor
fuel tank
CP3
3 Gear
pump Filter
4 Flow limiter
Metering
unit ZME
9 •Common Rail • Fuel tank
Other actuators Other sensors
1
Injector The conservation of fuel
2 Control unit
Accelerator
pedal
0 •High pressure pump
Engine
1 speed
(crank)
1 Tank
Prefilter
1 Engine
speed
High pressure
Low pressure
(cam)
6
ENGINE
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
ENGINE
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
5 • GEAR
Forward energy by engagement gear
8
ENGINE
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
ENGINE
Combustion at Expansion Stoke (1/3)
Compression Stroke
(High Air Temperature)
1. Fuel injection
3. Combustion
→ Start Burning as all-as-onceness
4. Diffusion combustion
Exhaust Stroke
10
ENGINE
Combustion at Expansion Stoke (2/3)
11
ENGINE
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 Hardness about confirmed weak point for increase durability though fatigue analysis
Apply designed part which is minimum of stress concentration
Reflect customer voice for convenience and safety
Main Design Point
1
• Increase Hardness about 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 curability of abrasion and safety factor
regarding power increasing
• 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 boarding
Convenience • Add a jacket water heater port : improve convenience regarding jacket heater connection
• Change turbocharger location : improve the generator assembly and prevent interference with
wire when lifting
3 • Change fuel strainer location : Keep distance from T/C for preventing fire by radiation
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(Change of Location)
Add Jacket Heater Port
• Deposition left and right
• Prevent interference when • Increase in convenience when
alternator assemble Jacket Heater connect
• Prevent interference with wire when • Increase in warm up efficuency
18
engine lifting
V12 Engine Development Scope
Turbocharger
Turbocharger
Bracket
20
Intake Air Bend
단열 공간 (틈새)
Air Bend
Air Outlet Air Bend
- Pipe
Air Outlet Pipe
21
FUEL PIPE & FUEL FILTER
23
Radiator & Intercooler System Design
24
Power-up Option
Radiator • Tropical Higher ATB 52℃
• Standard Higher43℃ 이상
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 - 664 / 903 723 / 983
(kWm/PS)
1500rpm(50Hz)
Prime
408 / 555 464 / 630 - 604 / 821 657 / 894
(kWm/PS)
Standby
513 / 697 556 / 756 737 / 1002 782 / 1063 828 / 1126
(kWm/PS
1800rpm(60Hz)
Prime
466 / 634 505 / 687 670 / 911 711 / 967 753 / 1023
(kWm/PS
29
Engine Specification_DP158L
Engine Type Water Cooled, 4 Cylce, 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_DP222L
31
V-Type Engine Cooling System
Engine Cooling System _ Diagram
33
Engine Cooling System _ Diagram
Cyl. Block
Heater Connection
Port(M30 x 1.5) Water Pump
- To Heater
34
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)
35
Engine Cooling System _ Coolant Management
[Coolant Capacity]
Coolant Capacity(ℓ)
Engine Model
Inside of Engine With Radiator
DP158L Approx. 20 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 3~5% + Coolant (Cleaned Tap Water) 50%
36
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
38
V-Type Lubrication System
윤활 System_엔진 오일의 기능
Function of Lubrication
40
Lubrication System _ Diagram
41
Lubrication System _ Engine Oil
43
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
45
Fuel System _ Diagram
46
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
47
Fuel System _ Injection Nozzle
48
연료 System_Inj.Nozzle Test
49
Fuel System _ Actuator
[Structure of Actuator]
51
Fuel System
Speed _ Governor
Controller Controller Wiring
SYSTEM
52
Fuel System _ Governor Controller Wiring
53
Fuel System_ Precaution about External Wiring
54
Fuel System_ Precaution about External Wiring
55
Fuel System _ Governor Controller
56
Fuel System _ Governor Controller Type
Part Number
Engine Model
(Color)
No Base Engine
Ring Gear
As-Is To-Be RPM
Teeth
300611-00683
1 1500 rpm 160 DV15/18/22
(Red)
65.11220-7011
(Red)
300611-00685
2 1500 rpm 152/146 DE08/DL11
(Green)
300611-00684
3 1800 rpm 160 DV15/18/22
(Blue)
65.11220-7012
(Blue)
300611-00686
4 1800 rpm 152/146 DE08/DL11
(Black)
57
V-Type Electrical System
전장 System_회로도
59
전장 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 L Terminal R - Body DC3V ~ 5V
[Starter Exterior ]
62
Electronic System _ Starter
63
Electronic System _ Cooling Water Temp Sensor
ㅡ VDO ㅡ DOOSAN
64
Electronic System _ Cooling Water Temp Swich
65
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 (순간 2초)
66
Electronic System _ Pick-Up Sensor
67
V-Type Engine
Disassemble
Engine disassemble _ Discharging Coolant
Radiator Cap (A) 1. Make sure that engine and radiator cooled
2. Open the radiator cap(A) and loosen the drain valve(B) is
located under the radiator to discharge the coolant
3. Disassemble the coolant discharge plug(C) of the cylinder
block, and discharge it to container
4. Drain cooling water in the oil cooler(D)
Drain Cock
(B)
Oil Cooler
Drain Hole
(D)
Cylinder Block
Drain Hole
(C)
69
Engine disassemble _ Discharging Engine Oil
Oil Drain
Valve
(A)
The drain valve(A) is located bottom of oil pan opens and 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.
70
Engine disassemble _ Disassemble Injection Pump
71
Engine Assemble _ Main BRG Cap
[Main Brg Cap Bolt(B) Tighten }
Tighten Bolt by Hand
Tighten BRG cap bolt(B) at torque of 15Kg.m
Tighten BRG cap bolt(B) at torque of 25Kg.m
Tighten BRG cap bolt(B) at torque of 30Kg.m
Mark(-) on the cap bolt head
Tighten BRG cap bolt at an angle of 90˚(CW)
Tighten BRG cap bolt at an angle of 10˚(CW)
※ When tightening, the order is from center to
outside(Refer to left figure)
Tightening Order
[The tightening order of Block Side Bolt(A) ]
Tighten left and right bolt at torque og 11.2Kg.m
72
Engine Assemble _ Cam Shaft
73
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
74
Engine Assemble _ Connecting Rod
10Kg.m + 90˚+10˚
75
Engine Assemble _ Cylinder Head
76
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
78
엔진 조립_Valve 간극 조정(DP222)
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 ○ ○ ○ ○ ○ ○
79
Engine Assembly _ 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
80
Engine Assemble _ Injection Timing Adjustment
1. Loose the Bolt(1,2,3,4,5) and Do not loose the one bolt 2. Re-Setting as same process(Previous Page) again
Bolt FIx
1
3
5
4
81
Engine Assemble _ Injection Timing Adjustment
4. After doing procedure No.3, Flange (FB) line and Pointer line
3. Turn the flywheel to the desired injection timing
may be misaligned
3
5
4
82
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 turinng the flywheel
Misalign Align
83
Controller Adjustment
Adjustment Controller _Installation and Precaution
85
Adjustment(Tuning) Order and Method
86
Adjustment(Tuning) Order and Method
87
Adjustment(Tuning) Order and Method
88
Adjustment(Tuning) Order and Method
89
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
91
Controller Trouble Shooting
TEST NORMAL ESTIMATED CAUSE of CORRECTIVE
STEP TERMINAL
PERIOD READING ABNORMAL READING ACTION
When stopping
1 F(+) / E(-) DC 24V
E/G 1. Battery Problem 1. Inspect battery line
When cranking 2. Wrong Wiring 2. Replace battery
2 F(+) / E(-) DC 15V of higher
start
1. Speed sensor defect
When stopping Tester ohmmeter
3 C/D 2. Damage of speed sensor wiring
E/G 300~1200Ω
or Wrong Wiring
1. Inspect sensor line
2. Replace speed sensor
1. Distance between speed sensor
When cranking Tester AC voltmeter
4 C/D and ring gear is too wide.
start 1.5 or higher
2. Speed Sensor defect
6 P(+) / G(-) KEY S/W ON 9.5V ~ 10.5V Controller device defect Replace controller
92
Controller Trouble Shooting
Trouble shooing with Multi-Tester
• SPECIFICATION
• Measure Tester
1) E - F (BATTERY – KEY ON)
KEY OFF
93
Controller Trouble Shooting
Trouble shooing with Multi-Tester
2) C – D (PICK UP SIGNAL)
3) A – B (ACTUATOR)
94
Trouble Shooting
Trouble Shooting _ Starter
96
Trouble Shooting _ Starter(4.5Kw)
Solenoid Terminal M
◆ Solenoid resistance must measured low resistance test, the wire short check in field
97
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
98
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 L Terminal R - Body DC3V ~ 5V
•Engine : V-TYPE ENGINE •Fuel Strainer Filter be blocked • The strainer filter is assembled for
preventing foreign object
•Failure Description :
Engine is stopped by alram
repeatedly
[Excessive foreign
object in Strainer filter] 101
Trouble Shooting _ Cooling Water mixed in Oil
[Root Cause]
The cooling water and oil mixed in oil pan . Cylinder Liner damaged
. Crack inside of Cyl.Block
. Cyl.liner O-Ring damaged
102
Trouble Shooting _ Engine oil mixed in Cooling Water
[Root Cause]
. Oil leakage from damaged oil cooler
. When engine operation, the oil mixed into coolin
Engine oil mixed in Cooling Water g water due to high oil pressure
103
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
104
Trouble Shooting _ Hunting(DB58T/D1146T) adjustment
6 4
5
1. Remove the idle sub spring cap nut(❶), Loose the spring fix Nut(❷),
8 Turn 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
9
105
Trouble Shooting _ Hunting( Electronical 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
106
Trouble Shooting _ Hunting( Electronical Governor) Check
107
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
108
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
109
Trouble Shooting _ Cylinder Liner Corrosion
Liner fitting is caused vapor bubble come from moving piston and liner
110
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
111
Trouble Shooting _ Cylinder Liner Corrosion
112
Trouble Shooting _ Cylinder Liner Corrosion
113
Trouble Shooting
Cooling system _ Cylinder Liner Corrosion
After 2086 hours operation with 5% antifreeze •After 2086 hours operation with 25% antifreeze
Antifreeze
114
Trouble Shooting _The Important of Fuel Filter
115
Trouble Shooting _The Important of Fuel Filter
116
Trouble Shooting _The Important of Fuel Filter
117
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
118
Trouble Shooting _ Turbo Charger
A Turbine dead-end is damaged by foreign object
Root Cause:
Engine inner part is broken
119
Trouble Shooting _ Turbo Charger
Root Cause : A piece of fabric, Wrench, Nuts, Screws and Foreign Object from Air-Cleaner
120
Trouble Shooting _ Turbo Charger
Root Cause:
Periodic Exchange exceed about en
gine oil and filter
121
Trouble Shooting _ Turbo Charger
Polluted Bearing
Root Cause :
The water and fuel enter the engine oil
122
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 123
Trouble Shooting _ Turbo Charger
124
Trouble Shooting _ Bearing
Normal Condition
125
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
126
Trouble Shooting _ Bearing
127
Trouble Shooting _ Bearing
A lack of the Engine Oil
- A shortage of oil clearance
- A blockage of oil line and damage and
block oil line
- Disturbance oil flow
- Oil filter and oil suction pipe damage
- Oil pump and oil relief valve have failure
- A lack of initial lubrication in lubrication
system
Surface Fatigue
- Overloading
- Uneven loading
- Using out of lifetime bearing
128
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
129
Trouble Shooting _ Bearing
130
Trouble Shooting _ Bearing
131
Trouble Shooting _ Bearing
132
Trouble Shooting _ Bearing
133
Trouble Shooting _ Bearing
134
Trouble Shooting _ Bearing
135
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 tatal generating set weight(wer
weight) should be considered)
① Engine
② Alternator
137
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 distribued.
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 .
무게 중심 합성
138
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
[공기 흐름도]
[기관실 환기]
139
Generator Engine Installation
[Ventilation System Consideration]
[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 rdiator
140
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
141
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
142
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
143
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㎡
창살(louvered Panel) 적
Grille 적용위한 허용 용 위한 허용 Inlet/Outlet
Inlet/Outlet 크기 크기
144
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 outletr.
The Recommended dimension is T ≥ A, B ≥ A
145
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
146
Generator Engine Installation
[Fuel System Installation Diagram]
147
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 enigne 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 배출구
148
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
149
Generator Engine Installation
[Exhaust System _ Exhaust pipe design and installation]
At least one bellows sould 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 woth high heat resistant material.
- lagging of the exhaust manifold and T/C is not permitted.
① Bellows
② Pipe
③ Silencer
④ Pipe Support
150
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)
151
Generator Engine Installation
[Cooling Performance _ Derating]
152
Appendix
153
Current for each suffix
154