Doosan GV158TIC Manual

950106-058010EN
GV158TIC, GV180TIC, GV222TIC
GAS GENERATOR ENGINE
Operation &
Maintenance Manual

FOREWORD
This manual is designed to serve as a reference for DOOSAN Infracore (here after DOOSAN) customers and distributors
who wish to gain basic product knowledge on DOOSAN GV158TIC, GV180TIC, GV222TIC natural gas engines.
These economical and high-performance natural gas engines (GV158TIC 8 cylinders),(GV180TIC 10 cylinders),
(GV222TIC 12 cylinders) are 4 strokes and V-type have been so designed and manufactured to be used for the generator
& power unit application. They meet all the requirements such as low noise, fuel economy, high engine speed and
durability.
To maintain the engine in optimum condition and retain maximum performance for a long time, CORRECT OPERATION
and PROPER MAINTENANCE are 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
During engine maintenance, please observe following instructions to prevent environmental damage;
● Take old oil to an old oil disposal point only.
● Ensure without fail that oil and diesel fuel will not get into the sea or rivers and canals or the ground.
● Treat undiluted anti-corrosion agents, antifreeze agents, filter element and cartridges as special waste.
● The regulations of the relevant local authorities are to be observed for the disposal of spent coolants and special waste.
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.
For the last, the content of this maintenance instruction may be changed without notice for some quality improvement and
please feel free to contact to our agents near by your location for any services. Thank you.
2020. 06.
950106-058010EN
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 unautho-
rized reproduction, printing and distribution thereof are strictly prohibited.

CONTENTS
1. Safety Regulations & Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1. General Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2. Handle Compressed Natural Gas Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3. Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.4. Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2. Technical Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.1. Engine Model and Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.2. Diagnostic Display Module (CPU - 95) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.3. Engine Characteristic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.4. Diagnosis and Remedy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.5. Engine Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3. Disassembly and Reassembly of Major Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.1. Engine Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.2. Measurement and Inspection of Major Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.3. Engine Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
3.4. Starting and Trial Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
3.5. Speed Controller Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
3.6. Display Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
3.7. Diagnosis and Remedies of Trouble Causes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
4. Electrical Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
4.1. Gas Fuel Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
4.2. Electrical Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
4.3. Speed Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
4.4. Ignition Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
4.5. Ignition Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
5. Maintenance of Major Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
5.1 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
5.2 Lubricating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
5.3. Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
5.4. Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
5.5. V-Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
5.6. Air Intake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

6. Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
6.1. Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
6.2. Inspection Prior to Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
●
Appendix

Safety Regulations & Engine Specifications- 1 -
1. Safety Regulations & Engine Specifications
1.1. General Notes
Day-to-day use of power engines and the service products necessary for running them presents no prob-
lems 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 sec-
tions 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.
1.2. Handle Compressed Natural Gas Safety
Natural gas is highly flammable and explosive and may be extremely cold. The following cautions must
be taken to avoid personal injury or engine damage.
●Do not smoke when installing or servicing
the engine or fuel system.
●Installation or servicing of natural gas
equipment must only be conducted in well
ventilated, natural gas compatible areas.
Do not install or service equipment in an
enclosed area where ignition sources are
present without ensuring that an unde-
tected gas leak may be safely vented with-
out being ignited.
●Do not vent natural gas or permit leaks
inside an enclosed area.
Bleed natural gas lines before installing or
servicing any component connected to the
fuel lines.
EB8O2001
EB8O2002

Safety Regulations & Engine Specifications - 2 -
1.2.1. Avoid heating near pressurized fluid lines
●Wear welding goggles and gloves when
welding or using an acetylene torch.
●Insure a that metal shield separated the
acetylene and oxygen which must be
chained to a cart.
●Do not weld or heat areas near fuel tanks
or fuel lines.
1.2.2. Venting an operable engine to relieve natural gas pressure
●To avoid personal injury an operable nat-
ural gas engine must be kept in a well
ventilated area away from open flames
and sparks.
●If the engine can run, use the following
venting procedure to relive the natural
gas pressure downstream of the shutoff
valve.
1) Shut off manual valves on natural gas
supply lines and main shutoff valve on
natural gas fuel supply line.
2) Start engine and run until it stalls due to
fuel starvation.
3) Check to make sure gauge pressure at point on the natural gas fuel line to be vented has been
reduced to zero. If not, repeat step 1) Then repeat step 2).
4) Disconnect vehicle batteries using switch in battery compartment or by disconnecting battery ground
cable.
5) Slightly loosen the NG fuel line fitting to be serviced in a well ventilated area to allow any remaining
gas to vent.
6) Completely open the fitting that was slightly opened and allow to vent in a well ventilated area.
HDO1049I
EB8O2003

Safety Regulations & Engine Specifications- 3 -
1.2.3. During commissioning, starting and operation
●This is the safety alert symbol. When you see this symbol in this manual, be alert to the potential for
personal injury.
●Carefully read all safety message in this manual and on your safety signs. Be sure new equipment
components and repair parts include the current safety signs.
●Avoid possible injury or death from runaway. Do not start engine by shorting across starter termi-
nals.
●Prevent fires by keeping machine clean of accumulated trash, grease, fuel and debris.
●When the engine is running, do not get too close to the rotating parts.
●Do not touch the engine with bare hands when it is warm from operation risk of bums.
●Exhaust gases are toxic. If it is necessary to run an engine in an enclosed area, remove the exhaust
gases from the area with an exhaust pipe extension. If you do not have an exhaust pipe extension,
open the doors and get outside air into the area.
●Keep vicinity of engine free of oil and grease. Accidents caused by slipping can have serious conse-
quences.
1.2.4. During maintenance and care
●Always carry out maintenance work when the engine is switched off. If the engine has to be main-
tained 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 rise of burns and scalding. Do not touch oil drain plug or oil filters 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 is unavoidable, comply with the instructions in the chapter "Maintenance and Care".
●Neither tighten up nor open pipes and hoses (lube oil circuit, coolant circuit and any additional
hydraulic oil circuit) during the operation. The fluids 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 radiator, wear goggles.
●Keep service products (anti-freeze) only in containers which can not be confused with drinks con-
tainers.
●Comply with the manufacturer's instructions when handling batteries.
Caution:
Accumulator acid is toxic and caustic. Battery gases are explosive.

Safety Regulations & Engine Specifications - 4 -
1.2.5. 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. Worn open-end wrench slip, which could lead to
Injury.
●When the engine is hanging on a crane, no-one must be allowed to stand or pass under it. Keep lift-
ing gear in good condition.
●When working on parts which contain asbestos, comply with the notes.
●When checking spark plug do not put your hands under the electric.
●When working on the electrical system disconnect the battery earth cable first. Connect it up again
last in prevent short circuits.
1.2.6. To prevent damage to engine and premature wear
(1) If faults occur, find the cause immediately and have it eliminated in order to prevent more seri-
ous of damage.
(2) 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".
(3) In addition to the above, note the following points.
●Never let the engine run when dry, i.e. without lube oil or coolant.
●Use only DOOSAN-approved service products (engine oil, anti-freeze and anticorrosion agent).
●Have the engine maintained at the specified intervals.
●Do not switch off the engine immediately when it is hot, but let it run without load for about 5 min-
utes so that temperature equalization can take place.
●Never put cold coolant into an overheated engine. See "Maintenance and care".
●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, cool-
ant temperature) function satisfactorily.
●Do not let the raw water pump run dry, If there is a risk of frost, drain the pump when the engine
is switched off.
(4) Keep no-load operation to a minimum. During no-load operation combustion chamber temperatures
drop to the point where fuel does not burn completely, causing slobbering and white smoke. Always
have some load connected when the gen set is run for long periods.