Doosan P180LE-II Generator Set

1. Remove plug screw in case cover on injection pump drive gear.
2. Turn crank pulley so mark on injection pump pointer coincides with matching mark (FB) on drive gear flange.
3. Check V-type edge of flywheel housing sight hole coincides with injection timing degree on flywheel.
4. To adjust, loosen fixing bolts (M8) of injection pump driving gear.
5. Turn crank pulley clockwise until V-groove of sight hole aligns with injection timing degree.
6. Coincide mark on injection pump pointer with FB mark by turning flange in oblong holes.
7. Tighten bolt (M8) to 2.2 kg.m and recheck fuel delivery start point.

Tools: Feeler gauge (60.99901-0027), Spanner, Screwdriver

1. Turn crankshaft to bring #1 cylinder piston to compression top dead center.
2. Loosen lock nuts of rocker arm adjusting screws.
3. Push feeler gauge of specified value between rocker arm and valve stem.
4. Adjust clearance with adjusting screw and tighten with lock nut.

⚠ Injection lines are designed for high operating pressures and should be handled with particular care.

⚠ Do not bend pipes to permanent deformation.

1. Clean seat in cylinder head.
2. Insert nozzle holder with new seal ring.
3. Tighten union nut with 120 N.m.
4. Install injection lines free of constraint.
5. Install leak fuel lines and screw delivery pipe at nozzle holder and injection pump.

1. Loosen the air removing screws of the cartridge filter.
2. Operate the manual pump of the fuel supply pump until bubbles disappear.
3. Suction chamber is continuously bled via relief valve during operation.

⚠ Never use steam sprayers, petrol, alkalis or hot liquids to clean the filter elements.

Tools: Air gun, Goggles

1. Clean by compressed air using an air gun with a 90° bent nozzle extension.
2. Blow out element from inside at maximum 500 kPa (5 bar) until no more dust comes out.
3. Or wash: preclean with compressed air, soak in lukewarm solvent 10 minutes, agitate 5 minutes.
4. Rinse thoroughly in clean water, shake out and dry at room temperature.
5. Check cartridge for damage before reinstalling.

1. Do this when cooling system has cooled down.
2. Remove cover from filler neck of radiator.
3. Remove drain plug in the cylinder block.

⚠ Do not put cold coolant into an engine which is warm from operation.

⚠ If the cap with working valves is opened it may not close tightly again.

1. Only when engine has cooled down, fill in the coolant slowly.
2. Make sure that all air can escape from the cooling system.
3. Run engine briefly and check coolant level once more.
4. Add coolant at the filler neck only.
5. Ensure the ratio of water to antifreeze is correct.

⚠ Mechanical over tightening can distort thread or damage the filter element seal.

1. Clean the area around the fuel filter head.
2. Remove the fuel filter and the thread adapter seal ring.
3. Clean gasket surface of filter head with clean lint free cloth.
4. Install new thread adapter seal ring supplied with the new filter.
5. Lubricate filter seal with clean oil and fill new filter with clean fuel.
6. Install filter on head and tighten until gasket contacts head surface.
7. Tighten an additional one-half to three-fourths of a turn.

Tools: V-belt tension tester

1. Remove fixing bolts and lock nut.
2. Adjust bolt until V-belts have correct tension.
3. Retighten lock nut and fixing bolts.
4. To change belts, loosen mounting bolts and lock nut and push tension pulley inwards by adjusting bolt.

1. Run engine at fast idling until temperature reaches normal operating condition.
2. Avoid overload or continuous high speed operation.
3. Prevent high speed operation with no load.
4. Avoid abrupt start and stop of the engine.
5. Keep engine speed under 70% of its maximum speed.
6. Check oil level, oil pressure warning lamp and water temperature gauge frequently.
7. At end of break-in (first 50 hours) remove break-in oil and replace oil filter.

⚠ Ensure that the engine can not be started by unauthorized persons.

1. Cut off the main circuit breaker of the generator control panel to stop.
2. After high load operation, do not shut down immediately; allow to idle about 5 minutes so temperatures equalize.
3. Remove key from starting lock.

1. Insert key in starting lock.
2. Move control lever to idle speed.
3. Rotate key switch clockwise; do not operate longer than 10 seconds.
4. After ignition, take hands off key switch and adjust control lever for desired speed.
5. If engine fails to start, release key, wait about 1 minute, then operate starter again.