Doosan/Daewoo Heavey Equipements Engines Models Operation and Maintenance Manuals & Shop Manuals Pack - MDOOENGOPEK.zip

Complete technical manual with electrical wiring diagrams for Doosan/Daewoo Engines, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Doosan/Daewoo Engines Models workshop service repair manual includes:

* Numbered table of contents easy to use so that you can find the information you need fast.

* Detailed sub-steps expand on repair procedure information

* Numbered instructions guide you through every repair procedure step by step.

* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.

* Notes, cautions and warnings throughout each chapter pinpoint critical information.

* Bold figure number help you quickly match illustrations with instructions.

* Detailed illustrations, drawings and photos guide you through every procedure.

* Enlarged inset helps you identify and examine parts in detail.

MANUAL LIST:

950106-014978 - Doosan Diesel Engine D34NAP SCR Operation and Maintenance Manual.pdf

950106-01198 - Doosan Diesel Engine D24NAP Operation and Maintenance Manual.pdf

950106-01257(C) - Doosan Diesel Engine D18NAP Operation and Maintenance Manual.pdf

950106-01402 - Doosan Diesel Engine DL06P Tier4 Final Operation and Maintenance Manual.pdf

Doosan Common Rail Engine (Euro-III) Technical Information.pdf

Doosan/Daewoo Diesel Engine D1146, D1146T, D2366, D2366T Service Manual.pdf

950106-00347 - Doosan Diseel Engine for Industrial DL08K Tier4 Interim Operation and Maintenance Manual.pdf

950106-00344 - Doosan Diseel Engine DL06K Tier4 Interim Operation and Maintenance Manual.pdf

65.99897-8095A - Doosan/Daewoo Diesel Engine for Industrial DE12T, DE12TI, DE12TIA and DE12TIS Operation & Maintenance Manual.pdf

65.99897-8121 - Doosan Diesel Engine DL06 Operation & Maintenance Manual.pdf

65.99897-8079A - Doosan/Daewoo Diesel Engine DB58, DB58S, DB58T, DB58TI and DB58TIS Operation & Maintenance Manual.pdf

Doosan Diseel Engine DV11 Operation and Maintenance Manual.pdf

Doosan Diseel Engine DL08C Maintenance Manual.pdf

65.99897-8076C - Doosan Generator Diesel Engine P158LE/-1/-2/-S/-III, P180LE/-1/-S/-II, P222LE/-1/-S/-II & Power Unit Diesel Engine PU158TI, PU180TI, PU222TI Operation & Maintenance Manual.pdf

65.99897-8079 - Doosan/Daewoo Diesel Engine DB58, DB58S, DB58T, DB58TI and DB58TIS Operation & Maintenance Manual.pdf

65.99897-8095B - Doosan/Daewoo Diesel Engine for Industrial DE12T, DE12TI, DE12TIA and DE12TIS Operation & Maintenance Manual.pdf

65.99897-8059 - Doosan/Daewoo Diesel Engine DV15, DV15T, DV15TI and DV15TIS (DV15 Tier-II) Maintenance Manual.pdf

65.99897-8095C - Doosan/Daewoo Diesel Engine for Industrial DE12T, DE12TI, DE12TIA and DE12TIS Operation & Maintenance Manual.pdf

Doosan/Daewoo Diesel Engine for Industrial DE12T, DE12TI, DE12TIA and DE12TIS Shop Manual.pdf

Doosan/Daewoo Diesel Engines DE12T, DE12TI, DE12TIA and DE12TIS Operation and Maintenance Manual.pdf

65.99892-8030B - Doosan Diesel Engine DE12, DE12T, DE12TI & DE12TIS Shop Manual.pdf

65.99892-8026A - Doosan Diesel Engine DB58, DB58T & DB58TI Shop Manual.pdf

65.99897-8056 - Doosan/Daewoo Diesel Engine D1146, D1146TI and DE08TIS Maintenance Manual.pdf

65.99897-8056 - Doosan/Daewoo Diesel Engine D1146, D1146TI, DE08TIS Maintenance Manual.pdf

65.99897-8078A - Doosan/Daewoo Generator Diesel Engine DE12T, POULS P126TI, P126TI-1, P126TI-II Operation & Maintenance Manual.pdf

Doosan/Daewoo DE Series Diesel Engines (DE12, DE12T, DE12TI and DE12TIS) Operation & Maintenance Manual.pdf

Doosan/Daewoo Diesel Engines DE12, DE12T, DE12TI, DE12TIA and DE12TIS Operation and Maintenance Manual.pdf

Doosan Diesel Engine For Industrial DB58, DB58S, DB58T, DB58TI, DB58TIS Engine Specifications & Injection Pump Data.pdf

Doosan/Daewoo Diesel Engine for Industrial DB58, DB58T, DB58TI Operation & Maintenance Manual.pdf

65.99897-8076A - Doosan/Daewoo Generator Diesel Engine P158LE, P180LE, P222LE Operation & Maintenance Manual.pdf

65.99897-8101 - Doosan Diseel Engine DL08 Shop Manual.pdf

Doosan/Daewoo Diesel Engine DV15, DV15T and DV15TIS Maintenance Manual.pdf

Doosan Diesel Engine for Industrial DE12, DE12T, DE12TIA, DE12TIS Specifications & Injection Pump Data.pdf

Doosan Tier4-i Engine Training

Total Pages/Size: 6,344 pages / 671 MB

File Format: PDF (bookmarked, Searchable, Printable, high quality)

Language: English

...

TABLE OF CONTENTS

D18NAP_Engine.....1

  Preface.....3

  Table of contents.....5

  1.General Preface.....11

    General Information.....11

    Danger, Warning, Caution, and Note.....12

    Engine Management.....15

  2.Operation and Management.....19

    Starting and Stopping of the Engine.....19

      Preparing for Start.....19

      Starting the Engine.....19

      After Starting the Engine.....19

      During Operation.....19

      Stopping the Engine.....19

    Break-in Period of the Engine.....20

      General Information.....20

      Break-in Period of a New Engine.....20

      Check Points.....20

      Operation after Break-in.....20

      Inspection after Starting the Engine.....21

      Engine Oil Pressure.....21

      Coolant Temperature.....21

      Revolutions per Minute (rpm).....21

    Operation in Winter.....22

      Cold Start.....22

      Preventing Coolant from Freezing.....22

      Preventing Overcooling of the Engine.....22

      Engine Oil.....22

    Inspection and Repair of the Engine.....23

      Checking Engine Parts after Prolonged Operation.....23

      Inspection and Repair of Supercharger.....23

      Intake Unit.....23

      Exhaust Unit.....23

      Lubrication Unit.....23

  3.Performance and Specifications.....27

    Engine Specifications and Performance.....27

      Engine Specifications.....27

      Engine output.....31

      Engine performance curve (DL01-LEE00).....32

      Engine performance curve (DL01-LEL00).....33

    Outside Drawing of the Engine (DL01-LEE00).....34

      Isometric assembly drawings.....34

      Assembly drawings (Front/Rear).....35

      Assembly drawings (Left/Right).....36

      Assembly drawings (Top/Bottom).....37

    Outside Drawing of the Engine (DL01-LEL00).....38

      Isometric assembly drawings.....38

      Assembly drawings (Front/Rear).....39

      Assembly drawings (Left/Right).....40

      Assembly drawings (Top/Bottom).....41

    Engine Identification Number.....42

      Engine number engraving.....42

      Cylinder block number engraving.....42

      Engraving of piston bore level of cylinder block.....42

      Engraving of main bearing bore level of cylinder block.....43

      Crankshaft main journal engraving.....43

      Connecting rod engraving.....43

      Piston engraving.....43

      Cylinder head gasket engraving.....44

  4.Regular Inspection.....47

    General Information.....47

      General Information.....47

      Routine Inspection.....47

    Regular Inspection Table.....48

      General Conditions.....48

    Engine oil.....49

      General Information.....49

      Engine oil standards.....49

      Engine Oil Capacity.....50

      Checking the Engine Oil.....50

      Replenishment of Engine Oil.....51

      Replacement of Engine Oil.....51

    Coolant.....54

      General Information.....54

      Coolant standards.....54

      Capacity of coolant.....54

      Checking the Coolant.....54

      Measurement of Coolant Concentration.....54

      Replenishment of Coolant.....56

      Replacement of Coolant.....56

    Fuel.....58

      General Information.....58

      Fuel Standards.....58

    Air filter.....59

      General Information.....59

      Cleaning of Air Filter.....59

      Cleaning of the Air Filter Element.....59

      Replacement of Air Filter Element.....60

  5.Failure Diagnosis.....65

    General Information.....65

      Failure Diagnosis Unit.....65

    Failure Code.....66

      Fault Code Items.....66

    Failure Code Diagnosis.....70

      P0402 EGR control fault (airflow error too high).....70

      P0401 EGR control fault (airflow error too low).....72

      P0406 EGR actuator position feedback signal high fault.....74

      P0407 EGR actuator position feedback signal low fault.....75

      P046D EGR actuator position feedback signal noisy fault.....76

      P0C17 EGR position learning fault (drifted).....77

      P0C18 EGR position learning fault (wrong range).....78

      U0140 J1939 CAN pedal fault.....79

      P0088 Rail pressure control fault.....80

      P2267 Water in Fuel sensor electrical fault (OC/SCVBATT).....82

      P2266 Water in Fuel sensor electrical fault (SCGND).....83

      P2269 Water in Fuel Detected.....84

      P0524 Oil pressure remains low at engine run.....85

      P0523 Oil pressure sensor high fault.....86

      P0522 Oil pressure sensor low fault.....87

      P0111 Intake Manifold Temperature plausibility fault.....88

      P0113 Intake Manifold Temperature sensor high fault.....89

      P0112 Intake Manifold Temperature sensor low fault.....90

      P0114 Intake Manifold Temperature sensor noisy fault.....91

      P0108 Manifold Pressure sensor electrical high fault.....92

      P0107 Manifold Pressure sensor electrical low fault.....93

      P2229 Barometric pressure sensor electrical high fault.....94

      P2228 Barometric pressure sensor electrical low fault.....95

      P0116 Coolant temperature plausibility fault.....96

      P0118 Coolant temperature sensor high fault.....97

      P0117 Coolant temperature sensor low fault.....98

      P00BD MAF plausibility high fault.....99

      P00BC MAF plausibility low fault.....101

      P0103 MAF sensor electrical high fault.....103

      P0102 MAF sensor electrical low fault.....104

      P0190 Rail Pressure Sensor gradient fault.....105

      P0193 Rail Pressure Sensor high fault.....106

      P0192 Rail Pressure Sensor low fault.....107

      P0087 Rail Pressure Sensor fault (pressure build up during cranking too slow).....108

      P0191 Rail Pressure Sensor fault (Sensor drift at key-on).....110

      P0002 Rail Pressure Control fault (RPC using IMV only).....111

      P0089 Rail Pressure Control fault (RPC using Rail Discharge).....113

      P0563 Battery voltage high fault.....115

      P0562 Battery voltage low fault.....116

      P0074 Inlet Air Temperature sensor gradient fault.....117

      P0073 Inlet Air Temperature sensor high fault.....118

      P0072 Inlet Air Temperature sensor low fault.....119

      P2428 Exhaust over temperature fault.....120

      P0181 Fuel temperature plausibility fault.....121

      P0183 Fuel temperature sensor high fault.....122

      P0182 Fuel temperature sensor low fault.....123

      P0196 Oil temperature plausibility fault.....124

      P0195 Oil temperature sensor signal fault.....125

      P060B ADC circuit fault.....126

      P0602 C2I data not programmed.....127

      P0603 ECU memory integrity fault (data / cal integrity).....128

      P0604 ECU memory integrity fault (RAM integrity).....129

      P0605 ECU memory integrity fault (code integrity).....130

      P062F ECU non volatile memory fault.....131

      P0371 Crank signal is too close to the previous one.....132

      P0339 CRANK signal fault (gap lost).....133

      P0372 Elapsed time between CPS events is too high.....134

      P0374 Crank signal lost(no CPS signal seen in 1 cam rotation).....135

      P0335 Crank signal over speed fault.....136

      P0344 CAM signal fault (missing event within the expected window).....137

      P0342 Cam signal lost (no cam signal seen in 2 crank rotations).....138

      P0341 Cam signal drift higher than threshold.....139

      P0340 Cam signal last learnt value is outside of limits.....140

      U0100 CAN communication error: CAN bus confirmed off.....141

      P0201 Injector Open Circuit fault (Cylinder #1).....142

      P02EE Injector Short Circuit fault (Cylinder #1).....144

      P0262 Wiring harness resistance high fault (Cylinder #1).....146

      P0261 Wiring harness resistance low fault (Cylinder #1).....147

      P029B Injector Minimum drive pulse drift (Cylinder #1).....148

      P0202 Injector Open Circuit fault (Cylinder #2).....149

      P02EF Injector Short Circuit fault (Cylinder #2).....151

      P0265 Wiring harness resistance high fault (Cylinder #2).....153

      P0264 Wiring harness resistance low fault (Cylinder #2).....154

      P029F Injector Minimum drive pulse drift (Cylinder #2).....155

      P0203 Injector Open Circuit fault (Cylinder #3).....156

      P02F0 Injector Short Circuit fault (Cylinder #3).....158

      P0268 Wiring harness resistance high fault (Cylinder #3).....160

      P0267 Wiring harness resistance low fault (Cylinder #3).....161

      P02A3 Injector Minimum drive pulse drift (Cylinder #3).....162

      P0384 Glow plug relay electrical fault (SCVBAT).....163

      P0383 Glow plug relay electrical fault (SCGND).....164

      P0380 Glow plug relay electrical fault (OC).....165

      P0325 Fault on the accelerometer 0 sensor decode circuit.....166

      P0007 Rail pressure control error (IMV resistance trim value is too high).....167

      P0006 Rail pressure control error (IMV resistance trim value is too low).....168

      P0004 Rail pressure control feedback high fault.....169

      P0003 Rail pressure control feedback low fault.....170

      P0259 RPC error (IMV current trim drift high/high).....171

      P0254 RPC error (IMV current trim drift high/low).....173

      P0253 RPC error (IMV current trim drift low/high).....175

      P0258 RPC error (IMV current trim drift low/low).....177

      P0252 RPC PWM error.....179

      P0251 IMV control fault.....181

      P2080 Turbo in temperature plausibility fault.....182

      P0546 Turbo in temperature sensor high fault.....183

      P0545 Turbo in temperature sensor low fault.....184

      P2081 Turbo in temperature sensor noisy fault.....185

      P0685 Main relay stuck fault.....186

      P068A Main relay unexpected low state.....187

      P062D Injector Bank 1 electric or SPI fault.....188

      P062E Injector Bank 2 electric or SPI fault.....190

      P2145 EGR H-Bridge driver short circuit to battery voltage.....191

      P2144 EGR H-Bridge driver short circuit to ground.....192

      P2143 EGR H-Bridge driver open circuit.....193

      P0404 EGR position control fault.....194

      P0641 5V Supply #1 fault.....195

      P0651 5V Supply #2 fault.....196

      P0697 5V Aux supply #2 fault.....197

      P025D IMV drive electrical fault (SCVBATT).....198

      P025C IMV drive electrical fault (SCGND).....199

      P025A IMV drive electrical fault (OC).....200

      P037F Glow plug feedback fault (SCVBAT).....201

      P037E Glow plug feedback fault (OC / SCGND).....202

      P0606, P0607, P060A, P060C ECU safety monitoring fault.....203

  6.About the engine.....207

    Marking system of Units.....207

      Unit Conversion Methods.....207

    Tightening Torque.....208

      Tightening Torque of Main Parts.....208

      Tightening Torque of General Bolts.....209

      Tightening torque of plug screw.....210

      Hollow Screw (4-Hole) Tightening Torque.....210

    Engine Disassembly.....211

      Special Tools.....211

      Procedure of Disassembling an Engine.....211

    Engine Assembly.....224

      Special Tools.....224

      Procedure of Assembling Engine.....225

  7.Cooling System.....249

    General Information.....249

      General Information.....249

      Specifications.....250

      Failure Diagnosis.....251

    Water pump.....252

      General Information.....252

      Water pump Disassembly.....252

      Water pump Assembly.....253

    Thermostat.....254

      General Information.....254

      Thermostat Disassembly.....254

      Check of Thermostat.....255

      Thermostat Assembly.....255

  8.Lubrication System.....258

    General Information.....258

      General Information.....258

      Specifications.....259

      Failure Diagnosis.....260

    Oil pump.....261

      General Information.....261

      Oil Pump Disassembly.....261

      Oil Pump Assembly.....262

      Disassembly of Oil Suction Pipe and Oil Delivery Pipe.....264

      Assembly of Oil Suction Pipe and Oil Delivery Pipe.....265

    Oil Filter Assembly.....267

      General Information.....267

      Disassembly of Oil Filter Assembly.....267

      Check of Oil Cooler.....268

      Assembly of Oil Filter Assembly.....268

  9.Fuel System.....272

    General Information.....272

      General Information.....272

      Specifications.....273

    Fuel return hose.....274

      General Information.....274

      Disconnection of fuel return hose.....274

      Check of fuel return hose.....274

      Connection of fuel return hose.....274

    Injector.....275

      General Information.....275

      How to Operate an Injector.....275

      Injector Disassembly.....276

      Injector Check.....278

      Injector Assembly.....278

    Common Rail.....281

      General Information.....281

      Injection Pipe.....283

      Common Rail Disassembly.....284

      Common Rail Check.....284

      Common rail assembly.....285

    Fuel injection pump.....286

      General Information.....286

      Disassembly of Fuel Injection Pump.....287

      Assembly of Fuel Injection Pump.....288

  10.Intake/Exhaust System.....292

    General Information.....292

      General Information.....292

    Specifications.....293

    Intake Manifold.....294

      Disassembly of Intake Manifold.....294

      Assembly of Intake Manifold.....295

    Turbocharger.....297

      General Information.....297

      Failure Diagnosis.....299

      How to Maintain Turbocharger.....302

      Turbocharger Disassembly.....303

      Turbocharger Check.....304

      Turbocharger Assembly.....305

      Disassembly of Exhaust Manifold.....306

      Assembly of Exhaust Manifold.....308

    Exhaust Gas Recirculation (EGR) System.....311

      General Information.....311

      Disassembly of EGR Cooler.....312

      Assembly of EGR Cooler.....312

      Disassembly of EGR Valve.....313

      Assembly of EGR Valve.....314

      Diesel Oxidation Catalyst (DOC).....317

  11.Cylinder block/head.....320

    General Information.....320

      General Information.....320

      Specifications.....321

    Cylinder Block.....322

      Disassembly of cylinder block.....322

      Check of Cylinder Block.....322

      Measurement of Inside Diameter of Main Bearing Bore of Cylinder Block.....322

      Measurement of Inside Diameter of Piston Bore of Cylinder Block.....322

      Measurement of Inside Diameter of Camshaft Bearing of Cylinder Block.....323

      Assembly of Cylinder Block.....323

    Timing gear case.....324

      Detaching timing gear case.....324

      Assembly of Timing Gear Case.....324

    Breather.....326

      Disconnection of Breather Hose.....326

      Connection of Breather Hose.....326

    Cylinder head.....327

      Disassembly of Cylinder Head.....327

      Check of Cylinder Head.....327

      Assembly of Cylinder Head.....327

    Cylinder Head Cover.....328

      Disassembly of Cylinder Head Cover.....328

      Assembly of Cylinder Head Cover.....330

    Oil Pan.....333

      Disassembly of Oil Pan.....333

      Assembly of Oil Pan.....333

      Disassembly of Engine Oil Level Gauge and Guide Tube.....334

      Assembly of Engine Oil Level Gauge and Guide Tube.....334

    Valve.....335

      Disassembly of Valve.....335

      Measurement of Inside Diameter of Valve Guide.....335

      Measurement of Valve Stem End.....335

      Measurement of Valve Step Height.....336

      Measurement of Gap between Piston and Valve.....336

      Check of Valve Spring.....337

      Assembly of Valve.....337

    Rocker Arm.....338

      Disassembly of Rocker Arm.....338

      Adjustment of Valve Gap.....340

      Check of Rocker Arm Shaft.....340

      Check of Rocker Arm.....341

      Assembly of Rocker Arm.....342

    Valve Tappet and Push Rod.....345

      Disassembly of Valve Tappet.....345

      Check of Valve Tappet.....345

      Assembly of Valve Tappet.....345

      Disassembly of Push Rod.....345

      Check of Warpage of Push Rod.....348

      Assembly of Push Rod.....348

    Camshaft.....352

      Disassembly of Camshaft.....352

      Measurement of Camshaft Journal Outside Diameter.....352

      Measurement of Camshaft.....353

      Assembly of Camshaft.....353

    Idle gear.....354

      Disassembly of Idle Gear.....354

      Measurement of Outside Diameter of Idle Gear Shaft.....355

      Measurement of Inside Diameter of Idle Gear.....355

      Assembly of Idle Gear.....356

    Lifting Hook.....359

      Disassembly of Lifting Hook.....359

      Assembly of Lifting Hook.....359

  12.Electric System.....364

    Electric Parts.....364

      Electric Parts.....364

    Circuit Diagram.....366

      General Information.....366

      Engine Connector.....367

      Engine Connector of Engine Control Unit (ECU).....368

    Air Heater.....370

      Disconnection of Glow Plug.....370

      Connection of Glow Plug.....370

    Switches and Sensors.....372

      Mass Air Flow Sensor (MAF).....372

      Boost Temperature Sensor (BTS).....372

      Boost Pressure Sensor (BPS).....372

      Exhaust Gas Temperature Sensor (EGTS).....372

      Oil Pressure and Temperature Sensor (OPTS).....373

      Water Temperature Sensor (WTS).....373

      Fuel temperature sensor (FTS).....373

      Rail pressure sensor (RPS).....373

      Injector #1(INJ).....374

      Injector #2 (INJ).....374

      Injector #3 (INJ).....374

      Injector #4 (INJ).....374

      Crank Shaft Position Sensor (CRK).....375

      CAM Shaft Position Sensor (CAM).....375

      Knock Sensor1(KNOCK1).....375

      Knock Sensor2(KNOCK2).....376

      Exhaust Gas Recirculation Valve Position Sensor (EGR).....376

      Inlet Metering Valve (IMV).....376

      Water In Fuel Sensor (WIFS).....377

    Wire harness.....378

      Disassembly of Wire Harness.....378

      Assembly of Wire Harness.....378

    Electronic Control Unit (ECU).....379

      General Information.....379

      Electronic Control Unit (ECU) Connectors.....379

      I/O of Electronic Control Unit (ECU).....380

      Operational Conditions of Electronic Control Unit (ECU).....380

  13.Others/Driving System.....384

    General Information.....384

      General Information.....384

    Crankshaft.....386

      Disassembly of Timing Wheel.....386

      Assembly of Timing Wheel.....386

      Disassembly of Crankshaft.....388

      Measurement of Crankshaft Main Journal Diameter.....388

      Measurement of Crankshaft Bearing Gap.....388

      Measurement of Crankshaft Warpage.....389

      Assembly of Crankshaft.....389

    Connecting Rod.....390

      Disconnection of Connecting Rod.....390

      Measurement of Inside Diameter of Connecting Rod Small-end.....390

      Measurement of Connecting rod large-end bore.....390

      Measurement of Gap of Connecting Rod Big-end.....391

      Assembly of Connecting Rod.....391

    Piston.....392

      Disassembly of Piston.....392

      Measurement of Outside Diameter of Piston Pin.....392

      Measurement of Inside Diameter of Piston Pin Bore.....392

      Measurement of Gap of Piston Ring End.....392

      Measurement of Step Height of Piston Top Side.....393

      Assembly of Piston.....393

    Crankshaft Pulley.....394

      Disassembly of Crankshaft Pulley.....394

      Assembly of Crankshaft Pulley.....394

    Others.....395

      Engine Timing.....395

      Adjustment of Engine Timing.....396

      Check of Gear Backlash.....396

      Check of Gear Axial Offset.....397