Doosan/Daewoo Heavey Equipements Engines Models Operation and Maintenance Manuals & Shop Manuals Pack
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
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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
